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Service Department. Technical Information

Service
Maintenance
Heading
1. Engine Overview
2. Service Work
3. General Information
4. Work Descriptions
5. Glossary
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
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All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E800051E4

Bora 1999 ➤ , Bora Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
Maintenance - Edition 05.2012
Contents
1 Engine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Service Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Oil Change Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Inspection Service through MY 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Inspection Service from MY 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Lifting Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Diagnostic Tool, Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Severe Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Vehicle Data Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.7 Hot Climate Countries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.8 Engine Code and Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.9 RME Biodiesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.10 Type Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Work Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Exhaust System, Inspect Visually For Leaks, Fasteners And Damage . . . . . . . . . . . . . . . . 19
4.2 Ball Joints, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Automatic Transmission 01M, Changing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4 Automatic Transmission 01M, Replacing ATF Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.5 Automatic Transmission
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4.6 Automatic ksw Transmission 01M, Checking
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4.7 Automatic
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4.8 aut Battery Terminals, Checking for Secure Fit o.r a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Battery, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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4.10 Tires, Tire Condition, Wear Pattern, Inflation Pressure and Tread Depth . . . . . . . . . . . . . . 22
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4.11 Brake System, Check for Leaks and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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4.12 Front and Rear Brake Pads, Checking Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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4.13 Brake and Clutch System, Changing Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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4.14 Brake Fluid Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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4.15 Direct Shift Gearbox (DSG) Transmission 02E, Fluid and Filter Change, 6-Speed, AWD
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4.16 Power Window Regulators, 8-Way Memory Seats, Performing Initialization . . . . . . . . . . . . 32

4.17 Performing Vehicle System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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4.18 Protective Joint Boots, Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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4.19 Noise Insulation, Installing, Golf R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.20 Haldex Clutch Oil Filter, Removing and Installing, All Wheel Drive (AWD) . . . . . . . . . . . . 36
4.21 Haldex Clutch, All Wheel Drive (AWD), Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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4.22 First Aid Kit Expiration Date, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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4.23 Fuel Filter, Diesel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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4.24 Fuel Filter, Diesel, Draining Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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4.25 Ribbed Belt, Checking Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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4.26 Cooling System, Checking Freeze Protection and Coolant Level . . . . . . . . . . . . . . . . . . . . 39

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4.27 Air Filter, Cleaning Housing and Removing and Installing Air Filter . . . . . . . . . . . . . . . . . . 42
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4.28 Upper Engine Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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4.29 Lower Engine Compartment Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . .
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4.30 Engine Oil Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.31 Engine Oil, Draining or Extracting and Filling; Replacing Oil Filter . . . . . . . . . . . . . . . . . . 51
4.32 Engine and Engine Compartment Components, Checking for Leaks and Damage . . . . . . 57
4.33 Perform a Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.34 Radio/Radio Navigation System, Attaching Serial Number and Code Number to Unit Card
........................................................................ 58
4.35 Radio/Radio Navigation System, Activating Anti-Theft Coding . . . . . . . . . . . . . . . . . . . . . . 58
Contents i
4.36 Wheel Bolts, Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.37 Attaching Wheel Housing Liner to Front Apron (Anniversary Golf GTI with 132 kW only)
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4.38 Tire RepairolKit, ksw Checking . . . . . . . .e.s .no.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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4.40 Sunroof,
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4.41 ssSunroof Water Drains, Checking and Cleaning . . c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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4.42 Windshield and Headlamp Washer System, Checking for Damage, Function and Spray
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Nozzle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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4.43 Windshield Wiper Blades, Checking for Damage, End Position and Adjustment Angle . . 71
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4.44 Manual Transmission/Final Drive, Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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4.45 Headlamps, Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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4.46 Service Interval Display, Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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4.47 Service Interval Display, Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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4.48 Tie Rod Ends, Checking Play, Security and Joint Boots . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.49 Language, Selecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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4.50 Dust and Pollen Filter, Cleaning Housing and Removing and Installing Filter Element . . . . 81
4.51 Transport Protection, Removing Locking Pieces from Front Axle Struts . . . . . . . . . . . . . . 81
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4.52 Door Arrester, Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4.53 Clock, Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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4.54 Underbody Components, Checking for Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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4.55 Toothed Belt and Camshaft Drive Tensioner, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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4.56 Camshaft Drive Toothed Belt, Checking, 4-Cylinder Gasoline Engine . . . . . . . . . . . . . . . . tion in 84
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4.57 Toothed Belt, Diesel, Checking for Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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4.58 Camshaft Drive Toothed Belt, Checking Condition and Tension, Diesel, Engine Codes ALH
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4.59 Spark Plugs, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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4.60 Rear Lid, Lubricating Multi-Joint Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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ii Contents
1 Engine Overview
(Edition 05.2012)
This chapter contains information on
♦ Gasoline engines ⇒ page 1
♦ Diesel engines ⇒ page 4
Note
The engine codes are organized alphabetically.
Gasoline Engines
Engines: ⇒ Gasoline Engine Gasoline Engine
Displacement I 2.0 2.8
Engine code AEG AFP
Number of cylinders/valves per cylinder 4/2 6/2
Output kW at RPM 85/5200 130/5800
Torque Nm at RPM 165/2600 245/3200
Bore diameter mm 82.5 81.0
Stroke mm 92.8 90.3
Compression ratio 10.5 10.1
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Engine code AVH

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1. Engine Overview 1

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Number of cylinders/valves per cylinder 4/5 4/5 4/5
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Output kW at RPM 110/5700 132/5500 110/5700
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Torque Nm at RPM 220/1950 235/1950 through 5000 220/1950 through
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Bore diameter mm 81.0 81.0 81.0
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Compression ratio 9.3 9.5 9.3

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RON unleaded, mini‐ 951 982 951

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Displacement I 2.0
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2 1. Engine Overview

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Displacement I 2.0
Engine code BBW
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1. Engine Overview 3

Displacement I 2.0
Engine code BEV
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Diesel engines
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Engines: ⇒ Diesel Engine

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Bore diameter 79.5
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Stroke mm 95.5
Fuel injection/Ignition TDI pump injector
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4 1. Engine Overview
2 Service Work
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2. Service Work 5
3 General Information
⇒ “3.1 Lifting Vehicle”, page 6
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⇒ “3.3 Diagnostic Tool, Connecting”, page 9 rised b ara
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⇒ “3.4 Severe Operating Conditions”, page 11 s au ra
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⇒ “3.5 Vehicle Identification Number”, page 11
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⇒ “3.6 Vehicle Data Label”, page 12
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⇒ “3.7 Hot Climate Countries”, page 13
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⇒ “3.8 Engine Code and Engine Identification”, page 14
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⇒ “3.9 RME Biodiesel”, page 14
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⇒ “3.10 Type Plate”, page 15
3.1 Lifting Vehicle
rrectne
⇒ “3.1.1 General Information”, page 6
ss
⇒ “3.1.2 Vehicle Hoist Lifting Points”, page 7
o
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f in
⇒ “3.1.3 Golf R32, Lifting”, page 7
form
mer
atio
⇒ “3.1.4 Floor Jack Lifting Points”, page 7
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3.1.1 General Information
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♦ Before driving a vehicle onto a lifting platform it must be

ensured that the vehicle weight does not exceed the per‐
missible lifting capacity of the platform.
♦ Vehicle may only be lifted at points indicated in illustration
in order to avoid damaging vehicle floor pan and to prevent
vehicle from tipping.
♦ Never start engine and engage a gear with vehicle lifted
so long as even one wheel has contact with the floor!
There is a risk of an accident if this is not observed!
♦ If work is to be performed under vehicle it must be sup‐
ported by suitable stands.
Floor Jack:
Always use a suitable rubber or wooden block between the jack
and the vehicle.
Do not lift the vehicle at the engine oil pan, transmission, or on
front or rear axles as serious damage may result.
Workshop Hoist:
Before driving the vehicle onto a workshop hoist, make sure there
is enough clearance between any low-lying vehicle components
and the hoist.
6 3. General Information
agen
Maintenance
AG. Volkswagen AG
do - Edition 05.2012
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3.1.2 Vehicle Hoist Lifting Points ho
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Front: ss
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nl
Position support plate at side member vertical stiffener in dotted
pt
du
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line area -arrow 1-. The center of the support plate must align with
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marking -arrow 2-.
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Position support plate at side member vertical stiffener in dotted
nf
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line area -arrow 1-. The center of the support plate must align with
rm
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marking -arrow 2-.
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3.1.3 Golf R32, Lifting

The are recesses inside the sill trim at the front and rear of the
vehicle.
3.1.4 Floor Jack Lifting Points

Front:
Behind these recesses -arrow- the vehicle can be lifted at the
vertical reinforcement of the side rails.
Rear:
-Arrow A- indicates the lifting point on the vertical reinforcement
of the side rail, at the height of the mark on the vehicle jack
-arrow B-.
Note
The vehicle may only be lifted at the areas designated in these

illustrations, otherwise serious damage to the vehicle may occur.
Never lift the vehicle by the sill trim.
3. General Information 7
3.2 Labels
⇒ “3.2.1 Attaching Data Label in the Luggage Compartment”,
page 8
⇒ “3.2.2 Next Service Label, Applying”, page 8
⇒ “3.2.3 Data Label, Applying in Customer Maintenance Booklet”,
page 9
3.2.1 Attaching Data Label in the Luggage

Compartment
Affix the lower of the two data label -2- (not natural gas vehicles)
in the luggage compartment, on the left side of the spare wheel
well.
or
Affix the lower of the two data label -1- (natural gas vehicles) in
the luggage compartment, left.
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3.2.2 Next Service Label, Applying s a c
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– “Your next service” decal: check off the oil change or inspec‐
an
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tion service (whichever is due next) and enter the date/mile‐

erm
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3. General Information
– Apply the label to the B-pillar on the driver side -arrow-.
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3.2.3 Data Label, Applying in Customer Main‐
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tenance Booklet
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– Apply the bottom data label -arrow- inside the customer Main‐
spec
tenance booklet.
t to the co
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3.3 Diagnostic Tool, Connecting
om
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Special tools and workshop equipment required

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♦ Vehicle Diagnosis, Testing and Information System - VAS

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♦ Vehicle Diagnosis, Testing and Information System - VAS

5051B-
♦ Vehicle Diagnosis and Service System - VAS 5052- or sub‐

sequent devices
♦ Diagnostic Cable - VAS 5051/6A-
♦ Diagnostic System - VAS 5053-
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♦ Diagnostic Cable - VAS 5052/3-

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panying diagnostic cable. Prote AG.
WARNING
♦ During a road test you must always secure testing and

measuring equipment on the back seat.
♦ Drivers must NEVER operate these tools while driving.
– Connect Diagnostic Cable - VAS 5051/6A- connector to Data

Link Connector (DLC).
The diagnostic connector -arrow- is located behind thewcover
agen
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– Set the parking brake. thoris nte
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– Automatic transmission: selector lever
ss in “P” or “N” position.
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– Manual transmission: shift lever in idle position.
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– Switch on the tester.
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– Switch the ignition on.
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Follow the instructions appearing on the screen to start the de‐
hole
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3.4 Severe Operating Conditions
rrectness of i
Under severe operating conditions, it is necessary to have some
work performed before the next service is due or between speci‐
l purpos
fied Service Intervals.

Severe Operating Conditions
nform
ercia
• Constant short-distance driving or stop-and-go driving in the

m
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com
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city
on in
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• High proportion of cold starts
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• Operating the vehicle in areas with extremely low tempera‐

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• Frequently running at idle for extended periods of time (e.g. a
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• Frequently driving full throttle or with a high load or a trailer
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• Running with diesel fuel with high sulfur content

• Frequently operating in areas with excessive dust
3.5 Vehicle Identification Number

The vehicle identification number is found in the plenum chamber.
It is visible through a window -arrow- in the plenum chamber cov‐
er.
Decoding VINs
WVW ZZZ 1J Z Y (3) 1)W 000 279

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Manu‐ Filler Type Filler Model
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facturer charac‐ charac‐rised byear ing Fac‐ ara
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3.6 Vehicle Data Label
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The vehicle data label -2- (non-natural gas vehicles) is located in
hole
rear of vehicle on the left by the spare wheel recess. The vehicle
spec
data label is also inside the customer Maintenance booklet.
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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com
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– Check the vehicle data label -arrow- (in trunk), to see if the
s
iva
do
vehicle is equipped with PR number “QG1” or with PR number
r
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“QG0 and/or QG2”. The PR number determines the Service
fo
en
ng
Intervals.
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Vehicles with time/distance dependent service are designated

with PR number “QG0 or QG2”.
The label contains the following vehicle data:

1 - Production control number
2 - Vehicle Identification Number
3 - Model identification number
4 - Model explanation/engine output
5 - Engine and transmission code letters
6 - Paint number/interior equipment identification number
7 - Optional equipment identification numbers
3.7 Hot Climate Countries
Note
The transmission ATF must also be replaced in countries with a

very hot climate. The ATF wears down in these climate conditions.
All countries affected are listed in the table below.
Hot Climate Countries

Afghanistan Egypt Algeria
Angola Equatorial. Guinea Ethiopia
Australia Bahrain (GCC) Benin (Dahomey)
Botswana Brunei Burkina Faso (Upper Volta)
Burundi China Democratic Republic of Congo
G. Volkswagen AG d
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Eritrea Gabon sed b y
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Ghana Guinea aut
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India Indonesia / (Borneo) Iraq ce
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Iran Israel Japan an

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Yemen (AGCC) Jordan Cameroon
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Qatar (AGCC) Kenya Congo

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Kuwait (AGCC) Lesotho Lebanon

hole
spec
Liberia Libya Madagascar

es, in part or in w
t to the co
Malawi Malaysia Mali

Morocco Mauritania Mauritius
rrectness of i
Mexico Mozambique Namibia

Republic of Niger Nigeria Oman (AGCC)
l purpos
Palestine Puerto Rico Rwanda

nf
ercia
Zambia Saudi Arabia (AGCC) Senegal

orm
Sierra Leone Zimbabwe Singapore

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Somalia South Africa Sudan

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Swaziland Syria Tanzania

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Thailand Togo Chad

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Tunisia Turkey Uganda

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3.8 Engine Code and Engine Identification

Engine code and engine number are found:
♦ on a sticker on the toothed belt guard, on the intake tube, or
on the subframe engine-side.
♦ Stamped on the cylinder block or on the cylinder head. Refer
to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr.
00 ; General Information .
♦ on the vehicle data label in the spare wheel well or on the floor
of the luggage compartment.
♦ on the vehicle data label in the Maintenance booklet.
3.9 RME Biodiesel

Only vehicles that are released by Volkswagen and are standard
or optionally (PR No. 2G0) equipped for the use of RME biodiesel
fuel are allowed be driven with RME biodiesel fuel.
Caution
♦ If RME biodiesel is used although your vehicle is not de‐

signed for it, the fuel supply system may be damaged.
♦ When filling tank with biodiesel, only use ME fuel corre‐
sponding to EN 14214 (FAME).
♦ If using biodiesel that differs from the standard, the fuel AG. Volkswagen A
filter could become clogged. olks
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For Volkswagen diesel engines, from calendar
s au week 05.2004, the ra
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RME biodiesel must correspond to EN 14214s (FAME).
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♦ RME means “rapeseed oil fatty acid-methyl-ester”.
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♦ EN means “Euro-Norm”.
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RME Biodiesel Characteristics spec

♦ When operating with biodiesel, mileage could be minimally

t to the co
reduced.
♦ When operating with biodiesel, fuel consumption could be
rrectne
minimally increased.
♦ RME biodiesel can be used in the winter to approximately -10
ss
℃
o
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f in
♦ When outside temperatures are below -10 ℃, we recommend

form
mer
the use of winter diesel fuel.

atio
om
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Note
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♦ When operating with Biodiesel, observe the change in inter‐

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vals for draining water and changing the fuel filter.
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50 km in order to prevent damage to the fuel injection system.
Borawa1999
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. Volkswagen AG
does1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 ➤
ks
by Vol not
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ara
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3.10 Type Plate th or
au ac
ss
ce
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– The type plate -arrow- is found on the right strut tower.
nl
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– In certain countries, the vehicles do not have a type plate.
erm
ab
ility
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es, in part or in w
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c
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AG. Volkswagen AG d
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16 4. Work Descriptions
AG. VBora
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4 Work Descriptions
h eo
aut ra
ss c
ce
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⇒ “4.1 Exhaust System, Inspect Visually For Leaks, Fasteners

un
pt
an
And Damage”, page 19
d
itte
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rm
ab
⇒ “4.2 Ball Joints, Checking”, page 19
pe
ility
ot
wit
⇒ “4.3 Automatic Transmission 01M, Changing ATF”, page 19
, is n
h re
hole
⇒ “4.4 Automatic Transmission 01M, Replacing ATF Strainer”,
spec
page 19
es, in part or in w
t to the co
⇒ “4.5 Automatic Transmission 01M, Checking Final Drive Gear
Oil”, page 20
rrectness of i
⇒ “4.6 Automatic Transmission 01M, Checking ATF Level and
Filling”, page 20
l purpos
⇒ “4.7 Automatic Transmission 09A, Checking ATF Level and

Filling”, page 20
nform
ercia
⇒ “4.8 Battery Terminals, Checking for Secure Fit”, page 20

m
a
com
tion in
⇒ “4.9 Battery, Checking”, page 21
r
te o
thi
s
⇒ “4.10 Tires, Tire Condition, Wear Pattern, Inflation Pressure
iva
do
r
and Tread Depth”, page 22

rp
cum
fo
en
ng
⇒ “4.11 Brake System, Check for Leaks and Damage”,

t.
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page 24
C py
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⇒ “4.12 Front and Rear Brake Pads, Checking Thickness”,
co Vo
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page 24
cted agen
Prote AG.
⇒ “4.13 Brake and Clutch System, Changing Brake Fluid”,

page 28
⇒ “4.14 Brake Fluid Level, Checking”, page 31
⇒ “4.15 Direct Shift Gearbox (DSG) Transmission 02E, Fluid and
Filter Change, 6-Speed, AWD”, page 32
⇒ “4.16 Power Window Regulators, 8-Way Memory Seats, Per‐
forming Initialization”, page 32
⇒ “4.17 Performing Vehicle System Test”, page 33
⇒ “4.18 Protective Joint Boots, Inspecting”, page 34
⇒ “4.19 Noise Insulation, Installing, Golf R32”, page 34
⇒ “4.20 Haldex Clutch Oil Filter, Removing and Installing, All
Wheel Drive (AWD)”, page 36
⇒ “4.21 Haldex Clutch, All Wheel Drive (AWD), Changing Oil”,
page 36
⇒ “4.22 First Aid Kit Expiration Date, Checking”, page 36
⇒ “4.23 Fuel Filter, Diesel, Removing and Installing”, page 36
⇒ “4.24 Fuel Filter, Diesel, Draining Water”, page 37
⇒ “4.25 Ribbed Belt, Checking Condition”, page 38
⇒ “4.26 Cooling System, Checking Freeze Protection and Coolant
Level”, page 39
⇒ “4.27 Air Filter, Cleaning Housing and Removing and Installing
Air Filter”, page 42
⇒ “4.28 Upper Engine Cover, Removing and Installing”,
page 44
⇒ “4.29 Lower Engine Compartment Cover, Removing and In‐
stalling”, page 49
⇒ “4.30 Engine Oil Level, Checking”, page 51
4. Work Descriptions 17
⇒ “4.31 Engine Oil, Draining or Extracting and Filling; Replacing

Oil Filter”, page 51
⇒ “4.32 Engine and Engine Compartment Components, Checking
for Leaks and Damage”, page 57
⇒ “4.33 Perform a Road Test”, page 57
⇒ “4.34 Radio/Radio Navigation System, Attaching Serial Num‐
ber and Code Number to Unit Card”, page 58
⇒ “4.35 Radio/Radio Navigation System, Activating Anti-Theft
Coding”, page 58
⇒ “4.36 Wheel Bolts, Tightening Specifications”, page 60
⇒ “4.37 Attaching Wheel Housing Liner to Front Apron (Anniver‐
sary Golf GTI with 132 kW only)”, page 62
⇒ “4.38 Tire Repair Kit, Checking”, page 63
⇒ “4.39 Power Steering, Checking Fluid Level”, page 64
⇒ “4.40 Sunroof, Checking Function, Cleaning and Lubricating
Guide Rails”, page 65
⇒ “4.41 Sunroof Water Drains, Checking. and Cleaning”,
AG Volkswagen AG d
page 66 ksw
agen oes
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⇒ “4.42 Windshield and iHeadlamp
ed
b Washer System, Checking for
ara
nte
rs
Damage, Function andut
ho Spray Nozzle Adjustment”, page 67 eo
ra
sa c
⇒ “4.43 Windshields Wiper Blades, Checking for Damage, End
ce
e
Position and Adjustment Angle”, page 71

nl
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du
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itte
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⇒ “4.44 Manual Transmission/Final Drive, Checking Oil Level”,

erm
ab
page 73
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⇒ “4.45 Headlamps, Checking and Adjusting”, page 73

h re
hole
⇒ “4.46 Service Interval Display, Resetting”, page 77

spec
es, in part or in w
t to the co
⇒ “4.47 Service Interval Display, Coding”, page 79

⇒ “4.48 Tie Rod Ends, Checking Play, Security and Joint Boots”,
page 80
rrectness of i
⇒ “4.49 Language, Selecting”, page 80

l purpos
⇒ “4.50 Dust and Pollen Filter, Cleaning Housing and Removing

and Installing Filter Element”, page 81
nf
ercia
orm
⇒ “4.51 Transport Protection, Removing Locking Pieces from

m
atio
m
Front Axle Struts”, page 81

o
n in
or c
⇒ “4.52 Door Arrester, Lubricating”, page 82

thi
te
sd
iva
⇒ “4.53 Clock, Setting”, page 83

r
rp
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ng
⇒ “4.54 Underbody Components, Checking for Damage”,

t.
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page 83 C py
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⇒ “4.55 Toothed Belt and Camshaft Drive Tensioner, Replacing”,
p by
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page 84 Prote
cted AG.
agen
⇒ “4.56 Camshaft Drive Toothed Belt, Checking, 4-Cylinder Gas‐

oline Engine”, page 84
⇒ “4.57 Toothed Belt, Diesel, Checking for Wear”, page 85
⇒ “4.58 Camshaft Drive Toothed Belt, Checking Condition and
Tension, Diesel, Engine Codes ALH with Automatic Transmis‐
sion”, page 85
⇒ “4.59 Spark Plugs, Removing and Installing”, page 86
⇒ “4.60 Rear Lid, Lubricating Multi-Joint Hinges”, page 94
Edition V0251206121 - 05/13/2015 - FB - JY1088125
4.1 Exhaust System, Inspect Visually For

Leaks, Fasteners And Damage
Additional Visual Inspection Golf R32
The rear muffler on the Golf R32 has an exhaust door with a vac‐
uum actuator -arrow-. Exhaust Door Valve 1 - N321- controls the
exhaust door.
n AG . Volkswagen AG
– Check the vacuum line from the exhaust doorksvalve
wage to the does
not
l
vacuum actuator. by
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– The exhaust door valve is located above the heat shield for
spec
the rear muffler, behind the stabilizer bar mount -1-.
es, in part or in w
t to the co
– Check the vacuum line -arrow- for proper routing and damage
(Ex. tears, abrasions, porosity).
rrectness of i
l purpos
Note
Correct any malfunctions (repair procedure).
nform
mercia
at
om
ion
c
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or
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ate
do
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4.2 Ball Joints, Checking

p
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Perform the following:

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– Check ball joint boots -arrow- for leaks and damage. opyri
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4.3 Automatic Transmission 01M, Changing

ATF
Refer to ⇒ Automatic Transmission; Rep. Gr. 37 ; Removal and
Installation , .
4.4 Automatic Transmission 01M, Replac‐

ing ATF Strainer
Installation , .
4.5 Automatic Transmission 01M, Checking

Final Drive Gear Oil
Installation , .
4.6 Automatic Transmission 01M, Checking

ATF Level and Filling
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4.8 Battery Terminals, Checking for Secure
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♦ Torque Wrench - V.A.G 1331/- (5 - 50 Nm)
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Tight battery connections assure trouble-free battery function and cted agen
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long service life.

– Open the battery jacket -arrow- (if equipped).
– Press tabs -arrows- together and fold the cover forward.
– By manually moving battery plus (B+) cable -2- and ground

(GND) cable -3- check whether battery connections
-4 and 5- are tight.
WARNING
If battery positive (B+) connection is loose, disconnect ground

(GND) cable first before attempting to remove or tighten plus
connection, to prevent personal injury. gen AG. Volkswagen AG d
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If battery plus (B+) connectionthoisr not tight: eo
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– First disconnect battery clamp -5- at battery minus pole.

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– Tighten battery plus (B+) connection to 6 Nm.
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– Attach the battery clamp -5- on battery negative terminal and
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tighten to 6 Nm.
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If ground connection on battery is not tight:

spec
es, in part or in w
t to the co
– Tighten the battery clamp -5- on the battery negative terminal
to 6 Nm.
rrectness of i
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4.9 Battery, Checking

nform
mercia
Refer to ⇒ Electrical Equipment; Rep. Gr. 92 ; Diagnosis and

a
com
tio
Testing , .
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4.10 Tires, Tire Condition, Wear Pattern, In‐

flation Pressure and Tread Depth
⇒ “4.10.2 Checking”, page 22
⇒ “4.10.3 Tires, Checking Wear Pattern”, page 23
⇒ “4.10.4 Tire Tread Depth (Including Spare Wheel), Checking”,
page 23
⇒ “4.10.5 Tires, Including Spare, Checking Pressure and Cor‐
recting”, page 23
WARNING
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♦ For safety reasons, all tires
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same make and tread se
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♦ AWD vehicles must ut have tires of the same make and tread
h or
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design. If not, the center differential could get damaged.
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Note
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♦ The tire pressures for relevant model are found on a sticker. spec
This sticker is on the inside of the fuel filler door or on the B-

pillar.
t to the co
♦ Observe that the inflation pressure specifications on the stick‐

er refer to the air pressure of cold tires. Do not reduce tire
rrectne
pressure when the tires are warm.

♦ Adapt tire pressure corresponding to load.
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♦ If the tire pressure for the spare wheel is not listed, then fill the
inform
spare wheel with the highest tire pressure specified for the
mer
vehicle.
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Winter tires
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♦ If winter tires are mounted, a label informing the customer of
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the speed limit must be affixed inside the passenger compart‐ cop Vo
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ment so that it is clearly visible.
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♦ On winter tires, the tire pressure must no longer be increased.

But this is true only if the winter tires being used are the exact
same size as the standard summer tire, and the speed index
does not exceed “H”. If you deviate from this, then you must
follow the tire manufacturer recommendations.
4.10.2 Checking
Delivery Inspection:
– Check tire tread and side walls for damage, if necessary re‐
move any foreign bodies, such as nails or screws.
Note
If damage is discovered, the tire must be examined

agen
to
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Inspection Service: tho
or
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– Check tire tread and side walls for damage, if necessary re‐
ce
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move any foreign bodies, such as nails or screws.
pt
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– Check tire treads for cupping, feathering, one-sided tread
erm
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wear, porous side walls, cracks, cuts, and rim damage.
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Note
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Inform the customer of any damage found.
4.10.3 Tires, Checking Wear Pattern
rrectne
The tread wear on the front tires will help determine whether toe
ss
or camber need to be checked.
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f in
♦ Feathered edges of the treads may indicate faulty toe adjust‐
form
mer
ment.
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♦ One-sided tread wear is mostly caused by faulty camber.
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or
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If such wear patterns are found, determine the causes by check‐

t
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ing the wheel alignment (repair measure).
pr
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4.10.4 Tire Tread Depth (Including Spare

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Wheel), Checking
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– Check tread depth Prote
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Minimum tread depth: 1.6 mm
Note
♦ This value may vary for individual countries due to different

legislative regulations.
♦ The minimum tread depth has been reached when the depth
of 1.6 mm (1/16 in.) can be measured at several points of the
wheel circumference or when the tread has worn down to the
wear indicators located at several points on the circumference
of the tire.
♦ If the tread wear is close to the wear limits, inform customer
and note findings on the repair order.
4.10.5 Tires, Including Spare, Checking Pres‐

sure and Correcting
Note
The required tires pressures for the relevant model are on a label
attached to the inside of fuel filler flap, or on driver side B-pillar.
Tire inflation pressure (including spare wheel): Checking, cor‐

recting inflation pressures using Tire Filler Unit - VAS 5216- if
necessary.
4.11 Brake System, Check for Leaks and

Damage
Check the following components for leaks and damage:
♦ Brake Master Cylinder
♦ Brake booster (with ABS: hydraulic unit)
♦ Brake pressure regulator
♦ Brake calipers
♦ Make sure the dust caps are on the brake fluid bleed valves.
– Make sure the brake hoses are not twisted.
– Turn steering to left stop and to right stop. During this operation
no brake hose must touch any vehicle components.
– Check brake hoses for porosity and cracks.
– Check brake hoses for chafing. lkswage es n
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– Check the brake line connections for leaks and ocorrosion
ris and tee
make sure they are attached securely. auth or
ac
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un
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Caution
an
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Correct any malfunctions (repair procedure).
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4.12 Front and Rear Brake Pads, Checking
spec
Thickness
t to the co
⇒ “4.12.1 Front Disc Brake Pads”, page 24
rrectne
⇒ “4.12.2 Rear Disc Brake Pads”, page 25
⇒ “4.12.3 Drum Brake Pads, Checking, Rear”, page 26
ss o
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4.12.1 Front Disc Brake Pads
inform
mer
Special tools and workshop equipment required atio

om
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c
♦ Torque Wrench - V.A.G 1332- (40 - 200 Nm)

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or
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♦ Flashlight and mirror

Removing Wheel Cover
The removal hook for removing the wheel cover is located in the
vehicle's tool kit.
The adapter for loosening and tightening of anti-theft wheel bolts
is part of the vehicle tool kit. Refer to
⇒ “4.36 Wheel Bolts, Tightening Specifications”, page 60 .
– To be better be able to evaluate the remaining pad

AG. Vthickness,
olkswagen AG
use a mirror and, if necessary, remove the agen does
olksw tire to check the not
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– Pull off wheel bolt covers if necessary,
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⇒ “4.36 Wheel Bolts, Tightening
ss Specifications”, page 60 . c
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– Mark installation position of wheel in relation to brake rotor.
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– Remove wheel bolts and then the wheel.
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– Measure thickness of inner and outer brake pad.
wit
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a - Pad thickness “without” backing plate
hole
spec
es, in part or in w
Wear limit: 2 mm
t to the co
With pad thickness (not including backing plate) of 2 mm, the
brake pads have reached their wear limit and must be replaced
rrectness of i
(repair procedure). Be sure to notify customer and mark findings
on repair order!
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Note
nform
mercia
at
When replacing brake pads, it is absolutely necessary to check
om
io
brake rotors for wear! Checking and replacing the brake pads, if
n
c
in t
or
necessary, is a repair measure.
his
ate
do
priv
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– Check the brake rotor for wear: »Chassis/brake systems« ⇒

f
en
g
Brake System; Rep. Gr. 46 ; Diagnosis and Testing »Front

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Wheel Brakes, Servicing« C py
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– Install wheel in previously marked position.
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– Tighten wheel bolts in diagonal sequence. Tightening torque,
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refer to
– Return the adapter to the vehicle tools.
– Pull off wheel bolt covers if necessary .
4.12.2 Rear Disc Brake Pads

♦ Torque Wrench - V.A.G 1332- (40 - 200 Nm)

Removing Wheel Cover
vehicle's tool kit.

is part of the vehicle tool kit, refer to
– Remove the trim using the removal hook, if necessary.
– Look through the opening with a flashlight and check the brake
pads.
Golf, Bora
– Check thickness of outer pad visually.
– With flashlight up inner brake pad and position mirror.
– Check thickness of inner pad visually.
a - Pad thickness inner and outer, not including backing plate AG. Volkswagen AG d
agen oes
ksw
Wear limit: 2mm by
Vol not
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Golf R32 hor eo
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nl
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– Measure thickness of inner and outer brake pad.
wit
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a - Pad thickness, not including backing plate
hole
spec
Wear limit: 2 mm
es, in part or in w
t to the co
Continuation (All Vehicles)
With pad thickness (not including backing plate) of 2 mm, the
rrectness of i
brake pads have reached their wear limit and must be replaced
(repair procedure). Be sure to notify customer and mark findings
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on repair order!
nform
ercia
Note
m
at
om
ion
c
When replacing brake pads, it is absolutely necessary to check
in t
or
his
e
brake rotors for wear! Checking and replacing the brake pads, if
at
do
riv
necessary, is a repair measure.

p
cum
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t.
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– Check the brake rotor for wear. Refer to ⇒ Suspension,
Co
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Wheels, Steering; Rep. Gr. 46 ; Removing and Installation t. C rig
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– Install the trim, if necessary.
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Prote AG.
4.12.3 Drum Brake Pads, Checking, Rear

♦ Torque Wrench - V.A.G 1332/- (40 - 200 Nm)
Remove Wheel Cover

vehicle's tool kit.
is part of the vehicle tool kit. Refer to
⇒ “4.36 Wheel Bolts, Tightening Specifications”, page 60 . gen AG. Volkswagen AG
wa does
olks not
– Remove the plug -1-. byV gu
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ility
ot
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spec
es, in part or in w
t to the co
– Check the brake pad thickness on the drum brake -a- without
rrectness of i
the backing plate by looking through the check hole -2-. Use
l purpos
a flashlight to make it easier to see the brake pad.

♦ Wear limit: 2,5 mm
nform
ercia
– Make sure there is no brake fluid or grease on the brake pads.

m
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Note
thi
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At a thickness of 2.5 mm, brake pads have reached their wear
um
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limit and should be replaced (repair measure). Be sure to notify
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customer and mark findings on repair order! t. Cop py
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Procedure
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⇒ Brake System; Rep. Gr. 46 ; Removal and Installation
– Install the plug -1- when the test is completed.
4.13 Brake and Clutch System, Changing

Brake Fluid
⇒ “4.13.1 Application Information and Safety Precautions”,
page 28
⇒ “4.13.2 Brake Fluid Specifications”, page 28
⇒ “4.13.3 Brake Fluid, Changing”, page 28
4.13.1 Application Information and Safety Pre‐

cautions
Note
♦ A new brake fluid had been used since MY 2006.

♦ The new brake fluid can also be used in older vehicles.
♦ New brake fluid can be mixed with previous brake fluid.
Caution
♦ Brake fluid must never come into contact with fluids con‐
taining mineral oils (oil, gas, cleaning solutions). Oils con‐
taining minerals damage seals and sleeves on brake
systems. olkswa AG. V gen AG
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♦ Brake fluid is poisonous. Do not let brakeVfluid
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♦ Brake fluid is hygroscopic, whichaumeans
th that it absorbs ra
moisture from the air. Always store
ss
brake fluid in air-tight c ce
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containers.
nl
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♦ Wash off any spilled brake fluid with plenty of water.

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♦ Do not reuse used / extracted brake fluid!

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♦ Observe waste disposal regulations!

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4.13.2 Brake Fluid Specifications

Permitted Brake Fluid Specifications:
rrectness of i
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03

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4.13.3 Brake Fluid, Changing

nform
ercia

m
at
om
♦ Brake Pedal Depressor - V.A.G 1869/2-

ion
c
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his
ate
do
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for
en
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t.
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Cop py
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Prote AG.
♦ Brake Filling and Bleeding Unit - VAS 5234-
♦ Brake Bleeder Socket - VAS 5519-
AG. Volkswagen AG d
agen oes
olksw not
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or eo
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♦ Brake Bleeder Tool - VAS 6564-

ility
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spec
es, in part or in w
t to the co
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Observe operating instructions for Brake Filling and Bleeding Unit

or c
- VAS 5234- !
thi
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– Set the pressure on the Brake Filling and Bleeding Unit - VAS
rp
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5234- . refer to ⇒ Brake System; Rep. Gr. 47 ; Description

f
en
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t.
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and Operation
Co
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– Unscrew brake fluid reservoir cap.
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Prote AG.
– Extract as much brake fluid as possible using suction hose

from Brake Filling and Bleeding Unit - VAS 5234- -1- or using
a suction bottle with built-in strainer.
Note
After extracting, observe that no further brake fluid runs into the
reservoir (the brake fluid level in the reservoir must align with the
lower edge of the strainer).
WARNING
Do not reuse used / extracted brake fluid!
– Install and extend Brake Pedal Depressor - V.A.G 1869/2- be‐

tween driver seat and brake pedal.
– Connect adapter -1- to brake fluid reservoir.

AG. Volkswagen AG d
agen oes
olksw not
Note byV gu
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If adapter -1- cannot be inserted
ss a due to reasons of space, use ra
c
Adapter - VAS 5234/1- .
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itte
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– Connect filler hose of Brake Filling and Bleeding Unit - VAS
erm
ab
5234- to adapter.
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Vehicles with Manual Transmissions:

h re
hole
– Remove cover cap from bleeder screw of clutch slave cylinder. spec
es, in part or in w
t to the co
– Connect bleeder hose -arrow- to clutch slave cylinder -1-,

open bleeder screw and let approximately 0.1 liters flow out.
Close bleeder screw.
rrectness of i
– Operate clutch pedal several times.

l purpos
All Vehicles
nform
ercia
– Remove caps from the bleeder screws.

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at
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or
his
ate
do
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for
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ng
t.
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– Connect collector bottle bleeder hose -1- to a front bleeder Cop py
screw, open bleed screw and allow the quantity to flow out (see ht. rig
rig ht
table). Close bleeder screw.
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co Vo
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cted agen
Repeat work procedure on right side of vehicle at front.
Prote AG.
– Connect collector bottle bleeder hose -1- to a rear bleeder

screw1), open bleeder screw and allow the corresponding
brake fluid quantity to flow out (see table). Close bleeder
screw.
Repeat work procedure on right side of vehicle at rear.
Sequence and Brake Fluid Capacity Table
Sequence: Brake fluid quantity which
brake wheel cylinder, must flow out of wheel brake
Brake Caliper cylinders
or brake calipers:
Left front 0.2 liter
Right front 0.2 liter
AG. Volkswagen AG d
Left rear 0.3 liter
lksw
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Right rear d0.3
b liter
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Clutch slave cylinder auth 0.1 liter eo
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Total quantity: approximately 1.1 liters
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pt
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2) Including brake fluid extracted from brake fluid reservoir and quantity from
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clutch slave cylinder.
erm
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ility
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– Fit cover caps to bleed screws of wheel brake cylinder and
wit
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brake caliper.
h re
hole
spec
– Move filler lever on Brake Filling and Bleeding Unit - VAS
es, in part or in w
5234- to position -B- (see user manual).
t to the co
– Remove the filler hose from the adapter.
– Remove the adapter from the brake fluid reservoir.
rrectness of i
– Check brake fluid level and fill if necessary.
l purpos
– Screw in sealing cap in brake fluid reservoir.
nform
ercia
– Remove brake pedal depressor.

m
at
– Check pedal pressure and brake pedal free play. Free travel:
om
ion
maximum 13 of the pedal travel
c
in t
or
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ate
do
riv
4.14 Brake Fluid Level, Checking

p
cum
for
en
ng
t.
Brake Fluid Level at Delivery Inspection:
yi Co
Cop py
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For the delivery inspection the fluid level must lie at the MAX.
gh ht
pyri by
marking -1-.
co Vo
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cted agen
Prote AG.
Note
To prevent the brake fluid from overflowing from the reservoir, the
level must not be over the MAX mark.
Brake Fluid Level at Inspection Service:

Brake fluid level must always be evaluated depending on brake
pad wear.
During operation of the vehicle, the brakes are automatically
readjusted depending on wear of the brake pads. Because of the
adjustment, brake fluid level will be slightly lower as a result.
• Recommended brake fluid level when brake pad wear limit is
nearly reached:
“At MIN-marking and slightly above it”, “NO TOPPING OFF RE‐
QUIRED”.
• Recommended brake fluid level when brake pads are new, or
pad wear limit is not nearly reached:
“Between the MIN and MAX marks”.
Caution
If brake fluid level is below MIN mark, check brake system “re‐
pair procedure”, before adding brake fluid.
4.15 Direct Shift Gearbox (DSG) Transmis‐

sion 02E, Fluid and Filter Change, 6-
Speed, AWD
– Refer to ⇒ Direct Shift Transmission; Rep. Gr. 34 ; Removal
and Installation .
4.16 Power Window Regulators, 8-Way

Memory Seats, Performing Initialization
⇒ “4.16.1 Power Window Regulators, Performing Initialization”,
page 32
⇒ “4.16.2 8-Way Memory Seat, Performing Initialization”,
page 33
4.16.1 Power Window Regulators, Performing

Initialization
AG. Volkswagen AG d
agen
Note olksw
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After disconnecting and connecting the vehicle battery uthe
th auto‐
or eo
matic opening and closing features for the electric windows
ss a do ra
c
not function. Before delivering a new vehicle the electric windows ce
le
un
must be initialized. Thereafter, the vehicle battery should not be

pt
an
d
disconnected again.
itte
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erm
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ility
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DANGER!
h re
ole,
spec
After disconnecting and connecting the battery the excess

t to the co
force limitation function of the electric windows does not func‐

tion. This can cause serious injuries if e.g. fingers are caught
in the window!
rrectne
Make sure the customer is aware of this!

ss o
cial p
Perform the following to initialize the power windows:

inform
mer
– Lock all doors completely.

atio
om
– Lock the vehicle doors from the outside, either at the driver or
n
c
i
or
passenger front door.

thi
te
sd
iva
– Unlock vehicle.
pr
cum
r
fo
en
ng
– Lock vehicle anew from outside using driver or front passenger

t.
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op
door. Hold key a minimum of 1 second in locking position when C py
ht. rig
doing this. rig ht
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by lksw
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Prote AG.
4.16.2 8-Way Memory Seat, Performing Initial‐

ization
Note
After disconnecting and reconnecting the vehicle battery, the

memory system for the electric seat adjustment will not function.
Before delivering a new vehicle the memory seat must be initial‐
ized. Thereafter, the vehicle battery should not be disconnected
again.
Perform the following procedure to initialize the power seat mem‐

ory:
– Open driver door.
– Turn on the ignition.
– Adjust seat surface forward and upward until stop.
– Move the backrest all the way forward.
4.17 Performing Vehicle System Test

– Connect the diagnostic tester. Refer to
⇒ “3.3 Diagnostic Tool, Connecting”, page 9 .
– Select operating mode “Guided Fault Finding” on the display.
– Then perform vehicle identification on tester. lkswage es n
o ot g
byV ua
Program now performs a vehicle system test automatically ir se and
d ran
tee
checks for all possible control modules for this vehicleuthtype.
o
or
a ac
ss
– Press > .
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pt
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an
Now all DTCs will be listed.
itte
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ility
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Note
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hole
spec
♦ At this point, it is reasonable to switch to the operating mode
es, in part or in w
"Guided Fault Finding" to perform further work using the VAS
t to the co
5051 and to prevent a second vehicle identification on the
tester.
♦ To do so, press operating mode button and then Guided Func‐ rrectness of i
tions.
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♦ Refer to the corresponding work descriptions for the continued

sequence.
nf
ercia
or
♦ In order to return to Guided Fault Finding, press the operating

m
m
atio
mode button and then Guided Fault Finding.

om
n in
or c
thi
te
sd
iva
Caution
o
r
rp
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m
f
en
ng
t.
In every case, the vehicle must be released to the customer
yi Co
op py
with the DTC memory erased. t. C rig
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Prote
Static Malfunctions
AG.
If one or more static malfunctions are stored in data memory, it is

recommended to arrange with the customer to repair this mal‐
function via Guided Fault Finding.
Sporadic Malfunctions
In the case that only sporadic malfunctions or notes are stored in
DTC memory and the customer has no complaints in conjunction
with an electronic vehicle system, erase the DTC memory.
– Press the Continue > button again to enter the test plan.
– Now end Guided Fault Finding via Go to button and then End.
All DTC memories will be checked now once more.
Then the diagnostic protocol is sent “online” or stored on the test‐
er.
Note
♦ If tester is not connected to the network, diagnostic protocol is

stored and the transmission follows as soon as tester is con‐
nected to the network.
♦ Protocols that have been stored and are older than four days
are erased automatically.
Vehicle system test is completed.
4.18 Protective Joint Boots, Inspecting

– Check outer CV joint boots -2- and inner CV joint boots -1- for
leaks and damage.
Note lkswage es n
o ot g
byV ua
d ran
ir se
For vehicles with All Wheel Drive (AWD), alsothcheck joint bellows
o tee
or
at rear axle. ss
au ac
ce
le
un
pt
an
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erm
ab
ility
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4.19 Noise Insulation, Installing, Golf R32

spec
t to the co
Note
rrectne
♦ The engine compartment cover is not installed at the factory

and must be installed during the delivery inspection.
ss o
♦ It is necessary to drill 3 additional holes in the front wheel

cial p
f in
housing liners.
form
mer
♦ The engine compartment cover, the fastening materials, as

atio
m
well as assembly instructions with drilling templates, are found

o
n
c
inside the vehicle.

or
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sd
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Necessary material:
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♦ 4 x spring nuts with self-tapping screws (anodized) for the side
Co
op py
engine compartment cover. t. C rig
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pyri by
♦ 12 spring nuts with self-tapping screws (black) for the bumper
co Vo
by lksw
cted
cover
agen
Prote AG.
♦ 9 spring nuts with self-tapping screws (black) for the engine

compartment cover -outer edges-
Preparing Work:
– Remove both front wheels.
Note
The following illustration shows the left wheel housing liner. The
fastening of the right wheel housing liner is the same but reversed.
– Cut out the two drilling templates.

– Attach and align the drilling template -2- to the wheel housing
liner -1-. Puncture the 3 drillings -arrows-.
– Use a 6 mm drill bit to drill the holes.

– Set the spring nuts on the indicated areas.
Installing lkswage es n
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byV ua
d ran
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a ac
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itte
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Rest the front edge of the engine compartment cover

-arrow A- on the bumper cover -1- and push in. Afterwards,
nform
ercia
push engine compartment cover up and have a second person

m
hold it.
at
om
ion
c
in t
or
his
te
Note
a
do
priv
cum
for
♦ The front edge of the engine compartment cover -arrow A-

en
ng
t.
yi
must rest on the bumper cover -1-.
Co
Cop py
t. rig
gh
♦ At the outer reaches -arrow B- the engine compartment cover
ht
pyri by
Vo
o
must rest on the bumper cover.
c by lksw
cted agen
Prote AG.
– First set the screw -arrow A-, on the respective side and tighten
to 1.5 Nm.
– Next, set screws at front -arrow B-, then at the sides
-arrow C-, and tighten to 1.5 Nm.
– Install the wheel housing liner screws -arrows D- and tighten
to 1.5 Nm.
– Install front wheels and tighten to specified tightening torque.
Refer to
4.20 Haldex Clutch Oil Filter, Removing and

Installing, All Wheel Drive (AWD)
– Refer to ⇒ Manual Transmission; Rep. Gr. 39 ; Removal and
Installation .
4.21 Haldex Clutch, All Wheel Drive (AWD),

Changing Oil
– Refer to ⇒ Manual Transmission; Rep.. VGr. 39 ; Removal and
AG olkswagen AG d
Installation ksw
agen oes
n
Vol ot g
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4.22 First AidoriKit
se Expiration Date, Checking
d ran
tee
h
ut or
At every inspectionssservice
a
the expiration date of the first aid kit ac
must be checked.
ce
le
un
pt
an
d
Inform the customer of expired dates.

itte
y li
erm
ab
4.23 Fuel Filter, Diesel, Removing and Instal‐

ility
ot p
wit
is n
ling
h re
ole,
spec
t to the co
Note
♦ Make sure that no diesel fuel gets onto the coolant hoses.
rrectne
Clean the hoses immediately, if necessary!

♦ Follow all waste disposal regulations!
ss o
cial p
f in
Removing
form
mer
– Remove retaining clamp -1- and regulating valve -2- with fuel
atio
m
hoses attached.
o
n
c
i
or
n thi
e
– Remove the fuel lines from the hose connections -3- and -4-.
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen the bolt -arrow- at the filter mounting pull out the filter
upward.
Installing
– Install the new regulating valve O-ring.
Note
The flow direction of the fuel is marked at the connections by ar‐

rows (please do not exchange connections).
– Fill new filter with diesel fuel. This way the engine can be star‐
ted faster.
– Slide the filter downward through the filter mounting and fasten
it at the bolt -arrow-. wage
e ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
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ss
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Install regulating valve -2- and attach retaining clamp -1-.
– Install the fuel lines to the hose connections -3- and -4- and
rrectness of i
secure hoses with hose clamps.
l purpos
– Start the engine and perform a visual inspection of the fuel

system for leaks.
nf
ercia
– Rev the engine several times. Afterwards, fuel must flow with‐
or
out bubbles through the transparent hose -C- at idle.
m
m
atio
om
n in
or c
thi
te
sd
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cu
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f
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ng
t.
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4.24 Fuel Filter, Diesel, Draining Water
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Note
agen
Prote AG.
♦ Make sure that no diesel fuel gets onto the coolant hoses.
Clean the hoses immediately, if necessary!
– Remove retaining clamp -1- and regulating valve -2- with fuel
hoses attached.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
– Connect hose at connection sleeve of water drain bolt
ility
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-arrow-, remove bolt, and drain approximately 0.1L of fluid.
wit
, is n
h re
– Tighten water drain bolt -arrow- and disconnect hose.
hole
spec
es, in part or in w
– Install the new regulating valve o-ring.
t to the co
rrectness of i
l purpos
nform
mercia
at
om
i
– Install regulating valve -2- and attach retaining clamp -1-.
on
c
in t
or
– Start the engine and perform a visual inspection of the fuel
his
ate
system for leaks.
do
priv
cum
or
– Rev the engine several times. Afterwards, fuel must flow with‐
f
en
ng
t.
yi
out bubbles through the transparent hose -C- at idle.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4.25 Ribbed Belt, Checking Condition

– Turn engine at vibration damper/ belt pulley -arrow- with sock‐

et wrench.
– With vehicle elevated, check ribbed belt -1- from below for:
♦ Sub-surface cracks (cracks, core ruptures, cross sectional
breaks)
♦ Separation (cover layer, belt cords)
♦ Breaks at lower layer
♦ Fraying of cords
♦ Wear at flanks (material wear, frayed flanks, hardening or
glazing of flanks, surface cracks)
♦ Oil or grease contamination
Note
Replace the belt if any damage is found. This will prevent any belt
malfunctions. Replacing the belt is a repair procedure.
4.26 Cooling System, Checking Freeze Pro‐

tection and Coolant Level
G. Volkswage nA n AG d
wage oes
Volks not
gu
by ara
Note ed nte
oris eo
th
s au ra
c
♦ All engines through
s MY 2007 are filled with coolant additive
ce
e
G12 Plus in accordance with TL VW 774 F (purple color). Only

nl
pt
du
an
use G12 Plus or G12 Plus Plus because of its advantages.

itte
y li
erm
ab
♦ G 12 Plus is suitable as a filled-for-life filling for cast iron and

ility
ot p
all-aluminum engines and gives optimum protection against

wit
, is n
freezing, corrosion damage, scaling and overheating.

h re
hole
spec
♦ G 12 Plus raises the boiling point to 135 ° C (275 ºF) and pro‐
es, in part or in w
vides for better heat dissipation.

t to the co
♦ The coolant portion of the mixture must amount to at least 40

% (freeze protection to -25 °C (-13 ºF) ) and should not exceed
rrectness of i
60 % (freeze protection to -40 °C (-40 ºF)). Otherwise the

freeze protection will be reduced and the cooling efficiency will
l purpos
be worsened.
♦ The freeze protection must be ensured down to approximately
nf
ercia
-25 °C (-13 ºF).

orm
m
atio
om

n in
or c
thi
e
♦ Refractometer - T10007 A-
t
sd
iva
o
r
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cu
o
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f
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
Note
Read the bright/ark boundary to obtain an accurate reading for

the following tests. Place a drop of water on the glass to improve
the readability of the bright/dark boundary. The bright/dark boun‐n AG. Volkswagen AG
dary can be clearly recognized on the “WATERLINE”. olkswage does
no
yV t gu
db ara
ise nte
– Check the concentration of the coolant additive
tho using
r refrac‐ eo
tometer - T10007- (operating instructions).
ss au ra
c
ce
e
The refractometer scale -1- is designed for coolant additives G12;
nl
pt
du
an
G12 Plus, G12 Plus Plus and G11. itte
y li
erm
ab
Scale -2- refers only to coolant additive G 13. (begins L80)
ility
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wit
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h re
hole
Note
spec
es, in part or in w
t to the co
♦ The freeze protection must be ensured down to approximately
-25 °C (-13 ºF).
♦ If for climatic reasons greater freeze protection is required, the
rrectness of i
amount of G12 Plus Plus can be increased, but only up to 60%
l purpos
(freeze protection down to approximately -40 °C (-40 ºF)), oth‐

erwise freeze protection and cooling effectiveness will be
reduced.
nf
ercia
orm
m
– If freeze protection is insufficient, drain off required quantity
atio
om
shown in freeze protection table and add coolant additive G
n in
or c
12 Plus Plus.
thi
te
sd
iva
– Check the freeze protection after the road test.
o
r
rp
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o
m
f
en
ng
Coolant Level, Checking and Filling

t.
yi Co
op py
– Check the coolant level in the coolant reservoir with the engine
t. C rig
gh ht
yri
cold. p by
o Vo
by c lksw
cted agen
Prote AG.
♦ Delivery inspection: coolant level at max. marking

♦ Inspection service: coolant level between the min. and max.
marks.
– If coolant level is too low, fill with coolant mixture.
Note
If the fluid loss is excessive, then determine the cause and repair
it.
WARNING
Use distilled water for mixing. Tap water and well water do not
have the necessary quality to assure the functionality of the
coolant. . Volkswage n AG n AG d
wage oes
Volks not
gu
by ara
Mixture Ratio ed nte
oris eo
h
ut ra
Freeze Coolant addi‐ sa
Water1
s c
ce
protection tive G 12 Plus
le
un
pt
to Plus /
an
d
itte
y li
TL VW 774 G
rm
ab
pe
ility
-25 °C (-13 approximately approximately 60 %
ot
wit
, is n
ºF) 40 %
h re
hole
spec
ºF) 50 %
es, in part or in w
t to the co
ºF) 60 %
rrectness of i
1)
Use only distilled water.
l purpos
Note
nform
mercia
♦ Coolant additive G 12 Plus Plus conforming to TL “VW 774 G”

a
com
tio
prevents freeze and corrosion damage, scaling, and raises the

n in
boiling point. For these reasons, the cooling system must be

r
te o
thi
filled with radiator freeze and corrosion protection fluid all year
s
iva
do
round.
r
rp
cum
fo
en
g
♦ Especially in countries with tropical climates or when vehicle

n
t.
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op
is driven under heavy load, the coolant improves the engine C py
t. rig
reliability by its increased boiling point. gh ht
pyri by
Vo
co lksw
by
♦ The coolant concentration must not be reduced by adding wa‐ Prote
cted AG.
agen
ter, even during the warmer season. The coolant additive ratio
must be at least 40%.
Freeze Protection Table

Freeze protection to °C Difference (in liters)
(°F)
Actual val‐ Specified 4-cylinder 5-cylinder 6-cylinder
ue value engine engine engine
0 (32) -25 (-13) 3.5 4.0 5.0
-35 (-31) 4.0 5.0 6.0
. Volkswagen AG
-5 (23) -25 (-13) 3.0 wagen AG 3.5 4.5
does
olks not
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-35 (-31) ised 3.5
b 4.5 5.5 ara
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-10 (14) -25 (-13)aut
h 2.0 3.0 3.5 ra
ss c
-35 (-31) 3.0 4.0 4.5
ce
le
un
pt
-15 (5) -25 (-13) 1.5 2.0 2.5
an
d
itte
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erm
-35 (-31) 2.0 3.0 3.5
ab
ility
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-20 (-4) -25 (-13) 1.0 1.5 1.5
wit
is n
h re
-35 (-31) 1.5 2.0 2.5
ole,
spec
-25 (-13) -35 (-31) 1.0 1.5 1.5
t to the co
-30 (-22) -35 (-31) 0.5 1.0 1.0
-35 (-31) -40 (-40) 0.5 0.5 0.5
rrectne
Note
ss o
cial p
f i
Follow all waste disposal regulations!
nform
mer
atio
m
– Check the freeze protection after the road test.

o
n
c
i
or
n thi
e
4.27 Air Filter, Cleaning Housing and Remov‐

t
sd
iva
o
pr
ing and Installing Air Filter

um
r
fo
en
ng
t.
yi Co
op
⇒ “4.27.1 Air Filter, Cleaning Housing, Replacing Filter, Cleaning C py
ht. rig
Snow Screen If Equipped”, page 42 rig ht
py by
co Vo
by lksw
⇒ “4.27.2 Snow Screen, 2.0L, Cleaning”, page 43 Prote
cted AG.
agen
4.27.1 Air Filter, Cleaning Housing, Replacing

Filter, Cleaning Snow Screen If Equip‐
ped
Note
♦ Depending on the equipment level, the air guide in the air filter
housing lower section may have screen installed near the air
intake.
♦ This screen prevents snow and ice from entering the air filter
housing and clogging the air filter during winter months.
♦ If a person reaches into air intake apparatus from the front, it
can be felt whether a snow strainer is installed.
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Bora 1999 ➤ , Boraau Variant 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998
th or ➤
ac
ss Maintenance - Edition 05.2012
ce
e
nl
pt
du
an
– Remove fastening bolts -arrows-.
itte
y li
erm
ab
– Lift and remove the air filter housing upper section.
ility
ot p
wit
, is n
– Remove old air filter -arrow-.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Removing and installing snow strainer. Refer to
m
⇒ “4.27.2 Snow Screen, 2.0L, Cleaning”, page 43 .
at
om
ion
c
in t
or
his
te
Note
a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
– Clean filter housing and insert new air filter.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Insert upper section of filter housing and tighten bolts

-arrows-.
4.27.2 Snow Screen, 2.0L, Cleaning

Snow strainer is located in air intake apparatus -4-.
– Remove upper section of air filter. Refer to
⇒ “4.27.1 Air Filter, Cleaning Housing, Replacing Filter, Clean‐
ing Snow Screen If Equipped”, page 42 .
– Remove air filter -1-.
– Remove lower section of air filter -7-.
– Remove air intake apparatus -4- and remove snow strainer
-5- from air intake apparatus.
– Clean snow strainer.
Installation is reverse of removal.
♦ Tightening torque -2- 10 Nm.
♦ Tightening torque -3- 3 Nm.
4.28 Upper Engine Cover, Removing and In‐

stalling
⇒ “4.28.1 Engine Cover, Removing and Installing, 1.4L with Igni‐
tion Coil”, page 44
⇒ “4.28.2 Engine Cover, Removing and Installing, 1.4L with Igni‐
tion Coil with Power Output Stage”, page 45
⇒ “4.28.3 Engine Cover, 1.8L, Removing and Installing”,
page 45
⇒ “4.28.4 Engine Cover, 2.0L, Removing and Installing”,
page 46
⇒ “4.28.6 Engine Cover, Removing and Installing, 2.8L Fuel In‐
jection Engines”, page 47
⇒ “4.28.7 Engine Cover, Removing and Installing, 3.2L Fuel In‐
jection Engines”, page 47 agen
AG. Volkswagen AG d
o w es n
olks o
⇒ “4.28.8 Engine Cover,edRemoving
by
V
and Installing, 4-Cylinder
t gu
aTDI
ran
Engines”, page 48 horis tee
t or
au ac
⇒ “4.28.9 EnginessCover, Removing and Installing, 4-Cylinder TDI
PD Engines”, page 48
ce
e
nl
pt
du
an
itte
4.28.1 Engine Cover, Removing and Installing,

y li
erm
1.4L with Ignition Coil ab

ility
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wit
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Removing h re
hole
spec
– Remove hex socket head bolts -arrows- and remove engine
es, in part or in w
cover.
t to the co
Installing
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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r
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cu
– Install the engine cover and tighten the hex socket head bolt
o
m
f
en
ng
-arrows- to 10 Nm.
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.4L with Ignition Coil with Power Output
Stage
Removing
– Pull off hose from oil separator or check-valve from upper sec‐
tion of air filter housing.
– Disengage engine cover -arrows-, pull off from throttle valve

control module and remove upward.
Installing
n AG. Volkswagen AG
– Place and press
ksw on engine cover on to
age doesthrottle valve control
not
Vol
module dand
by on to mounting points so that they
gu
ar engage.
e an
ris te
– Connect
ut
ho connector and hose connection beneathe engine
or cov‐
er.
ss
a ac ce
le
un
pt
an
d
itte
y li
erm
ab
ility
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is n
h re
4.28.3 Engine Cover, 1.8L, Removing and In‐

ole,
spec
stalling
t to the co
Note
rrectne
There are different versions of engine covers.

ss o
cial p
f i
Version 1
nform
mer
Removing
atio
om
n
c
– Loosen screws -arrows- and remove engine cover -A- upward.

i
or
n thi
te
sd
a
Installing
iv
o
pr
cum
r
fo
– Install engine cover -A- and fasten screws -arrows-.

en
ng
t.
yi Co
Cop py
Version 2
t. rig
gh ht
pyri by
Vo
o
Removing
c by lksw
cted agen
Prote AG.
– Loosen screws -arrow- and remove engine cover upward.
Installing
– Install engine cover and fasten locking screws -arrows-.

stalling
Removing agen
AG. Volkswagen AG d
oes
olksw not
V
– Pry the cover off -arrows- and loosenedtheby nuts underneath. gu
ara
ris nte
o
– Unscrew nut -1-. aut
h eo
ra
ss c
– Pull out oil dipstick.
ce
e
nl
pt
du
an
– Lift engine cover and pull off toward front.
itte
y li
erm
ab
Installing
ility
ot p
wit
, is n
– Tighten collar nut to 7 Nm.
h re
hole
spec
– Seal collar nut with cover cap.
es, in part or in w
t to the co
Note
rrectness of i
l purpos

nf
ercia
stalling
rm
m
atio
om
n in
Removing
or c
thi
te
– Pull off engine cover -1- upward and remove.

sd
iva
o
r
rp
cu
Installing
o
m
f
en
ng
t.
yi Co
– Place engine cover -1- on to mounting points and press on so t. Cop py
that they engage.
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
lkswage es n Maintenance - Edition 05.2012
o o
t gu
yV
db ara
ir se nte
aut
ho eo
ra
2.8L Fuel Injection Engines
ss c
ce
le
un
pt
Removing
an
d
itte
y li
rm
ab
– Pull off engine cover -1- upward and remove.
pe
ility
ot
wit
Installing
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
– Install engine cover -1- and clip into place.
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3.2L Fuel Injection Engines
Removing
– Unclip and remove cover for wiring guides -1-.
– Release engine cover -2- at the indicated points -arrows- and
remove upwards.
Installing
– Set the engine cover -2- on the indicated points -arrows- and
secure into place.
– Install cover for wiring guides -1-.

4-Cylinder TDI Engines
AG. Volkswagen AG d
Removing ksw
agen oes
not
ol
yV gu
– Pry the cover off -arrows-
ised band loosen the nuts underneath. ara
nte
or eo
h
– Unscrew nut -1-. s aut ra
c
s
– Pull out oil dipstick.
ce
e
nl
pt
du
an
itte
– Lift engine cover and pull off toward front.
y li
erm
ab
ility
Installing
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
rrectness of i
l purpos
4-Cylinder TDI PD Engines
nf
ercia
Removing
orm
m
– Disengage engine cover at fastening points -arrows B- and lift.
atio
om
n in
c
– Then remove it from the bracket -arrow A-.

or
thi
te
sd
a
Installing
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– First slide the engine cover -B arrows- into the bracket

-A arrows-.
– Then position the engine cover on the other mounting points

-B arrows- and press it on until it engages.
4.29 Lower Engine Compartment Cover, Re‐

moving and Installing
AG. Volkswagen AG d
♦ Torque Wrench
olks
-wV.A.G
agen 1783- oes
not
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db ara
rise nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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h re
ole,
spec
t to the co
♦ Cordless Drill 12V/2.0 Ah - VAS 5826-

rrectne
Engine compartment cover (noise insulation) Golf, Bora

⇒ page 49
ss o
Engine compartment cover (noise insulation) Golf R32

cial p
f in
⇒ page 50
form
mer
atio
Golf, Bora
om
n
c
– Remove the bolts -arrows- with Cordless Drill 12V/2.0 Ah -

or
n thi
e
VAS 5826- and then remove the engine compartment cover.

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
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Prote AG.
– Unclip mounting clips -arrows- and unscrew bolt -1-.

– Remove left and right engine compartment cover.
Note
Do not use the clips again. Replace them each time the engine
compartment cover is removed.

Additional Powertrain Protection:
The tightening specification for the additional
agen
AG. Volkswapowertrain
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does protec‐
tion is 35 Nm. V olksw not
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The following illustration shows the right side of the engine com‐
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partment cover. The fastening of the left side is the same but
h re
hole
reversed.
spec
es, in part or in w
t to the co
– Remove the bolts -arrows- with Cordless Drill 12V/2.0 Ah -
VAS 5826- and then remove the engine compartment cover. rrectness of i
Installing
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– Set the front edge of the engine compartment cover
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-arrow A- on the edge of the bumper cover -1- and push in.
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second person hold it. Prote AG.
Note
♦ The front edge of the engine compartment cover -arrow A-

must rest on the bumper cover -1-.
♦ At the outer reaches -arrow B- the engine compartment cover
must rest under the bumper cover.
– First set the screw -arrow A-, on the respective side and tighten
to 1.5 Nm
– Next, set screws at front -arrow B-, then at the sides

-arrow C-, and tighten to 1.5 Nm.
– Install the wheel housing liner screws -arrows D- and tighten
to 1.5 Nm.
AG. Volkswagen AG d
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4.30 Engine Oil Level, Checking
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Note the
aut following: ra
c
ss
– After turning off the engine, wait at least 3 minutes for the oil
ce
le
un
pt
to flow back into the oil pan.
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– Pull the dipstick out, wipe if off with a clean cloth and then
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insert it back in all the way.
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Follow all disposal regulations. rrectne
– Pull out the dipstick again and check the oil level.
A - Do not add oil.
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B - Engine oil can be filled up to the -A- range.

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C - Add oil. The oil level must be at least in the upper third of the
mer
atio
measuring range -B-.

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– Drain or extract some of the oil if the oil level goes above the
or
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-A- mark to prevent damage to the catalytic converter.

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– Fill the oil until it reaches the -A- marking if the oil level goes
um
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below the -C- marking. For the correct oil specification, refer
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to ⇒ Fluid Capacity Tables; Rep. Gr. 03 .
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4.31 Engine Oil, Draining or Extracting and
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Filling; Replacing Oil Filter
⇒ “4.31.1 Engine Oil, Draining or Extracting and Filling”,
page 51
⇒ “4.31.2 Oil Filter, Replacing”, page 53
⇒ “4.31.3 Engine Oil, Filling”, page 56
4.31.1 Engine Oil, Draining or Extracting and

Filling
♦ Oil Extractor - V.A.G 1782-
♦ Used Oil Collection And Extraction Device - VAS 6622-
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♦ Oil Absorbent Towel - VAS 6204/1-
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Engine Oil, Draining or Extracting
h re
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spec
es, in part or in w
t to the co
Note
♦ On engines with standing oil filter module, oil filter should be

changed before the oil change. Removing the filter element rrectness of i
will open a valve and oil in the filter housing will flow automat‐
l purpos
ically into the crankshaft housing.

♦ If engine oil is drained and not extracted using old oil extraction
nf
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unit, replace oil drain plug. This prevents leaks.

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♦ Follow all disposal regulations.

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– Extract engine oil using Oil Extractor - V.A.G 1782-

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– Extract the engine oil using a Used Oil Collection And Extrac‐ Cop py
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tion Device - VAS 6622-
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– Remove oil drain plug
– Let engine oil drain.
Note
Follow all disposal regulations.
– Install the new oil drain plug and seal hand-tight and then
tighten to the tightening specification.
– Fill the engine oil. For specifications and cpacities, refer to ⇒
Fluid Capacity Tables; Rep. Gr. 03 .
Oil drain plug tightening specifications:

The tightening specifications depend on the engine codes. Refer
to ⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr.
17 ; Assembly Overview .
Caution
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♦ Torque settings must not be exceeded d byV
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♦ A torque figure that is too high may lead to leaksuorth even
o
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damage the oil pan. ss
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4.31.2 Oil Filter, Replacing
erm
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Oil Filter, Removing and Installing, 1.6L, 1.8L and 2.0L Fuel In‐
wit
is n
jection Engines ⇒ page 54 .
h re
ole,
spec
jection Engines ⇒ page 54 .
t to the co
Oil Filter, Removing and Installing, SDI and TDI Diesel Engines
⇒ page 54 .
rrectne
Oil Filter, TDI PD Diesel, Replacing ⇒ page 55
s
s o
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♦ Oil filter wrench - VAS 3417-
form
mer
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♦ Torque Wench (5 - 50 Nm)
♦ Oil Flter Wench (commercially available)

or
♦ Oil filter strap wrench
Oil Filter, 1.8L and 2.0L, Replacing

– Oil filter -arrow- is best removed from under the vehicle, loos‐
ening it with a strap wrench. AG. Volkswagen
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– Clean the sealing surface on the engine.
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– Coat the rubber seal on the new oil filter lightly with oil. The oil
ot
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filter can adhere better when tightening, which allows for best
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hole
spec
– Screw in filter and tighten hand-tight.
es, in part or in w
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Oil Filter, Removing and Installing, SDI and TDI Diesel Engines
rrectness of i
– Loosen the cap -1- using the Oil FIlter Wrench - VAS 3417- .
l purpos
– Replace O-rings -2- and -3- and the oil filter element -4-.
nform
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Note
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– Tighten the cap -1- using the Oil Filter Wrench - VAS 3417- .
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Cap tightening specification: 25 Nm

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– Remove oil drain plug -1- and drain oil.
Note

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– Loosen lower portion of filter housing -3- at the hex -2- y V or cir‐
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cumference -4- and remove. ir se
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– Remove the old air filter. au or
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– Wipe the air filter housing with a cloth.
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– Coat the new Oring with oil.
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– Install the new air filter and Oring.
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– Tighten the filter housing lower section -3- at the hex bolt -2-
h re
hole
to 30 Nm.
spec
es, in part or in w
– Install the drain plug -1- with a new seal and tighten it to 10
t to the co
Nm.
Oil Filter, Replacing, TDI PD Diesel Engines
rrectness of i
Removing
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Note
nform
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at
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♦ Coat the new O-rings with oil before installing them.

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Loosen sealing cap -arrow- e.g. using 36 mm Wrench or using 36

f
en
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t.
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mm Socket - T10125- .
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Note
by lksw
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Prote AG.
Loosen cap before draining/extracting so that engine oil can flow

out of filter housing.
– Clean sealing surfaces at cap and at oil filter housing.
Installing
– Install oil filter -3-
– Replace the o-rings -2 and 4-.
AG. Volkswagen AG d
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– Install the cap -arrow- and tighten it to 25 Nm. utho eo
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Install in reverse order of removal. s
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4.31.3 Engine Oil, Filling
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General Information
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mer
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Note
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– After the oil is filled, wait 3 minutes and then check the oil level.
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Turbo-engines:
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• After the engine oil and oil filter have been replaced, observe cop Vo
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the following when first starting the engine:
agen
Prote AG.
• As long as the oil pressure warning light in the instrument

panel insert flashes, the engine is only to run at idle. Do not
touch the accelerator pedal! Bumping the accelerator pedal
can damage the turbocharger or destroy it completely.
• Only when the warning light extinguishes, is the full oil pres‐
sure achieved, and the engine can be accelerated.
– Pull out the oil dipstick and wipe it with clean cloth. Insert the
dipstick and push it all the way down.
– Pull out the dipstick again and check the oil level.
n AG. Volkswagen A
Capacities with filter ochange,
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G do
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Tables;
Rep. Gr. 03 . d by V ua
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A - Do not add
ut
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B - Engine oil can be filled up to the -A- range.
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C - Add oil. The oil level must be at least in the upper third of the
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measuring range -B-.
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– Drain or extract some of the oil if the oil level goes above the
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-A- mark to prevent damage to the catalytic converter.
h re
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spec
– Fill the oil until it reaches the -A- marking if the oil level goes
es, in part or in w
below the -C- marking. For the correct oil specification, refer
t to the co
to ⇒ Fluid Capacity Tables; Rep. Gr. 03
4.32 Engine and Engine Compartment Com‐
rrectness of i
ponents, Checking for Leaks and Dam‐
l purpos
age
nf
ercia
o
Perform visual check as follows:
rm
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atio
m
– Check engine and components in engine compartment for

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leaks and damage.

or
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– Check the lines, hoses and connections on the following sys‐

iv
o
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♦ Fuel system
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♦ Heating and ventilation system rig ht
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♦ Brake system Prote
cted AG.
agen
for leaks, abrasions, porosity and brittleness.
Note
♦ Make sure the all malfunctions detected are rectified within

repair measures.
♦ Determine cause of fluid loss, which cannot be attributed to
normal use and repair.
4.33 Perform a Road Test

The following checks depend on the vehicle equipment level and
the available testing possibilities (city or rural).
During the road test, check the following:
– Engine: performance, stalling, idle, acceleration
– Clutch: starting, pedal force, smell
– Shifting: ease of movement, shift lever position
– Automatic transmission: selector lever position, shift lock/ig‐
nition key interlock, shift behavior, instrument cluster display
– Foot and parking brake: function, free travel and effectiveness,
pulling to one side, rubbing, squeaking
– ABS function: when braking with activated ABS, the brake
pedal must pulse noticeably.
– Steering: function, steering travel, steering wheel center posi‐
tion when driving straight ahead.
– Sunroof: function
– Radio: reception, speed compensated volume, static

– Multi-function display: functions
– A/C system: function
– Vehicle: pulling to one side while driving straight ahead (level
road)
– Imbalance: wheels, driveshafts, propshaft
– Wheel bearing: noises agen
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– Engine: warm starting behavior byV gu
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4.34 Radio/Radio Navigation System, At‐
h
aut ra
ss c
taching Serial Number and Code Num‐
ce
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nl
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du
ber to Unit Card
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The code number for the unit must be entered to deactivate the
ility
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radio/radio navigation system electronic lock.
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The unit code number and serial numbers are indicated on the
hole
spec
unit card.
es, in part or in w
t to the co
The unit card is located in the front of the owner's manual.
– Affix the serial number and code number to the unit card.
rrectness of i
4.35 Radio/Radio Navigation System, Acti‐
l purpos
vating Anti-Theft Coding
nf
ercia
orm
m
⇒ “4.35.2 ALPHA Radio Units, Activating Security Code”,
atio
m
page 58
o
n in
or c
thi
e
⇒ “4.35.3 BETA Radio Units, Activating Security Code”,

t
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iva
page 59
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⇒ “4.35.4 On the Radio Navigation System activate the security yi

t.
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code as follows:”, page 59 ht. Cop py
rig
rig ht
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Prote AG.
Radios and radio/navigation systems are delivered with a security
code. Fixed code means that every unit with anti-theft coding has
been programmed with its own code. This code is not active from
the factory.
4.35.2 ALPHA Radio Units, Activating Security

Code
The security coding of the ready-to-use unit is only activated by
entering the fixed code. Activate the security code as follows:
– Turn on radio.
– The display will indicate “SAFE”.
– Press and hold buttons TP and TA -1- at the same time until
the digital display indicates “1000”. Release buttons!
– Using the station preset buttons 1 through 4, enter the code
number found on the radio card sticker. Button 1 adjusts the
number in the first position, button 2 the second, etc...
– Thereafter, press and hold the buttons TP and TA -1- at the

same time until the frequency display indicates “SAFE”. Re‐
lease button! Shortly thereafter, a frequency will automatically
be selected.
If the security code was entered in the radio properly, the LED
next to radio name will flash with the ignition turned off and key
removed. If the LED flashes, the radio is ready for operation and
the anti-theft coding is active.
4.35.3 BETA Radio Units, Activating Security

Code
– Turn on radio.
– The display will indicate “SAFE”.
– After 3 seconds, “1000” will be indicated on the display.
– Using the station preset buttons 1 through 4, enter the code
number found on the radio card sticker. Button 1 adjusts the AG. Volkswagen A
number in the first position, button 2 the second, etc...olkswagen G do
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– Afterwards, press and hold either the the seekss button -1- or
ce
le
tuning button -2- for at least 2 seconds. Release buttons.

un
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If the security code was entered in the radio properly, after a short
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“Learning phase” the actual frequency will be displayed. During
pe
ility
this pause, the strongest frequency stations in the region will be
ot
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stored in internal memory and become readily available. With the
h re
ignition off and key removed, the LED in the bottom left of the
hole
spec
radio must flash. If the LED flashes, the radio is ready for opera‐
es, in part or in w
tion and the anti-theft coding is active.
t to the co
rrectness of i
l purpos
4.35.4 On the Radio Navigation System acti‐ nform

ercia
vate the security code as follows:

m
– Turn on the radio/navigation system by pressing button -1-.

com
tion in
r
– Enter the numeric code, by turning the button -2- until the de‐
te o
thi
sired number appears in the display -3-. Confirm the number

s
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and move on to the next field by briefly pressing the button.

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Cop py
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Prote AG.
– Once the code is completely entered, confirm the entire code

by pressing and holding the button -2- (for at least 2 seconds).
If the security code was entered in the radio properly, after a short
“Learning phase” the actual frequency will be displayed. During
this pause, the strongest frequency stations in the region will be
stored in internal memory and become readily available. With the
ignition off and key removed, the LED in the bottom right of the
radio/navigation system must flash. If the LED flashes, the radio/
navigation system is ready for operation and the anti-theft coding
is active.
4.36 Wheel Bolts, Tightening Specifications

Wheel Bolt Covers, Removing and Installing ⇒ page 60
Installation tool for wheel cover (only anniversary Golf GTI)
⇒ page 60
Wheel Bolt Locks, Loosening and Tightening ⇒ page 61
Wheel Bolts, Tightening ⇒ page 62
AG. Volkswagen AG d
Wheel Bolt Covers, Removing and Installing ksw
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Depending on vehicle equipment, the wheel bolts may be covered

un
pt
an
d
by the following components:

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ility
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♦ Wheel bolt cover caps
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♦ Center wheel cover
ole,
spec
♦ Full wheel cover
t to the co
– Remove the corresponding wheel bolt cover, if present.
rrectne
Note
ss
The pulling hook for removing the cover caps or center wheel
o
cial p
f
cover is located in the vehicle tool kit.
inform
mer
atio
Installation tool for wheel cover (only anniversary Golf GTI)

om
n
c
i
or
– Place the wheel cover installation tool in the vehicle tool kit, as
thi
e
shown in the illustration -arrow-.

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Cop py
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Prote AG.
Removing Center Wheel Cover

– Insert removal hook into one of the holes of the center hubcap
and pull in -direction of arrow-.
Installation Information
Note
♦ Cover caps protect the wheel bolts and should be reinstalled

after final tightening of the wheel bolts.
♦ Note that the center wheel cover tab must engage into rim
recess for some rims.
♦ Place adapter and extractor in vehicle tool kit after completing
work.
– On vehicles with full covers, install full wheel cover by guiding
ksw
age es n
the tire inflating valve through the designated recess Vol
y-arrow-.
ot g
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ris tee
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ility
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spec
es, in part or in w
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Wheel Bolt Locks, Loosening and Tightening
rrectness of i
l purpos
Note
♦ The adapter to loosen/tighten the anti-theft wheel bolts is lo‐
nf
ercia
o
cated with the vehicle tool kit.
rm
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atio
m
♦ If the adapter to loosen/tighten the anti-theft wheel bolts is not

o
n in
c
present in the vehicle, use Master Wheel Bolt Key Set -

or
thi
e
T10101- .
t
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♦ If adapter has been lost, a new replacement adapter can be

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en
obtained only via the code number.

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Special tools and workshop equipment required cop Vo
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Prote
♦ Master Wheel Bolt Key Set - T10101-
AG.
– Slide adapter into anti-theft wheel bolt until it stops.
– Slide wheel wrench on to adapter until it stops.

– Perform final tightening of wheel mounting bolts to the correct
tightening torque.
Wheel Bolts, Tightening
♦ Torque Wrench - V.A.G 1332-
AG. Volkswagen AG d
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ility
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Note
spec
es, in part or in w
t to the co
Make sure the wheel bolts are tightened in diagonal sequence.
Tightening Specification: 120 Nm
rrectness of i
4.37 Attaching Wheel Housing Liner to Front
l purpos
Apron (Anniversary Golf GTI with 132
nf
ercia
kW only)
orm
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c
Note
or
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♦ The wheel housing liner must be fastened to the front apron

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by an additional fixing bolt. This will help prevent damage to m

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the wheel housing liner.
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♦ The following illustration shows the right wheel housing liner.
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The fastening of the left wheel housing liner is the same but
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reversed. Prote AG.
♦ The fastening -1- in the illustration was performed by the fac‐

tory.
Necessary material:
♦ 2 x “N 015 439 1” spring nut
♦ 2 x “N 907 750 01” Torx socket head self-tapping screw (4.8
x 16)
Work sequence for the additional fastener -2-:

– Attach and align spring nut -2- on the right front apron.
Measurements -A- and -B- = 10 mm.
Drill a 4 mm hole.
– Tighten the TORX bolt -1- and the additional TORX bolt N 907
750 01 (4.8 x 16) -2- to the wheel housing liner.
AG. Volkswagen AG d
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4.38 Tire Repair Kit, Checking

is n
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spec
Golf, Jetta
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The tire repair kit is located in the spare wheel well -arrow-
Golf R32
rrectness o
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mer
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The tire sealant is located in the luggage compartment, -1-. AG. Volkswagen AG d
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♦ The tire sealant in the bottle has a limited shelf-life. s
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un
pt
♦ The expiration date -arrow- is written on the bottle.
an
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ility
In this example, the expiration date, 05/2003, has passed. Re‐
ot p
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place the bottle.
is n
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– Verify the expiration date.
spec
– Replace tire sealant, if expiration date has been reached. urposes, in part or in wh
t to the co
Caution
rrectne
♦ Tire sealant must not be older than 4 years.
ss o
♦ If the bottle was opened, e.g. for a flat tire, it must also be
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replaced.
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♦ Residual tire sealant or full bottles, which have expired, must
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♦ Old tire sealant or remainder of it must not be mixed with other
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4.39 Power Steering, Checking Fluid Level

Cold Fluid
– With engine not running, move front wheels in straight-ahead
position.
– Guide a suitable screwdriver into recess on sealing cap
-arrow- and unscrew sealing cap with fluid dipstick.
– Clean dipstick with clean cloth.
– Screw cap on hand-tight and remove again.
Note
Screw cap fully in to get an accurate fluid level reading.
– Check fluid level: the fluid level must be in the hatched area
-A-
Note
♦ If fluid level is above specified range, fluid must be extracted

off.
♦ If the fluid level is below the specified level, check the power
steering system for leaks (repair measure). It is not sufficient
just to add fluid. If no leaks are detected, top off with power
steering fluid “G 002 000”.
– Screw in sealing cap hand-tight (using screwdriver).

Warm Fluid, above 50 °C (122 ºF)
– With engine not running, move front wheels in straight-ahead
position.
AG. Volkswagen AG d
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– Guide a suitable screwdriver into recess on sealing d by cap
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-arrow- and unscrew sealing cap with fluid dipstick.
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– Clean dipstick with clean cloth. ss a c
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– Screw cap on hand-tight and remove again.
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Screw cap fully in to get an accurate fluid level reading.
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– Check fluid level: the fluid level must be between the min. and
rrectness of i
max. markings.
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Note
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♦ If fluid level is above MAX. marking, the oil must be extracted.

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♦ If fluid level is below MIN. marking, then the power steering

or
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system must be checked for leaks (repair measure). It is not

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sufficient just to add fluid. If no leaks are detected, top off with
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power steering fluid “G 002 000”.

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– Screw in sealing cap hand-tight (using screwdriver).
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4.40 Sunroof, Checking Function, Cleaning
cted agen
Prote AG.
and Lubricating Guide Rails

– Check sunroof functionality.
– Clean the guide rails -arrows- and then lubricate them with
Adhesive Lubricating Paste - G 060 751 A2- .
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4.41 Sunroof Water Drains, Checking and
hole
spec
es, in part or in w
Cleaning
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rrectness of i
♦ Cleaning And Insertion Aid - VAS 6620-
l purpos

– Open the sunroof.
nform
ercia
– Make sure the sunroof drain holes -arrows- are not blocked
m
with dirt. Clean them if necessary.
at
om
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c
– Pour tap water through the sunroof drains and make sure the
in t
or
his
e
water flows unobstructed out of the drain valves in the A-pil‐

at
do
riv
lars.
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Prote AG.
– If the water drains poorly or not at all, then insert the cleaning
and insertion aid - VAS 6620- carefully into the sunroof water
drain.
– Move the cleaning and insertion aid - VAS 6620- back and
forth up to the drain valve and push out any dirt.
– Using tap water, pour water through the sunroof drain holes
one more time.
– Remove any dirtwaaround
gen AG the drainn A
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4.42 Windshield and Headlamp Washer Sys‐
wit
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tem, Checking for Damage, Function
hole
spec
and Spray Nozzle Adjustment
es, in part or in w
t to the co
⇒ “4.42.1 Windshield Wiper/Washer System Freeze Protection,
Checking and Filling”, page 67
rrectness of i
⇒ “4.42.2 Windshield Washer System, Checking and Adjusting
l purpos
Spray Nozzle Position”, page 69

⇒ “4.42.3 Headlamp Washer System, Checking Spray Nozzles”,
nf
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page 71
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4.42.1 Windshield Wiper/Washer System

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Freeze Protection, Checking and Filling

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If during the function test it is determined that the wiper blades
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are »shuddering« or making noises, check the pitch angle of the
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wiper blades. Refer to
cted agen
Prote AG.
⇒ “4.43 Windshield Wiper Blades, Checking for Damage, End
Position and Adjustment Angle”, page 71 .
Note
If during the function test it is determined that the wiper blades

pulsate or make noises, check the installed angle of the wiper
blades. Refer to
⇒ “4.43 Windshield Wiper Blades, Checking for Damage, End
Position and Adjustment Angle”, page 71 .
Checking freeze protection concentration:

♦ Refractometer - T10007 A-
Note
Read the bright/ark boundary to obtain an accurate reading for

the following tests. Place a drop of water on the glass to improve
the readability of the bright/dark boundary. The bright/dark boun‐
dary can be clearly recognized on the “WATERLINE”.
– Check the concentration of the anti-freeze additive using Re‐

fractometer - T10007 A- (operating instructions).
AG. Volkswagen AG d
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The scale -1- of the refractometer is designed specifically for gen‐

uine Volkswagen Windshield Clear “G 052 164”.
Volkswagen AG
The scale -2- is designed for commercially available windshield swagen AG. does
washer fluid as well as a mixture of commercially available wind‐
by
Vol
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shield washer fluid and “G 052 164”. ris
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Mixture Ratio ss au ra
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Freeze protection to Windshield Washer Water
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G 052 164
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-17/-18 ℃ (1.4/0.4 1 part 3 part
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-22/-23 ℃ 1 part 2 part
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(-7.6/-9.4ºF)
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-37/-38 ℃ 1 part 1 part
(-34.6/-36.4)
rrectness of i
Filling-up with Fluid:
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The windshield washer system fluid reservoir must be filled.

Use only “Genuine Volkswagen Windshield Clear” all-year-round
nf
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when topping-up the windshield wash/wipe system.
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♦ Vehicles with fan type spray jets must be filled with “Genuine
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low viscosity at minus temperatures. The complicated spray Cop py
jet system could otherwise become blocked due to crystallized
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washer fluid that can affect the fan pattern of the spray jet.
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“Genuine Volkswagen windshield clear” assures that the fan cted agen
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type spray jets remain functional even at low temperatures.
♦ Genuine Volkswagen windshield cleanser “G 052 164” pro‐
tects the spray jets, fluid reservoir and hoses from freezing.
♦ Use genuine Volkswagen windscreen cleanser “G 052 164” in
the warmer periods of the year also. The powerful cleanser
removes wax and oil deposits from the windows.
♦ Freeze protection (anti-freeze) must be guaranteed to approx‐
imately -15 C (5 ºF) (approximately -35 ºC (-31 ºF)in countries
with an arctic climate) in the washer system.
4.42.2 Windshield Washer System, Checking

and Adjusting Spray Nozzle Position
Windshield
Note
The spray nozzles must not be cleaned opposite to direction of

spray, e.g. blown-through from front.
The washer nozzles are preset. Small height adjustments can be

made.
If both spray fields are not at same height, adjust spray direction
upward or downward as follows:
AG. Volkswagen AG d
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– Turn the eccentric at the spray nozzles with a screwdriver in ss
ce
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the direction indicated.

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Back Window:
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Windshield Washer Aiming Tool - T10127-
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Prote AG.
Windshield Washer Aiming Tool - T40187-
Note
♦ If the spray field is uneven or does not adjust to the middle of

the wiper field, replace the washer nozzle (repair measures).
♦ Never use a needle or similar device to adjust washer nozzle,
as damage to the washer nozzle water canal may result.
– Check the washer nozzle setting.

Rear Window Washer Nozzle Setting:
The spray nozzle must encounter wiper area at center.
– Adjust the nozzle if necessary.
4.42.3 Headlamp Washer System, Checking

Spray Nozzles
Caution
The spray nozzles can be checked for functionality, but they

cannot be adjusted.
Golf
Spray jet adjustment for left headlamp (right headlamp is identi‐
cal):
– Check nozzle adjustment.
a 100 mm c 55 mm
b 75 mm d 125 mm
If the spray pattern differs from the specification, perform a repair.
Jetta
Spray nozzle adjustment for left headlamp (right headlamp is

identical):
– Check nozzle adjustment.
a 165 mm
b 55 mm
If the spray pattern differs from the specification, perform a repair.
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4.43 Windshield Wiper Blades, Checking for

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Damage, End Position and Adjustment

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⇒ “4.43.1 Windshield Wiper Blades Parked Position, Adjusting”,

ole,
spec
page 71
t to the co
⇒ “4.43.2 Windshield Wiper Blades, Checking Angle and Adjust‐

ing”, page 72
rrectne
4.43.1 Windshield Wiper Blades Parked Posi‐

tion, Adjusting
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Refer to ⇒ Electrical Equipment; Rep. Gr. 92 ; Description and

f in
Operation
form
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71
Prote AG.
4.43.2 Windshield Wiper Blades, Checking An‐

gle and Adjusting
Note
♦ With the installation of Aero wiper blades the angle setting ex‐
amination of the wiper arms is not valid.
♦ The angle setting of the Aero wiper arm is always the same
and can not be changed or adjusted.
♦ Check the angle setting of other wiper blades, and only if the
wiper blades pulsate or make noise.

♦ Wiper Blade Adjuster - VAS 3358B-
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– Park windshield wiper arms.
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– Remove windshield wiper.
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– Set windshield wiper arm -2- in the Wiper Blade Adjuster - VAS
hole
3358B- and secure with the locking screw -3-.
spec
es, in part or in w
– Check the angle setting.
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Angle Setting (specified values) for
Left-hand Drive Vehicles rrectness of i
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Driver's side - 8.5°

Passenger side - 1.0°
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Rear wiper 0°
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Tolerance ± 2°
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If necessary, adjust angle setting to specified value as follows:

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– Position the 24 mm wrench -1- on the adjustment device and

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adjust the windshield wiper arm -2- to the specified value

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– Release wiper arm -2- from adjustment fixture and again tight‐ p by
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– Compare adjusted value with specified value. If necessary re‐
peat procedure until specified value is reached.
– Remove adjustment fixture and reinstall wiper blade.
– Check wiper blade for pulsation-free operation.
. Volkswagen AG
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4.44 Manual olkTransmission/Final Drive,
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Checking Oil Level
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– Refer toss a⇒ Manual Transmission; Rep. Gr. 34 ; Description
ac
and Operation , .
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4.45 Headlamps, Checking and Adjusting
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⇒ “4.45.2 Headlamps, Checking Adjustment with New Test
hole
Screen without 15° Adjustment Line”, page 74
spec
es, in part or in w
t to the co
⇒ “4.45.3 Adjusting Headlamps for the Golf”, page 75
⇒ “4.45.4 Headlamps, Adjusting, Jetta”, page 75
rrectness of i
⇒ “4.45.5 Headlamps, Checking Headlamp with Gas Discharge
Lamps”, page 76
l purpos
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ercia
Checking headlamp adjustment for headlamps with gas dis‐

m
charge lamps. Refer to
at
om
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⇒ “4.45.5 Headlamps, Checking Headlamp with Gas Discharge
n
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Lamps”, page 76
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♦ Headlamp Adjuster - VAS 5046/-

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or
♦ Headlamp Adjuster - VAS 5047-
♦ Headlamp Adjuster - VAS 5208A-
♦ Headlamp Adjuster - VAS 5209A-
Basically all procedures describing headlamp adjustments and
checks apply for all countries. However, check with local author‐
ities for adjustment requirements.
Checking and Adjusting Conditions:
♦ Tire pressure must be OK.
♦ Lenses must not be damaged or dirty.
♦ Reflectors and bulbs OK.
♦ Vehicle must be properly loaded.
Load: Vehicle must be loaded with one person on the driver seat,
weighing 165 lbs (75 kg), otherwise vehicle must be empty (curb
weight).
The curb weight is the weight of the vehicle ready to be operated
with filled fuel tank (at least 90% filled), including the weight of all
equipment usually carried in the car such as spare wheel, tools,
car jack, fire extinguisher, etc.
If the fuel tank is not at least 90% full, adjust the weight as follows:
– Read fuel level from fuel gauge. Calculate additional weight
needed using the following table. Place extra weight in lug‐
gage compartment.
Tank Filling Table
Fuel Level According Additional Weight
to fuel gauge in Luggage Compartment Lbs
(Kg)
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Example:
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If the fuel tank is half full, place a weight of 44 lbs (20 kg) in the
ot
luggage compartment.
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Note
t to the co
For additional weight use containers filled with water. A container
filled with 5 liters of water weighs approximately 11 lbs (5 kg).
rrectness of i
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Move vehicle back and forth a few meters or bounce front and
rear of vehicle several times up and down to settle suspension.
nform
ercia
♦ Vehicle and headlamp adjuster must be on a level surface ⇒

User manual for headlamp adjuster.
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♦ Vehicle and headlamp adjuster must be aligned.

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♦ Inclination dimension must be set.

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In the trim above the headlamp, inclination measurements are

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stamped in “%”. Headlamps must be adjusted according to this

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information. Percentage information is based on a projection dis‐ Cop py
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tance of 10 meters. For example: inclination of 1.2% converts to rig ht
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approximately 12 cm. co Vo
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On North America vehicles, set the inclination to 0.7 %.
♦ The knurl wheel for the headlamp range adjuster must be lo‐
cated in basic setting (-).
♦ Manual range control is not available in certain markets so the
-0- setting is not used.
♦ Head lamp side adjustment is not possible on USA and Can‐
ada vehicles, and for this reason, cannot be turned. If the
headlamp has been replaced, then a one time adjustment is
permissible. After adjusting, seal off the screw for the lateral
adjustment with a cap. Refer to the Parts Catalog. Press the
cap into the lateral adjustment opening.
4.45.2 Headlamps, Checking Adjustment with

New Test Screen without 15° Adjust‐
ment Line
Headlamps:
Please check the following:
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Bora 1999 ➤ , Bora Variant
horis 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998
tee ➤
t or
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– With the low beam switched on check whether the horizontal
pt
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light-dark border of the setting line -1- contacts the test sur‐
y li
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– Check whether the break-away point -2- between the left hor‐
wit
, is n
h re
izontal part and the rising part on the right of the light-dark
hole
border runs vertically through the center point -3-. The bright
spec
core of the light beam must be on the right of the vertical line.
es, in part or in w
t to the co
Note
rrectness of i
♦ To make it easier to find break-away point -2- cover and un‐
l purpos
cover left half of headlamp (as viewed when looking forward)
a few times. Then check dipped beam again.
nf
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♦ After correct adjustment of low beams the center point of the
rm
m
main beam must lie on the center mark -3-.
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Other Additional Head Lamps
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Accessory auxiliary headlamp systems must be checked and ad‐

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justed according to the guidelines valid for them.
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4.45.3 Adjusting Headlamps for the Golf
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Adjusting headlamps for the Jetta, refer to
agen
Prote AG.
⇒ “4.45.4 Headlamps, Adjusting, Jetta”, page 75
Note
At the same time the low-beam headlamps are adjusted, the fog
lamps and high-beam headlamps are adjusted as well.
Headlamp (left):
Both right headlamp adjustment screws are the same, but re‐
versed.
A - Lateral adjustment
B - Height adjustment
– Insert a screwdriver through the holes -A- and -B- and adjust
the headlamp.
Note
Also, check if the reflectors in both headlamps adjust equally by

manipulating the headlamp range adjuster.
4.45.4 Headlamps, Adjusting, Jetta

Adjusting headlamps for the Golf, refer to
⇒ “4.45.3 Adjusting Headlamps for the Golf”, page 75
Note
At the same time the low-beam headlamps are adjusted, the fog
lamps and high-beam headlamps are adjusted as well.
AG. Volkswagen AG d
Maintenance - Edition 05.2012 ksw
agen oes
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Headlamp (left): ris
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tee
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Both right headlamp adjustment screws are the same, but
ss re‐
ac
versed.
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1 - Lateral adjustment
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2 - Height adjustment
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Turn the thumbwheel using a screwdriver to adjust the up and
h re
down and laterally.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Also, check if the reflectors in both headlamps adjust equally by
manipulating the headlamp range adjuster. l purpos
4.45.5 Headlamps, Checking Headlamp with
nform
ercia
Gas Discharge Lamps

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Basically all procedures describing headlamp adjustments and co Vo
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checks apply for all countries. However, check with local author‐
cted agen
Prote AG.
ities for adjustment requirements.
The following conditions apply for adjusting headlamps with gas
discharge bulbs:
• Tire pressure must be OK.
• Lenses must not be damaged or dirty.
• Reflectors and bulbs OK.
• Parking brake must be released and no gears selected.
• The steering should not be locked.
• The vehicle must not be moved during basic setting (do not
“open/close” doors, lean on vehicle or exit/enter vehicle).
• There should be no driver or any loads in the vehicle.
• Move vehicle back and forth a few meters or bounce front and
rear of vehicle several times up and down to settle suspension.
• Vehicle and headlamp adjuster must be on a level surface
• Vehicle and headlamp adjuster must be aligned.
• Inclination dimension must be set.
In the trim above the headlamp, inclination measurements are
stamped in “%”. Headlamps must be adjusted according to this
information. Percentage information is based on a projection dis‐
tance of 10 meters. For example: inclination of 1.2% converts to
approximately 12 cm.
Left headlamp:
Perform basic setting with the Vehicle Diagnosis, Testing and In‐
formation System - VAS 5051B- :
– Switch on the ignition.
olkswagen AG
en AG. V
olks 1999 ➤ , Golf 1998 ➤ , sGolf
wag doe
not Variant 1998 ➤
byV Maintenance -guEdition
ara 05.2012
ed
ris nte
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– Select “Guided Functions” ss
a ra
c
ce
le
– Select “Headlamp Range Control”
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– Select “Perform basic setting”
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ility
– Follow the instructions on the tester.
ot
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, is n
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– Check the headlamp adjustment and, if necessary, adjust the
hole
headlamps.
spec
es, in part or in w
t to the co
Adjusting procedure for Golf , refer to
⇒ “4.45.3 Adjusting Headlamps for the Golf”, page 75 , for Jetta,
refer to ⇒ “4.45.4 Headlamps, Adjusting, Jetta”, page 75
rrectness of i
End Adaptation
l purpos
Indicated on display:
– Press the Go to button -arrow- on the display.
nform
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– Press the End -arrow- button on the screen.
– Press Exit button in exit menu.
– Turn off the ignition and disconnect the diagnostic connector.
4.46 Service Interval Display, Resetting
Note
The service interval display can also be reset manually. Make

sure the service interval display is coded to fixed intervals, that is,
every 15,000 km or 12 months. The adaptation channel for the oil
quality will also change when doing this.
Service interval display must be reset at

♦ Vehicle release inspection
♦ Every service
(adapted)!
– Connect the diagnostic tester
– Touch the “GUIDED FUNCTIONS” button/field on the screen.
If the indications shown in the work procedure are not indicated

on the display: ⇒ User manual for VAS5051 tester .
– Press “ > ” button to confirm.
– Select in succession:
♦ Brand
♦ Type
♦ Model year
♦ Versions
♦ Engine code
– Confirm vehicle identification.
♦ “Instrument cluster” -arrow-
♦ “Service interval display, resetting”
lkswage es n
o ot g
byV ua
d ran
ir se tee
– Perform Adaptation according ato
uth instructions from “GUIDED
o
or
ac
FUNCTIONS”. ss
ce
le
un
End Adaptation
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Press the Go to button -arrow- on display.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Press End button -arrow- on display.
– Press Exit button in exit menu.
– Turn off ignition and disconnect diagnostic connection.
After switching on the ignition, service event is no longer indicated
in the odometer display in the instrument panel insert.
4.47 Service Interval Display, Coding

– Connect the diagnostic tester
– Touch the “GUIDED FUNCTIONS” button/field on the screen.
Note AG. Volkswagen AG d

agen oes
olksw not
yV gu
If the indications shown in the work procedure
ised b are not indicated ara
nte
on the display:⇒ User manual for VAS5051hor tester . eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
♦ Brand
y li
erm
ab
♦ Type
ility
ot p
wit
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♦ Model year
h re
hole
spec
♦ Versions
es, in part or in w
t to the co
♦ Engine code
– Confirm vehicle identification.
rrectness of i
If the vehicle identification procedure was performed correctly,
press “ > ” button for confirmation.
l purpos
nf
ercia
♦ “Instrument cluster” -ARROW-.

rm
m
atio
m
♦ “Adapting service interval extension”.

o
n in
or c
– Perform Adaptation according to instructions from “GUIDED

thi
te
sd
a
FUNCTIONS”.
iv
o
r
rp
cu
o
End Adaptation
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Press the Go to button -arrow-on display. agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Press Exit button -arrow-on display.
rrectness of i
– Press End button in exit menu.
l purpos
– Turn off ignition and disconnect diagnostic connection.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
4.48 Tie Rod Ends, Checking Play, Security
en
ng
t.
yi Co
op
and Joint Boots
C py
t. rig
gh ht
pyri by
Vo
o
Perform the following: by c lksw
cted agen
Prote AG.
– With vehicle raised (wheels off ground) check tie rods by mov‐
ing tie rods -arrow- and wheels. Play: no play
– Check attachments
– Check boots (left of -arrow-) for damage and proper installa‐
tion.
4.49 Language, Selecting

Does not apply to German-speaking countries.
Note
The language variations for driver information can only be adap‐

ted for midline and highline instrument panel inserts.

– On the display of the diagnostic tester, select the mode of op‐
eration “Guided Fault-finding”.
– Then perform vehicle identification on diagnostic tester.
– Select “Instrument cluster” on the display.

– Select “Adapting language for Navigation” on the display.
– Confirm the selection by pressing the right arrow.
– Select the appropriate language and confirm with “Yes”.
– Complete the language adaptation by pressing the Go to and
End buttons.
– Turn the ignition off.
4.50 Dust and Pollen Filter, Cleaning Hous‐

ing and Removing and Installing Filter
Element
AG. Volkswagen AG d
agen
Procedure olksw
oes
not
byV gu
ara
d
Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep.
oris Gr.
e nte
eo
80 ; Removal and Installation aut
h
ra
ss c
4.51 Transport Protection, Removing Lock‐
ce
le
un
pt
an
d
ing Pieces from Front Axle Struts

itte
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
♦ Locking pieces are installed at suspension strut piston rod for
es, in part or in w
t to the co
some vehicle versions.
♦ Other vehicle versions have locking pieces installed in front
axle coil springs.
rrectness of i
♦ Locking pieces should prevent vehicle from bouncing when
l purpos
being driven on to an automobile transport or railroad car and

thereby become damaged.
nform
mercia
a
com
t
Caution
ion in
r
te o
thi
Locking pieces must always be removed before delivering the
s
iva
do
vehicle! An “Attention” hanging tag is secured to interior mirror
r
rp
cum
to make this point absolutely clear.
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
– Vehicles with locking pieces in suspension struts are identified py by
o Vo
by a hanging tag on mirror -arrow-.
by c lksw
cted agen
Prote AG.
Removing Locking Pieces on Piston Rod
– Slide suspension strut protective boot -arrow- upward.
– Press locking piece -arrow- from piston rod.

– Slide suspension strut protective boot downward on to sus‐
pension strut.
Removing Locking Pieces on Coil Spring
AG. Volkswagen AG d
agen oes
Note Volksw not
gu
d by ara
ise nte
r
♦ Removal of the wheels is necessary. ut
ho eo
ra
s a c
♦ Be careful not to damage surface of coil springs. s
ce
e
nl
pt
du
an
itte
– Relieve load on coil springs by raising vehicle on lifting plat‐
y li
erm
ab
form.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Press locking piece -arrow- from piston rod. rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
4.52 Door Arrester, Lubricating Cop py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
lkswage es n
o ot g
byV ua
d ran
ir se
th 1999 ➤ , Golf 1998 ➤ , Golf Variant 1998 e➤
o te
or
u
ss
a
Maintenance - Edition 05.2012ac
ce
e
nl
pt
du
– Grease door arrester at points shown -arrows-.
an
itte
y li
erm
ab
– Use lubrication paste - G 000 150- or lock cylinder grease
ility
ot p
spray - G052778A2- .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
4.53 Clock, Setting
m
at
om
i
Perform the setting as follows:
on
c
in t
or
Hour setting:
his
ate
do
riv
– Turn the adjusting button -1- (to the lower right of the tachom‐
p
cum
or
eter) counterclockwise.
f
en
ng
t.
yi Co
op
With every brief turn of the adjusting button, the setting changes
C py
t. rig
gh
by one hour. When turning and holding the adjusting button, the
ht
pyri by
Vo
setting continually adjusts.
co lksw
by
cted agen
Prote AG.
Minute setting:
– Turn the adjusting button -1- clockwise.
With every brief turn of the adjusting button, the setting changes
by one minute. When turning and holding the adjusting button,
the setting continually adjusts.
The clock can be set accurately to the second using the adjust‐
ment button -1- as follows:
– Turn the adjusting button to the right until the clock is one mi‐
nute less than the time that is to be set.
– Briefly turn the adjusting button to the right as soon as the
second indicator of the reference clock reaches the full minute
mark.
4.54 Underbody Components, Checking for

Damage
During visual inspection, check floor pan, wheel housings, sills
and especially all sealing caps for damage!
On sealing caps -arrows-, check for cracks, displacement and
corrosion of underbody guard in particular.
Note
Correct any malfunctions (repair procedure). This can help pre‐

vent corrosion and rust-through.
4.55 Toothed Belt and Camshaft Drive Ten‐

sioner, Replacing
⇒ “4.55.1 Toothed Belt and Camshaft Drive Tensioning Roller,
Removing and Installing, Diesel, Engine Codes ALH and BEW”,
page 84
⇒ “4.55.2 Camshaft Drive Toothed Belt, Removing and Installing,
4-Cylinder, 5-Valve Gasoline, Engine Code AWP”, page 84
4.55.1 Toothed Belt and Camshaft Drive Ten‐

sioning Roller, Removing and Installing,
Diesel, Engine Codes ALH and BEW
– Refer to ⇒ Engine Mechanical, Fuel Injection and Glow Plug;
Rep. Gr. 15 ; Removal and Installation
4.55.2 Camshaft Drive Toothed Belt, Remov‐

ing and Installing, 4-Cylinder, 5-Valve
Gasoline, Engine Code AWP
– Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
4.56 Camshaft Drive Toothed Belt, Checking,

4-Cylinder Gasoline Engine
Checking toothed belt condition
olks
wage es n
ot g
byV ua
– Toothed Belt Guard, ris Removing and Installing, Upper Sectionntee
ed ra
refer to ⇒ EngineutMechanical,
ho Fuel Injection and Ignition; Rep. or
Gr. 15 ; Removal
ss
a
and Installation ac
ce
e
nl
– Check the toothed belt for:

pt
du
an
itte
y li
♦ Cracks, cross-sectional breaks

erm
ab
ility
ot p

wit
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h re
♦ Wear-through on cover layer

hole
spec
es, in part or in w
t to the co
♦ Surface cracks (plastic shroud)

rrectness of i
l purpos
Note
nf
ercia
It is essential to replace toothed belt if malfunctions are found.

orm
This will prevent any belt malfunctions. Replacing the belt is a

m
atio
m
repair procedure.
o
n in
or c
thi
te
sd
While checking the condition, take notice of the following defects:

iva
o
r
rp
cu
A - Tears (cover side)

o
m
f
en
ng
t.
yi Co
B - Lateral movement Cop py
ht. rig
rig ht
C - Fraying py by
co Vo
by lksw
cted agen
D - Tears (in teeth) Prote AG.
4.57 Toothed Belt, Diesel, Checking for Wear

♦ Vernier caliper (commercially available)
– Remove engine cover.
– Open the clips on the upper toothed belt guard.
– Pull upper toothed belt guard to side and remove if necessary.
– Measure the width of the toothed belt using a caliper.
Engine code Wear limit
AGP, AGR, AHF, ALH, AQM, ASV 22 mm
AJM through MY 00 27 mm
Note
♦ With a toothed belt width of 22 mm or 27 mm, the toothed belt

has reached its wear limit and must be replaced (repair meas‐
ure). Be sure to notify customer and mark findings on repair
order!
♦ When performing control and tuning work, under no circum‐
stances may the engine be turned over free of the camshaft.
Noncompliance may result in serious engine damage. Volkswa AG. gen AG
agen does
olksw not
yV gu
db ara
4.58 Camshaft Drive Toothed Belt, Checking tho
rise nte
eo
Condition and sTension,
s Diesel, Engine au ra
c
Codes ALH with Automatic Transmis‐
ce
e
nl
pt
du
an
sion
itte
y li
erm
ab
ility
ot p
⇒ “4.58.1 Checking Toothed Belt Condition”, page 85

wit
, is n
h re
⇒ “4.58.2 Toothed Belt, Checking Tension”, page 86

hole
spec
⇒ “4.58.3 Toothed Belt, Tensioning”, page 86

es, in part or in w
t to the co
4.58.1 Checking Toothed Belt Condition

– Open fasteners of upper toothed belt cover and remove cover.
rrectness of i
– Check the toothed belt for:

l purpos
♦ Cracks, cross-sectional breaks

nf
ercia

orm
m
atio
♦ Wear-through on cover layer

om
n in
or c
thi
te
sd
iva
♦ Surface cracks (plastic shroud)

o
r
rp
cu
o
m
f
en

ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note
op Vo
by c lksw
cted agen
Prote AG.
It is essential to replace toothed belt if malfunctions are found.
This will prevent any belt malfunctions. Replacing the belt is a
repair procedure.
While checking the condition, take notice of the following defects:

A - Tears (cover side)
B - Lateral movement
C - Fraying
D - Tears (in teeth)
Note
Upper toothed belt cover must remain removed to check the

toothed belt tension.
4.58.2 Toothed Belt, Checking Tension

Refer to ⇒ Engine Mechanical, Fuel Injection and Glow Plug;
Rep. Gr. 15 ; Removal and Installation agen
AG. Volkswagen AG d
oes
ksw not
Vol
4.58.3 Toothed Belt, Tensioninged by gu
ara
nte
ris
tho eo
Refer to ⇒ Engine Mechanical, sFuel
au Injection and Glow Plug; ra
c
s
ce
e
nl
pt
du
4.59 Spark Plugs, Removing and Installing
an
itte
y li
erm
ab
⇒ “4.59.1 Spark Plugs, Removing and Installing, 1.4L Engines
ility
ot p
with Ignition Coil”, page 86
wit
, is n
h re
⇒ “4.59.4 Spark Plugs, 1.8L with Ignition Transformer, Replac‐
hole
spec
ing”, page 89
es, in part or in w
t to the co
⇒ “4.59.6 Spark Plugs, Replacing, 1.8L Engines with Connected
Ignition Coils with Power Output Stages”, page 91
⇒ “4.59.5 Spark Plugs, Replacing, 1.8L Engines with Threaded rrectness of i
Ignition Coils with Power Output Stages”, page 90
l purpos
⇒ “4.59.7 Spark Plugs, 2.0L Engines, Replacing”, page 93

nf
ercia
⇒ “4.59.2 Spark Plugs, Removing and Installing, 2.8L Engines, 4-

or
Valve, with Ignition Coil”, page 87

m
m
atio
m
⇒ “4.59.3 Spark Plugs, Replacing, 2.8L and 3.2L Engines, 4-

o
n in
or c
Valve with Ignition Coil with Power Output Stage”, page 88

thi
te
sd
iva
4.59.1 Spark Plugs, Removing and Installing,

o
r
rp
cu
o
m
f
1.4L Engines with Ignition Coil

en
ng
t.
yi Co
Cop py
t.
rig
gh ht
pyri by
Vo
co
♦ Spark Plug Wrench - 3122 B-
by lksw
cted agen
Prote AG.
– Remove oil cap -1-.
– Remove spark plug wires -2- from the cover -3- and pull cover
slightly upward.
– Remove spark plug connectors and wires with the cover and
lay aside.
– Remove spark plugs using Spark Plug Wrench - VAS 3122B- .
Note
♦ Plug designation and tightening specification, refer to ⇒ En‐

gine Mechanical, Fuel Injection and Ignition; Rep. Gr.swa
g15
en A; G. V
olkswagen AG
does
Specifications . by
Volk not
gu
ara
ed
♦ Follow all waste disposal regulations! ris nte
tho e or
au ac
ss
– Install new spark plugs using Spark Plug Wrench - VAS
ce
e
nl
pt
3122B- .
du
an
itte
y li
erm
– Install spark plug cover.
ab
ility
ot p
wit
, is n
– Install oil cap -1-.
h re
hole
spec
– Connect spark plug connectors.
es, in part or in w
t to the co
– Press the spark plug wires -2- into the spark plug cover.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
4.59.2 Spark Plugs, Removing and Installing,
te
sd
iva
o
2.8L Engines, 4-Valve, with Ignition Coil
r
rp
cu
o
m
f
en
ng
t.
yi
Removing and installing top engine cover, refer to
Co
op py
. C rig
ht ht
rig
page 44 . py by
co Vo
by lksw
cted agen
– Remove spark plug wires with Removal/Installation Tool - Prote AG.
T10029- .
Note

gine Mechanical, Fuel Injection and Ignition; Rep. Gr. 28 ;
Specifications »Spark Plug Test Data«.

3122B- .
– Connect spark plug connectors.
– Check ignition cables and connectors for proper connections.
Removing and installing top engine cover. Refer to
page 44 .
4.59.3 Spark Plugs, Replacing, 2.8L and 3.2L

Engines, 4-Valve with Ignition Coil with
Power Output Stage
page 44 .
– Disconnect connector for spark plugs with power output stage
-arrows-. Volkswa AG. gen AG
agen does
olksw not
yV gu
db ara
rise nte
tho eo
au ra
c
ss
ce
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un
pt
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d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Unlock the connector locating device with the Assembly Tool
t to the co
- T10118- .
– Place the Assembly Tool - T10118- on the connector locating
device -arrow-, and carefully pull the connector off. rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
– Push the Remover - T10095/a- from the straight connector

en
ng
t.
yi
side, in the direction of the arrow, on the ignition coil with power
Co
op py
output stage
. C rig
ht ht
rig by
py Vo
– Pull the ignition coil with power output stage up perpendicu‐
co lksw
by
cted agen
larly and out. Prote AG.
– Observe the installed locations of the ignition coils with power

output stages to the connectors, before they are removed
-arrows-.
The straight side of the connector must fit to the straight side of
the ignition coil with power output stage.
. Volkswagen AG
gen AG d
Bora 1999 ➤Vo,lkBora
swa Variant 1999 ➤ , Golf
oes
no1998
t gu ➤ , Golf Variant 1998 ➤
d by Maintenance
ara - Edition 05.2012
ise n
r tee
ho
ut or
– Remove spark plugs with the
ss Spark
a
Plug Wrench - VAS ac
3122B- .
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
♦ Spark plug identification and tightening specification, refer to
h re
hole
⇒ Engine Mechanical, Fuel Injection and Ignition; Rep. Gr.
spec
28 ; Specifications .
es, in part or in w
t to the co
rrectness of i
3122B- .
l purpos
– Carefully place the ignition coils with power output stages on
nform
ercia
the spark plug connectors, so that the straight connector sides

match one another -arrows-.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Connect connectors 1 to 6 for ignition coils with power output

stages.
– Set the engine cover -2- on the indicated points -arrows- and
secure into place.
page 44 .
4.59.4 Spark Plugs, 1.8L with Ignition Trans‐

former, Replacing
Removing and installing top engine cover
page 44 .
– Remove spark plug wires with Removal/Installation Tool -
T10029- .
Note

Specifications

3122B- .
– Install spark plug wires with Removal/Installation Tool -

T10029- .
– Clip spark plug wires into engine cover.
page 44 .
4.59.5 Spark Plugs, Replacing, 1.8L Engines

with Threaded Ignition Coils with Power
Output Stages
page 44 .
Note
Note installation position before pulling out ignition coils with pow‐
er output stages.
– Remove the bolts -1- on the ignition coils with power output
stages.
– Remove the ignition coils with power output stages -2-.
– Remove spark plugs with the Spark Plug Wrench - VAS
3122B- .
AG. Volkswagen AG d
agen oes
ksw
Note byV
ol not
gu
ara
ed
ris nte
o eo
♦ Spark plug identification
aut and tightening specification, refer to
h
ra
⇒ Engine Mechanical, s Fuel Injection and Ignition; Rep. Gr.
s c
ce
le
28 ; Specifications
un
pt
an
d
itte

y li
erm
ab
ility
ot p

wit
is n
3122B- .
h re
ole,
spec
– Make sure the seal for the ignition coils with power output
stages is seated correctly.

t to the co
– Tighten the ignition coils with power output stages to 10 Nm.

rrectne
– Check spark plug wires for tight fit.

ss
Note
o
cial p
f inform
mer
♦ Observe installation position.

atio
m
♦ Further installation is the reverse of removal.

o
n
c
i
or
n thi
te
sd
a

iv
o
pr

um
r
fo
en
ng
page 44 .
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4.59.6 Spark Plugs, Replacing, 1.8L Engines

with Connected Ignition Coils ol
with
ksw
agen Pow‐
AG. Volkswagen AG d
oes
not
er Output Stages ised byV gu
ara
n r tee
ho
Removing and installing top engine cover.
sa
ut Refer to or
ac
s
ce
le
page 44 .
un
pt
an
d
itte
y li
erm
ab
ility
Note
ot p
wit
is n
h re
♦ To pull off spark plugs, place the Ignition Coil Puller - T40039-
ole,
spec
on the top thick rib -arrow- of ignition coils with power output
stages.
t to the co
♦ If lower ribs are used, these can be damaged
rrectne
– Remove the bolt -arrow- from the vacuum reservoir -1- and set
ss
the reservoir aside with the lines connected.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove the socket head hex bolts -arrows- and the vacuum
reservoir bracket -1-.
Spark plugs are located under ignition coils with power output
stages -2-.
Note
Note installation position of ignition coils with power output

stages!
– Remove both bolts -1-.
– Push connector in direction of ignition coils with power output

stages, press catch down by hand and disconnect connectors
-arrows-.
– Pull all ignition coils approximately 30 mm out of cylinder head
in direction of arrow using the Ignition Coil Puller - T40039- .
– Remove spark plugs with the Spark Plug Wrench - 3122 B- .
Note n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
♦ Spark plug identification and tightening specification, referristo
ed ran
tee
⇒ Engine Mechanical, Fuel Injection and Ignition; Rep.uthGr.
o
or
28 ; Specifications . ss
a ac
ce
le

un
pt
an
d
itte
y li
rm
ab
– Screw in new spark plugs using Spark Plug Wrench - 3122 B-
pe
ility
and tighten to correct tightening torque.
ot
wit
, is n
h re
hole
– Guide ignition coils with power output stages into cylinder

spec
es, in part or in w
head.
t to the co
– Align ignition coils with power output stages into designated
recesses of cylinder head cover.
rrectness of i
– Connect all connectors to ignition coils -arrows-.

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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– Press the ignition coils with power output stages onto the spark
plugs by hand, until they stop. They must engage audibly.
– Secure wiring using bolts -1-.
– Install holder for vacuum reservoir -1- and fasten with socket
head hex bolt -arrows-.
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– Install the vacuum reservoir -1- and tighten the bolts to 5 Nm.
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– Disconnect connectors for fuel injectors of first and fourth cyl‐

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– Install new spark plugs using Spark Plug Wrench - 3122 B- .
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– Connect spark plug connectors using Puller - T10112- .
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4.60 Rear Lid, Lubricating Multi-Joint Hinges
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Lubricating:
– Open rear lid.
– Remove left/right lid hinge cover if present.
– Spray each of the four hinge joints on both rear lid hinges
-arrows-.
Note
♦ Included spray tube must be inserted in sprayer head to aim

spray.
♦ Shake spray can about five times.
♦ Spray must not be shaken too long or hard because otherwise
spray oil will foam up and its lubricating ability is reduced.
– Completely open and close rear lid several times.

– Reassemble vehicle.
– Clean excess oil from body and joints.
Additional Steps for Stiff Hinges:
Note
♦ These additional steps do not belong to the service scope and

should be handled as repair measures.
♦ In order to make hinges move more easily again and to protect
them from corrosion, perform the following procedure:
– Open rear lid.

– Remove left/right lid hinge cover if present.
– Remove the gas-filled strut -2-: Refer to »Body Exterior« ⇒

Body Exterior; Rep. Gr. 55 ; Removal and Installation .
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– Spray each of the four hinge joints on both rear lid hinges
-arrows-.
Note
♦ Included spray tube must be inserted in sprayer head to aim

spray.
♦ Shake spray can about five times.
♦ Spray must not be shaken too long or hard because otherwise
spray oil will foam up and its lubricating ability is reduced.
In order for the universal oil to move into the hinge joints, the
hinges in the joint area must have a temperature at least 30 de‐
grees Celsius.
In cold exterior temperatures, the hinges must be warmed up in
the joint area with a hot air gun to approximately 30 - 40 degrees
Celsius before spraying.
– Completely open and close rear lid about 15 times.
Note
This entire hinge treatment procedure must be performed at least

3 times in order to keep the hinges moving easily and to protect
against further corrosion.
– Clean excess oil from body and joints.

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– Reassemble vehicle. olksw not
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Bora 1999 ➤ , aBora
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Term Description
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ABS ( Anti-lock braking system ), the ABS is a regulation device in the brake system, that
spec
prevents the wheels from locking up while braking. This allows lane stability and steering
es, in part or in w
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capacity to be maintained.
Automatic Trans‐ ( Automatic Transmission Fluid ) Transmission oil for automatic transmission.
mission Fluid
rrectness of i
ATF level "Fill height" of ATF in transmission.
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CO ( Carbon monoxide ) results by incomplete combustion of fuels containing carbon
CZ ( Cetane Number ) Measure for ignition quality/performance of Diesel fuel
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DIN Deutsches Institut für Normung e.V (German Institute for Standards)
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ET-No. Abbreviation for Replacement Part Number.
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EN Euro-Norm
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EOBD Euro On Board Diagnostic (OBD)
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FAME Fatty Acid Methyl Ester
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TFSI Turbo ( Fuel Stratified Injection ) concerns the fuel injection p by
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MIL ( Malfunction Indicator Light ) American name for Malfunction Indicator Lamp (MIL) -
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K83-
OBD On Board Diagnostic, OBD monitors all components that influence the emission quality
OBD-II American On Board Diagnostic (OBD)
PD Pump-injector - Fuel injection unit for diesel engines
PR number Abbreviation for production control number. They designate, among other things, op‐
tional equipment, country-specific variations
PM ( Particulate matter ) Soot particle value of diesel engine emissions
QG0 Vehicle “not” equipped at the factory with components for LongLife service. Time and
distance dependent intervals (fixed intervals) apply for maintenance.
QG1 Vehicles equipped at the factory with active LongLife service. This means, vehicles have
a flexible service interval display and are equipped with the following components:
♦ Flexible service interval indicator in instrument cluster
♦ Engine oil level sensor
♦ Brake pad wear indicator
QG2 LongLife service is not activated at the factory. This means, vehicles have a fixed service
interval display (time and distance dependent maintenance intervals) and are equipped
with the following components:
♦ Fixed service interval indicator in instrument cluster
♦ Engine oil level sensor
♦ Brake pad wear indicator
Readiness code 8 digit binary code which indicates whether all emissions-relevant diagnostics were per‐
formed by engine management.
RON ( Research Octane Number ) Measure for anti-knock properties of gasoline
SAE ( Society of Automotive Engineers ) Society which generates designations / guidelines
as to how legal requirements can be implemented (e.g. Norms)
SD Normally aspirated Diesel engine
SDI Normally aspirated Diesel engine with direct injection
TDI Turbo Diesel engine with direct injection
VEP Distributor injection pump
ULEV Ultra Low Emission Vehicles
SIE Service Interval extension
5. Glossary 97
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Common - Rail English term referring to a common high pressure injection line (rail) that supplies fuel
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DPF Diesel Particulate Filter, particle filter is installed behind catalytic converter and filters
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soot particles from exhaust gas
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LongLife Service LongLife Service makes possible extremely long Inspection or Oil change intervals cor‐
spec
responding to individual driving patterns and corresponding operating conditions. A
t to the co
special engine oil is required for LongLife Service.
Snap sensor Also called finger sensor, or (oxygen sensor heater), (oxygen sensor flat) or planar oxy‐
gen sensor. Output of Lambda value is performed via an erratically rising voltage curve.
rrectne
Lambda value is determined from a change in voltage. Sensor is used as a sensor
behind catalytic converter.
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Broad band sensor Also called Universal Oxygen Sensor. Output of Lambda value is performed via a nearly
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linear increase of current strength. Lambda value is determined from a change in current
inform
strength. This makes possible a measurement of the Lambda value over a large meas‐
mer
urement range (broad band). Sensor is implemented as a sensor before catalytic
atio
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converter.
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TPM, TPI Tire pressure monitoring, tire pressure indicator
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RDW Market designation, for example “rest of the world”

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98 5. Glossary
Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
en AG
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•= Disconnect the battery negative terminal (ground strap) whenever agyou fuel
doesystem or the electrical
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system. Do not smoke or work near heaters or other fire hazards.
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•= Volkswagen is constantly improving its vehicles and
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these changes, both in parts and specifications,
ac
are made applicable to earlier models. Therefore,s part numbers
listed in this manual are for reference only. Always
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check with your authorized Volkswagen retailer parts department for the latest information.
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•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
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reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
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•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
spec
es, in part or in w
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
t to the co
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
rrectness of i
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
l purpos
become inoperable, even if the correct code is used in a later attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
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keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
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starting the vehicle while you are under it.
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•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
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others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
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Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills. t. rig
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•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear Prote
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goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
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•= Before starting risea job, make certain that you have all theannecessary
tee tools and parts on hand. Read all the
ho
instructionsaut thoroughly; do not attempt shortcuts. Use toolsorthat
a are appropriate to the work and use only
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replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
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•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
pe
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might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
ot
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once, but do not store the oily rags, which can ignite and burn spontaneously.
h re
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spec
es, in part or in w
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
t to the co
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
listed.
rrectness of i
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
l purpos
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
nform
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the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
m
govern the disposal of wastes.

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•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
s
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serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
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trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
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•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
p by
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negative terminal (ground strap) and the ABS control module connector.
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agen
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag
gen AG
.can
Volksincrease
wagen AGthe risk of injury in an accident.
d wa oes
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Page 3 of 3
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Service agen

Bora Variant 1999 ➤

Golf Variant 1998 ➤

Service Department. Technical Information

Copyright © 2015 Volkswagen AG, Wolfsburg D3E800051E4

4.11 Brake System, Check for Leaks and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.12 Front and Rear Brake Pads, Checking Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.13 Brake and Clutch System, Changing Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.14 Brake Fluid Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.16 Power Window Regulators, 8-Way Memory Seats, Performing Initialization . . . . . . . . . . . . 32

4.18 Protective Joint Boots, Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.19 Noise Insulation, Installing, Golf R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.22 First Aid Kit Expiration Date, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.23 Fuel Filter, Diesel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.24 Fuel Filter, Diesel, Draining Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.25 Ribbed Belt, Checking Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.26 Cooling System, Checking Freeze Protection and Coolant Level . . . . . . . . . . . . . . . . . . . . 39

4.36 Wheel Bolts, Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.45 Headlamps, Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.46 Service Interval Display, Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.47 Service Interval Display, Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.52 Door Arrester, Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4.54 Underbody Components, Checking for Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4.57 Toothed Belt, Diesel, Checking for Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

with Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

The engine codes are organized alphabetically.

1) In exceptional circumstances gasoline min. 91 RON unleaded, but with reduced

Engines: ⇒ Gasoline Engine

Engine code AVH

Bore diameter 82.5

Compression ratio 10,5

Fuel injection/Ignition Motronic M 5.9.2

1) In exceptional circumstances gasoline min. 91 RON unleaded, but with reduced

Number of cylinders/valves per cylinder 4/5 4/5 4/5

Output kW at RPM 110/5700 132/5500 110/5700

Torque Nm at RPM 220/1950 235/1950 through 5000 220/1950 through

Compression ratio 9.3 9.5 9.3

RON unleaded, mini‐ 951 982 951

Engines: ⇒ Gasoline Engine

2) In exceptional circumstances gasoline min. 95 RON unleaded, but with reduced

Engines: ⇒ Gasoline Engine

Compression ratio 10.0

Engines: ⇒ Gasoline Engine

2) In exceptional circumstances gasoline min. 95 RON unleaded, but with reduced

Engines: ⇒ Gasoline Engine

Fuel injection/Ignition Motronic M 5.9.2

On Board Diagnostic (OBD) yes

Engines: ⇒ Diesel Engine

Engine code BEW

Number of cylinders/valves per cylinder 4/2

Output kW at RPM 74/4000

Refer to ⇒ Maintenance Intervals; Rep. Gr. 03

2.3 Inspection Service from MY 00

⇒ “3.8 Engine Code and Engine Identification”, page 14

3.1 Lifting Vehicle

♦ Before driving a vehicle onto a lifting platform it must be

Position support plate at side member vertical stiffener in dotted

3.1.3 Golf R32, Lifting

3.1.4 Floor Jack Lifting Points

The vehicle may only be lifted at the areas designated in these

3.2.1 Attaching Data Label in the Luggage

tion service (whichever is due next) and enter the date/mile‐

– Apply the label to the B-pillar on the driver side -arrow-.

3.2.3 Data Label, Applying in Customer Main‐