1997-2004 Volkswagen Golf MK4 Service Manual – PDF DOWNLOAD
DESCRIPTION:
1997-2004 Volkswagen Golf MK4 Service Manual – PDF DOWNLOAD
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.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
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
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
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
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
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.
TABLE OF CONTENTS:
1997-2004 Volkswagen Golf MK4 Service Manual – PDF DOWNLOAD
Cover.pdf (p.1)......................................................................................................................................................................................................... 1 Contents.pdf (p.2)...................................................................................................................................................................................................... 2 00-Maintenance & General Info.pdf (p.3-782)............................................................................................................................................................................. 3 00-01 VW Maintenance Chart Rev. 2008............................................................................................................................................................................... 3 00-02 VW Maintenance Chart Rev. 2009................................................................................................................................................................................ 26 00-03 Maintenance Intervals All..................................................................................................................................................................................... 32 03 – Maintenance, Diagnosis..................................................................................................................................................................................... 36 1 MY 2015 Maintenance Intervals ............................................................................................................................................................................ 36 1.1 MY 2015 Maintenance Intervals - USA................................................................................................................................................................. 36 1.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 36 1.1.2 Service at 20,000€miles....................................................................................................................................................................... 37 1.1.3 Service at 30,000€miles....................................................................................................................................................................... 37 1.1.4 Service at 40,000€miles....................................................................................................................................................................... 38 1.1.5 Service at 50,000€miles....................................................................................................................................................................... 39 1.1.6 Service at 60,000€miles....................................................................................................................................................................... 39 1.1.7 Service at 70,000€miles....................................................................................................................................................................... 40 1.1.8 Service at 80,000€miles....................................................................................................................................................................... 41 1.1.9 Service at 90,000€miles....................................................................................................................................................................... 42 1.1.10 Service at 100,000€miles..................................................................................................................................................................... 42 1.1.11 Service at 110,000€miles..................................................................................................................................................................... 43 1.1.12 Service at 120,000€miles..................................................................................................................................................................... 43 1.1.13 Service at 130,000€miles..................................................................................................................................................................... 45 1.1.14 Service at 140,000€miles..................................................................................................................................................................... 45 1.1.15 Service at 150,000€miles..................................................................................................................................................................... 46 1.1.16 Time-Dependent Maintenance Items............................................................................................................................................................. 46 1.1.17 Brake Fluid Replacement...................................................................................................................................................................... 47 1.2 MY 2015 Maintenance Intervals - Canada.............................................................................................................................................................. 47 1.2.1 Service at 15.000€kilometres.................................................................................................................................................................. 48 1.2.2 Service at 30.000€kilometres.................................................................................................................................................................. 48 1.2.3 Service at 45.000€kilometres.................................................................................................................................................................. 49 1.2.4 Service at 60.000€kilometres.................................................................................................................................................................. 50 1.2.5 Service at 75.000€kilometres.................................................................................................................................................................. 51 1.2.6 Service at 90.000€kilometres.................................................................................................................................................................. 52 1.2.7 Service at 105.000€kilometres................................................................................................................................................................. 52 1.2.8 Service at 120.000€kilometres................................................................................................................................................................. 53 1.2.9 Service at 135.000€kilometres................................................................................................................................................................. 54 1.2.10 Service at 150.000€kilometres................................................................................................................................................................ 55 1.2.11 Service at 165.000€kilometres................................................................................................................................................................ 56 1.2.12 Service at 180.000€kilometres................................................................................................................................................................ 57 1.2.13 Service at 195.000€kilometres................................................................................................................................................................ 58 1.2.14 Service at 210.000€kilometres................................................................................................................................................................ 59 1.2.15 Service at 225.000€kilometres................................................................................................................................................................ 59 1.2.16 Time-Dependent Maintenance Items............................................................................................................................................................. 60 1.2.17 Brake Fluid Replacement...................................................................................................................................................................... 61 1.3 MY 2015 Maintenance Intervals - e-Golf.............................................................................................................................................................. 61 1.3.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 61 1.3.2 Service at 20,000€miles....................................................................................................................................................................... 62 1.3.3 Service at 30,000€miles....................................................................................................................................................................... 62 1.3.4 Service at 40,000€miles....................................................................................................................................................................... 63 1.3.5 Service at 50,000€miles....................................................................................................................................................................... 64 1.3.6 Service at 60,000€miles....................................................................................................................................................................... 64 1.3.7 Service at 70,000€miles....................................................................................................................................................................... 65 1.3.8 Service at 80,000€miles....................................................................................................................................................................... 66 1.3.9 Service at 90,000€miles....................................................................................................................................................................... 67 1.3.10 Service at 100,000€miles..................................................................................................................................................................... 67 1.3.11 Service at 110,000€miles..................................................................................................................................................................... 68 1.3.12 Service at 120,000€miles..................................................................................................................................................................... 68 1.3.13 Time-Dependent Maintenance Items............................................................................................................................................................. 69 1.3.14 Brake Fluid Replacement...................................................................................................................................................................... 70 2 MY 2014 Maintenance Intervals ............................................................................................................................................................................ 71 2.1 MY 2014 Maintenance Intervals (All Vehicles Except Touareg and Routan) - USA........................................................................................................................ 71 2.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 71 2.1.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 72 2.1.3 Service at 30,000€miles....................................................................................................................................................................... 72 2.1.4 Service at 40,000€miles....................................................................................................................................................................... 73 2.1.5 Service at 50,000€miles....................................................................................................................................................................... 74 2.1.6 Service at 60,000€miles....................................................................................................................................................................... 74 2.1.7 Service at 70,000€miles....................................................................................................................................................................... 75 2.1.8 Service at 80,000€miles....................................................................................................................................................................... 76 2.1.9 Service at 90,000€miles....................................................................................................................................................................... 77 2.1.10 Service at 100,000€miles..................................................................................................................................................................... 77 2.1.11 Service at 110,000€miles..................................................................................................................................................................... 78 2.1.12 Service at 120,000€miles..................................................................................................................................................................... 78 2.1.13 Service at 130,000€miles..................................................................................................................................................................... 80 2.1.14 Service at 140,000€miles..................................................................................................................................................................... 80 2.1.15 Service at 150,000€miles..................................................................................................................................................................... 81 2.1.16 Time-Dependent Maintenance Items............................................................................................................................................................. 81 2.1.17 Brake Fluid Replacement...................................................................................................................................................................... 82 2.2 MY 2014 Maintenance Intervals (Touareg Only) - USA.................................................................................................................................................. 83 2.2.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 83 2.2.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 83 2.2.3 Service at 30,000€miles....................................................................................................................................................................... 84 2.2.4 Service at 40,000€miles....................................................................................................................................................................... 84 2.2.5 Service at 50,000€miles....................................................................................................................................................................... 86 2.2.6 Service at 60,000€miles....................................................................................................................................................................... 86 2.2.7 Service at 70,000€miles....................................................................................................................................................................... 87 2.2.8 Service at 80,000€miles....................................................................................................................................................................... 87 2.2.9 Service at 90,000€miles....................................................................................................................................................................... 88 2.2.10 Service at 100,000€miles..................................................................................................................................................................... 89 2.2.11 Service at 110,000€miles..................................................................................................................................................................... 89 2.2.12 Service at 120,000€miles..................................................................................................................................................................... 90 2.2.13 Time-Dependent Maintenance Items............................................................................................................................................................. 91 2.2.14 Brake Fluid Replacement...................................................................................................................................................................... 91 2.3 MY 2014 Maintenance Intervals (Only Jetta, Jetta GLI, Jetta Hybrid, The Beetle, The Beetle Convertible, and Golf Wagon) - Canada.................................................................... 92 2.3.1 Service at 15.000€kilometres.................................................................................................................................................................. 92 2.3.2 Service at 30.000€kilometres.................................................................................................................................................................. 93 2.3.3 Service at 45.000€kilometres.................................................................................................................................................................. 94 2.3.4 Service at 60.000€kilometres.................................................................................................................................................................. 94 2.3.5 Service at 75.000€kilometres.................................................................................................................................................................. 96 2.3.6 Service at 90.000€kilometres.................................................................................................................................................................. 96 2.3.7 Service at 105.000€kilometres................................................................................................................................................................. 97 2.3.8 Service at 120.000€kilometres................................................................................................................................................................. 98 2.3.9 Service at 135.000€kilometres................................................................................................................................................................. 99 2.3.10 Service at 150.000€kilometres................................................................................................................................................................ 100 2.3.11 Service at 165.000€kilometres................................................................................................................................................................ 101 2.3.12 Service at 180.000€kilometres................................................................................................................................................................ 101 2.3.13 Service at 195.000€kilometres................................................................................................................................................................ 103 2.3.14 Service at 210.000€kilometres................................................................................................................................................................ 104 2.3.15 Service at 225.000€kilometres................................................................................................................................................................ 104 2.3.16 Time-Dependent Maintenance Items............................................................................................................................................................. 105 2.3.17 Brake Fluid Replacement...................................................................................................................................................................... 106 3 MY 2013 Maintenance Intervals ............................................................................................................................................................................ 107 3.1 MY 2013 Maintenance Intervals (All Vehicles Except Touareg and Routan) - USA........................................................................................................................ 107 3.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 107 3.1.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 108 3.1.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 108 3.1.4 Service at 40,000€miles....................................................................................................................................................................... 109 3.1.5 Service at 50,000€miles....................................................................................................................................................................... 110 3.1.6 Service at 60,000€miles....................................................................................................................................................................... 110 3.1.7 Service at 70,000€miles....................................................................................................................................................................... 111 3.1.8 Service at 80,000€miles....................................................................................................................................................................... 111 3.1.9 Service at 90,000€miles....................................................................................................................................................................... 112 3.1.10 Service at 100,000€miles..................................................................................................................................................................... 113 3.1.11 Service at 110,000€miles..................................................................................................................................................................... 113 3.1.12 Service at 120,000€miles..................................................................................................................................................................... 114 3.1.13 Service at 130,000€miles..................................................................................................................................................................... 115 3.1.14 Time-Dependent Maintenance Items............................................................................................................................................................. 115 3.1.15 Brake Fluid Replacement...................................................................................................................................................................... 116 3.2 MY 2013 Maintenance Intervals (Touareg Only) - USA.................................................................................................................................................. 117 3.2.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 117 3.2.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 117 3.2.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 118 3.2.4 Service at 40,000€miles....................................................................................................................................................................... 119 3.2.5 Service at 50,000€miles....................................................................................................................................................................... 120 3.2.6 Service at 60,000€miles....................................................................................................................................................................... 120 3.2.7 Service at 70,000€miles....................................................................................................................................................................... 121 3.2.8 Service at 80,000€miles....................................................................................................................................................................... 121 3.2.9 Service at 90,000€miles....................................................................................................................................................................... 122 3.2.10 Service at 100,000€miles..................................................................................................................................................................... 123 3.2.11 Service at 110,000€miles..................................................................................................................................................................... 123 3.2.12 Service at 120,000€miles..................................................................................................................................................................... 124 3.2.13 Time-Dependent Maintenance Items............................................................................................................................................................. 125 3.2.14 Brake Fluid Replacement...................................................................................................................................................................... 125 3.3 MY 2013 Maintenance Intervals (All Vehicles) - Canada............................................................................................................................................... 126 3.3.1 Service at 15.000€km.......................................................................................................................................................................... 126 3.3.2 Service at 30.000€km.......................................................................................................................................................................... 127 3.3.3 Service at 60.000€km.......................................................................................................................................................................... 128 3.3.4 Service at 75.000€km.......................................................................................................................................................................... 129 3.3.5 Service at 90.000€km.......................................................................................................................................................................... 129 3.3.6 Service at 105.000€km......................................................................................................................................................................... 130 3.3.7 Service at 120.000€km......................................................................................................................................................................... 131 3.3.8 Service at 135.000€km......................................................................................................................................................................... 132 3.3.9 Service at 150.000€km......................................................................................................................................................................... 133 3.3.10 Service at 165.000€km........................................................................................................................................................................ 134 3.3.11 Service at 180.000€km........................................................................................................................................................................ 134 3.3.12 Service at 195.000€km........................................................................................................................................................................ 136 3.3.13 Time-Dependent Maintenance Items............................................................................................................................................................. 136 3.3.14 Brake Fluid Replacement...................................................................................................................................................................... 137 4 MY 2012 Maintenance Intervals ............................................................................................................................................................................ 138 4.1 MY 2012 Maintenance Intervals (All Vehicles Except Touareg and Routan) - USA........................................................................................................................ 138 4.1.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 138 4.1.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 139 4.1.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 139 4.1.4 Service at 40,000€miles....................................................................................................................................................................... 140 4.1.5 Service at 50,000€miles....................................................................................................................................................................... 141 4.1.6 Service at 60,000€miles....................................................................................................................................................................... 141 4.1.7 Service at 70,000€miles....................................................................................................................................................................... 142 4.1.8 Service at 80,000€miles....................................................................................................................................................................... 142 4.1.9 Service at 90,000€miles....................................................................................................................................................................... 143 4.1.10 Service at 100,000€miles..................................................................................................................................................................... 144 4.1.11 Service at 110,000€miles..................................................................................................................................................................... 144 4.1.12 Service at 120,000€miles..................................................................................................................................................................... 145 4.1.13 Service at 130,000€miles..................................................................................................................................................................... 146 4.1.14 Time-Dependent Maintenance Items............................................................................................................................................................. 146 4.1.15 Brake Fluid Replacement...................................................................................................................................................................... 147 4.2 MY 2012 Maintenance Intervals (Touareg Only) - USA.................................................................................................................................................. 148 4.2.1 Service at 10,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 148 4.2.2 Service at 20,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 148 4.2.3 Service at 30,000€miles (Included in the Volkswagen Carefree Maintenance Program)............................................................................................................. 149 4.2.4 Service at 40,000€miles....................................................................................................................................................................... 150 4.2.5 Service at 50,000€miles....................................................................................................................................................................... 151 4.2.6 Service at 60,000€miles....................................................................................................................................................................... 151 4.2.7 Service at 70,000€miles....................................................................................................................................................................... 152 4.2.8 Service at 80,000€miles....................................................................................................................................................................... 152 4.2.9 Service at 90,000€miles....................................................................................................................................................................... 153 4.2.10 Service at 100,000€miles..................................................................................................................................................................... 154 4.2.11 Service at 110,000€miles..................................................................................................................................................................... 154 4.2.12 Service at 120,000€miles..................................................................................................................................................................... 155 4.2.13 Time-Dependent Maintenance Items............................................................................................................................................................. 156 4.2.14 Brake Fluid Replacement...................................................................................................................................................................... 156 4.3 MY 2012 Maintenance Intervals - Canada.............................................................................................................................................................. 157 4.3.1 Service at 15.000€km.......................................................................................................................................................................... 157 4.3.2 Service at 30.000€km.......................................................................................................................................................................... 158 4.3.3 Service at 45.000€km.......................................................................................................................................................................... 159 4.3.4 Service at 60.000€km.......................................................................................................................................................................... 159 4.3.5 Service at 75.000€km.......................................................................................................................................................................... 160 4.3.6 Service at 90.000€km.......................................................................................................................................................................... 161 4.3.7 Service at 105.000€km......................................................................................................................................................................... 162 4.3.8 Service at 120.000€km......................................................................................................................................................................... 162 4.3.9 Service at 135.000€km......................................................................................................................................................................... 164 4.3.10 Service at 150.000€km........................................................................................................................................................................ 164 4.3.11 Service at 165.000€km........................................................................................................................................................................ 165 4.3.12 Service at 180.000€km........................................................................................................................................................................ 166 4.3.13 Service at 195.000€km........................................................................................................................................................................ 167 4.3.14 Time-Dependent Maintenance Items............................................................................................................................................................. 168 4.3.15 Brake Fluid Replacement...................................................................................................................................................................... 168 4.4 MY 2012 Maintenance Intervals - Routan - USA........................................................................................................................................................ 169 4.4.1 Service at 8,000 Miles........................................................................................................................................................................ 169 4.4.2 Service at 16,000 Miles....................................................................................................................................................................... 169 4.4.3 Service at 24,000 Miles....................................................................................................................................................................... 170 4.4.4 Service at 32,000 Miles....................................................................................................................................................................... 170 4.4.5 Service at 40,000 Miles....................................................................................................................................................................... 170 4.4.6 Service at 48,000 Miles....................................................................................................................................................................... 170 4.4.7 Service at 56,000 Miles....................................................................................................................................................................... 170 4.4.8 Service at 64,000 Miles....................................................................................................................................................................... 171 4.4.9 Service at 72,000 Miles....................................................................................................................................................................... 171 4.4.10 Service at 80,000 Miles...................................................................................................................................................................... 171 4.4.11 Service at 88,000 Miles...................................................................................................................................................................... 171 4.4.12 Service at 96,000 Miles...................................................................................................................................................................... 172 4.4.13 Service at 104,000 Miles..................................................................................................................................................................... 172 4.4.14 Service at 112,000 Miles..................................................................................................................................................................... 172 4.4.15 Service at 120,000 Miles..................................................................................................................................................................... 172 4.4.16 Service at 128,000 miles..................................................................................................................................................................... 173 4.4.17 Service at 136,000 Miles..................................................................................................................................................................... 173 4.4.18 Service at 144,000 Miles..................................................................................................................................................................... 173 4.4.19 Service at 152,000 Miles..................................................................................................................................................................... 173 4.5 MY 2012 Maintenance Intervals - Routan - Canada..................................................................................................................................................... 174 4.5.1 Service at 13,000 Kilometers.................................................................................................................................................................. 174 4.5.2 Service at 26,000 Kilometers.................................................................................................................................................................. 174 4.5.3 Service at 39,000 Kilometers.................................................................................................................................................................. 174 4.5.4 Service at 52,000 Kilometers.................................................................................................................................................................. 175 4.5.5 Service at 65,000Kilometers................................................................................................................................................................... 175 4.5.6 Service at 78,000 Kilometers.................................................................................................................................................................. 175 4.5.7 Service at 91,000 Kilometers.................................................................................................................................................................. 175 4.5.8 Service at 104,000 Kilometers................................................................................................................................................................. 175 4.5.9 Service at 117,000 Kilometers................................................................................................................................................................. 176 4.5.10 Service at 130,000 Kilometers................................................................................................................................................................ 176 4.5.11 Service at 143,000 Kilometers................................................................................................................................................................ 176 4.5.12 Service at 156,000 Kilometers................................................................................................................................................................ 176 4.5.13 Service at 169,000 Kilometers................................................................................................................................................................ 177 4.5.14 Service at 182,000 Kilometers................................................................................................................................................................ 177 4.5.15 Service at 195,000 Kilometers................................................................................................................................................................ 177 4.5.16 Service at 208,000 Kilometers................................................................................................................................................................ 177 4.5.17 Service at 221,000 Kilometers................................................................................................................................................................ 177 4.5.18 Service at 234,000 Kilometers................................................................................................................................................................ 177 4.5.19 Service at 247,000 Kilometers................................................................................................................................................................ 178 5 MY 2011 Maintenance Intervals............................................................................................................................................................................. 179 5.1 MY 2011 Maintenance Intervals (Except Routan) - USA................................................................................................................................................. 179 5.1.1 Time Dependent Service........................................................................................................................................................................ 179 5.1.2 Service at 10,000€miles....................................................................................................................................................................... 180 5.1.3 Service at 20,000€miles....................................................................................................................................................................... 180 5.1.4 Service at 30,000€miles....................................................................................................................................................................... 181 5.1.5 Service at 40,000 miles....................................................................................................................................................................... 182 5.1.6 Service at 50,000 miles....................................................................................................................................................................... 183 5.1.7 Service at 60,000 miles....................................................................................................................................................................... 183 5.1.8 Service at 70,000 miles....................................................................................................................................................................... 184 5.1.9 Service at 80,000 miles....................................................................................................................................................................... 185 5.1.10 Service at 90,000 miles...................................................................................................................................................................... 186 5.1.11 Service at 100,000 miles..................................................................................................................................................................... 187 5.1.12 Service at 110,000 miles..................................................................................................................................................................... 187 5.1.13 Service at 120,000 miles..................................................................................................................................................................... 188 5.1.14 Service at 130,000 miles..................................................................................................................................................................... 189 5.2 MY 2011 Maintenance Intervals (Except Routan) - Canada.............................................................................................................................................. 190 5.2.1 Time Dependent Service........................................................................................................................................................................ 190 5.2.2 Service at 15,000€kilometers.................................................................................................................................................................. 191 5.2.3 Service at 30,000€kilometers.................................................................................................................................................................. 192 5.2.4 Service at 45,000€kilometers.................................................................................................................................................................. 192 5.2.5 Service at 60,000€kilometers.................................................................................................................................................................. 193 5.2.6 Service at 75,000€kilometers.................................................................................................................................................................. 194 5.2.7 Service at 90,000€kilometers.................................................................................................................................................................. 195 5.2.8 Service at 105,000€kilometers................................................................................................................................................................. 196 5.2.9 Service at 120,000€kilometers................................................................................................................................................................. 196 5.2.10 Service at 135,000€kilometers................................................................................................................................................................ 198 5.2.11 Service at 150,000€kilometers................................................................................................................................................................ 198 5.2.12 Service at 165,000€kilometers................................................................................................................................................................ 199 5.2.13 Service at 180,000€kilometers................................................................................................................................................................ 200 5.2.14 Service at 195,000€kilometers................................................................................................................................................................ 201 5.3 MY 2011 Maintenance Intervals - Routan - USA........................................................................................................................................................ 203 5.3.1 Service at 8,000 miles........................................................................................................................................................................ 203 5.3.2 Service at 16,000 miles....................................................................................................................................................................... 203 5.3.3 Service at 24,000 miles....................................................................................................................................................................... 203 5.3.4 Service at 32,000 miles....................................................................................................................................................................... 204 5.3.5 Service at 40,000 miles....................................................................................................................................................................... 204 5.3.6 Service at 48,000 miles....................................................................................................................................................................... 204 5.3.7 Service at 56,000 miles....................................................................................................................................................................... 204 5.3.8 Service at 64,000 miles....................................................................................................................................................................... 204 5.3.9 Service at 72,000 miles....................................................................................................................................................................... 205 5.3.10 Service at 80,000 miles...................................................................................................................................................................... 205 5.3.11 Service at 88,000 miles...................................................................................................................................................................... 205 5.3.12 Service at 96,000 miles...................................................................................................................................................................... 205 5.3.13 Service at 104,000 miles..................................................................................................................................................................... 206 5.3.14 Service at 112,000 miles..................................................................................................................................................................... 206 5.3.15 Service at 120,000 miles..................................................................................................................................................................... 206 5.3.16 Service at 128,000 miles..................................................................................................................................................................... 206 5.3.17 Service at 136,000 miles..................................................................................................................................................................... 206 5.3.18 Service at 144,000 miles..................................................................................................................................................................... 206 5.3.19 Service at 152,000 miles..................................................................................................................................................................... 207 5.4 MY 2011 Maintenance Intervals - Routan - Canada..................................................................................................................................................... 207 5.4.1 Service at 13,000 kilometers.................................................................................................................................................................. 207 5.4.2 Service at 26,000 kilometers.................................................................................................................................................................. 208 5.4.3 Service at 39,000 kilometers.................................................................................................................................................................. 208 5.4.4 Service at 52,000 kilometers.................................................................................................................................................................. 208 5.4.5 Service at 65,000 kilometers.................................................................................................................................................................. 208 5.4.6 Service at 78,000 kilometers.................................................................................................................................................................. 208 5.4.7 Service at 91,000 kilometers.................................................................................................................................................................. 209 5.4.8 Service at 104,000 kilometers................................................................................................................................................................. 209 5.4.9 Service at 117,000 kilometers................................................................................................................................................................. 209 5.4.10 Service at 130,000 kilometers................................................................................................................................................................ 209 5.4.11 Service at 143,000 kilometers................................................................................................................................................................ 210 5.4.12 Service at 156,000 kilometers................................................................................................................................................................ 210 5.4.13 Service at 169,000 kilometers................................................................................................................................................................ 210 5.4.14 Service at 182,000 kilometers................................................................................................................................................................ 210 5.4.15 Service at 195,000 kilometers................................................................................................................................................................ 210 5.4.16 Service at 208,000 kilometers................................................................................................................................................................ 211 5.4.17 Service at 221,000 kilometers................................................................................................................................................................ 211 5.4.18 Service at 234,000 kilometers................................................................................................................................................................ 211 5.4.19 Service at 247,000 kilometers................................................................................................................................................................ 211 6 MY 2010 Maintenance Intervals............................................................................................................................................................................. 212 6.1 MY 2010 Maintenance Intervals - USA................................................................................................................................................................. 212 6.1.1 Time Dependent Service........................................................................................................................................................................ 212 6.1.2 Service at Each 5,000 miles through 35,000 miles.............................................................................................................................................. 213 6.1.3 Service at 10,000€miles....................................................................................................................................................................... 213 6.1.4 Service at 20,000€miles....................................................................................................................................................................... 213 6.1.5 Service at 30,000€miles....................................................................................................................................................................... 214 6.1.6 Service at 40,000€miles and each 5,000 miles After............................................................................................................................................ 214 6.1.7 Service at 40,000 miles....................................................................................................................................................................... 214 6.1.8 Service at 50,000 miles....................................................................................................................................................................... 216 6.1.9 Service at 60,000 miles....................................................................................................................................................................... 216 6.1.10 Service at 70,000 miles...................................................................................................................................................................... 217 6.1.11 Service at 80,000 miles...................................................................................................................................................................... 217 6.1.12 Service at 90,000 miles...................................................................................................................................................................... 218 6.1.13 Service at 100,000 miles..................................................................................................................................................................... 219 6.1.14 Service at 110,000 miles..................................................................................................................................................................... 219 6.1.15 Service at 120,000 miles..................................................................................................................................................................... 220 6.2 MY 2010 Maintenance Intervals - Canada.............................................................................................................................................................. 221 6.2.1 Time Dependent Service........................................................................................................................................................................ 221 6.2.2 Service at 15,000€kilometers or one year from vehicle in-service date......................................................................................................................... 222 6.2.3 Service at 30,000€kilometers.................................................................................................................................................................. 222 6.2.4 Service at 45,000€kilometers.................................................................................................................................................................. 223 6.2.5 Service at 60,000€kilometers.................................................................................................................................................................. 223 6.2.6 Service at 75,000€kilometers.................................................................................................................................................................. 225 6.2.7 Service at 90.000€kilometers.................................................................................................................................................................. 225 6.2.8 Service at 105,000€kilometers................................................................................................................................................................. 226 6.2.9 Service at 120,000€kilometers................................................................................................................................................................. 226 6.2.10 Service at 135,000€kilometers................................................................................................................................................................ 227 6.2.11 Service at 150,000€kilometers................................................................................................................................................................ 228 6.2.12 Service at 165,000€kilometers................................................................................................................................................................ 228 6.2.13 Service at 180,000€kilometers................................................................................................................................................................ 229 6.3 MY 2010 Maintenance Intervals - Routan - USA........................................................................................................................................................ 230 6.3.1 Service at 6,000 miles........................................................................................................................................................................ 231 6.3.2 Service at 12,000 miles....................................................................................................................................................................... 231 6.3.3 Service at 18,000 miles....................................................................................................................................................................... 231 6.3.4 Service at 24,000 miles....................................................................................................................................................................... 232 6.3.5 Service at 30,000 miles....................................................................................................................................................................... 232 6.3.6 Service at 36,000 miles....................................................................................................................................................................... 232 6.3.7 Service at 42,000 miles....................................................................................................................................................................... 232 6.3.8 Service at 48,000 miles....................................................................................................................................................................... 232 6.3.9 Service at 54,000 miles....................................................................................................................................................................... 232 6.3.10 Service at 60,000 miles...................................................................................................................................................................... 233 6.3.11 Service at 66,000 miles...................................................................................................................................................................... 233 6.3.12 Service at 72,000 miles...................................................................................................................................................................... 233 6.3.13 Service at 78,000 miles...................................................................................................................................................................... 233 6.3.14 Service at 84,000 miles...................................................................................................................................................................... 233 6.3.15 Service at 90,000 miles...................................................................................................................................................................... 233 6.3.16 Service at 96,000 miles...................................................................................................................................................................... 234 6.3.17 Service at 102,000 miles..................................................................................................................................................................... 234 6.3.18 Service at 108,000 miles..................................................................................................................................................................... 234 6.3.19 Service at 114,000 miles..................................................................................................................................................................... 234 6.3.20 Service at 120,000 miles..................................................................................................................................................................... 234 6.3.21 Service at 126,000 miles..................................................................................................................................................................... 235 6.3.22 Service at 132,000 miles..................................................................................................................................................................... 235 6.3.23 Service at 138,000 miles..................................................................................................................................................................... 235 6.3.24 Service at 144,000 miles..................................................................................................................................................................... 235 6.3.25 Service at 150,000 miles..................................................................................................................................................................... 235 6.4 MY 2010 Maintenance Intervals - Routan - Canada..................................................................................................................................................... 236 6.4.1 Service at 10,000 kilometers.................................................................................................................................................................. 236 6.4.2 Service at 20,000 kilometers.................................................................................................................................................................. 236 6.4.3 Service at 30,000 kilometers.................................................................................................................................................................. 237 6.4.4 Service at 40,000 kilometers.................................................................................................................................................................. 237 6.4.5 Service at 50,000 kilometers.................................................................................................................................................................. 237 6.4.6 Service at 60,000 kilometers.................................................................................................................................................................. 237 6.4.7 Service at 70,000 kilometers.................................................................................................................................................................. 237 6.4.8 Service at 80,000 kilometers.................................................................................................................................................................. 237 6.4.9 Service at 90,000 kilometers.................................................................................................................................................................. 237 6.4.10 Service at 100,000 kilometers................................................................................................................................................................ 238 6.4.11 Service at 110,000 kilometers................................................................................................................................................................ 238 6.4.12 Service at 120,000 kilometers................................................................................................................................................................ 238 6.4.13 Service at 130,000 kilometers................................................................................................................................................................ 238 6.4.14 Service at 140,000 kilometers................................................................................................................................................................ 238 6.4.15 Service at 150,000 kilometers................................................................................................................................................................ 238 6.4.16 Service at 160,000 kilometers................................................................................................................................................................ 239 6.4.17 Service at 170,000 kilometers................................................................................................................................................................ 239 6.4.18 Service at 180,000 kilometers................................................................................................................................................................ 239 6.4.19 Service at 190,000 kilometers................................................................................................................................................................ 239 6.4.20 Service at 200,000 kilometers................................................................................................................................................................ 239 6.4.21 Service at 210,000 kilometers................................................................................................................................................................ 240 6.4.22 Service at 220,000 kilometers................................................................................................................................................................ 240 6.4.23 Service at 230,000 kilometers................................................................................................................................................................ 240 6.4.24 Service at 240,000 kilometers................................................................................................................................................................ 240 6.4.25 Service at 250,000 kilometers................................................................................................................................................................ 240 7 MY 2009 Maintenance Intervals............................................................................................................................................................................. 241 7.1 MY 2009 Maintenance Intervals - USA................................................................................................................................................................. 241 7.1.1 Time-Dependent Maintenance Items.............................................................................................................................................................. 241 7.1.2 Service every 5,000 miles..................................................................................................................................................................... 242 7.1.3 Service at 10,000 miles....................................................................................................................................................................... 242 7.1.4 Service at 20,000 miles....................................................................................................................................................................... 242 7.1.5 Service at 30,000 miles....................................................................................................................................................................... 243 7.1.6 Service at 40,000 miles....................................................................................................................................................................... 243 7.1.7 Service at 50,000 miles....................................................................................................................................................................... 244 7.1.8 Service at 60,000 miles....................................................................................................................................................................... 245 7.1.9 Service at 70,000 miles....................................................................................................................................................................... 245 7.1.10 Service at 80,000 miles...................................................................................................................................................................... 246 7.1.11 Service at 90,000 miles...................................................................................................................................................................... 247 7.1.12 Service at 100,000 miles..................................................................................................................................................................... 247 7.1.13 Service at 110,000 miles..................................................................................................................................................................... 248 7.1.14 Service at 120,000 miles..................................................................................................................................................................... 248 7.1.15 Service at 130,000 miles..................................................................................................................................................................... 249 7.2 MY 2009 Maintenance Intervals - Canada.............................................................................................................................................................. 250 7.2.1 Time Dependent Service........................................................................................................................................................................ 250 7.2.2 Service at 15,000€kilometers or one year from vehicle in-service date......................................................................................................................... 251 7.2.3 Service at 30,000€kilometers.................................................................................................................................................................. 251 7.2.4 Service at 45,000€kilometers.................................................................................................................................................................. 252 7.2.5 Service at 60,000€kilometers.................................................................................................................................................................. 252 7.2.6 Service at 75,000€kilometers.................................................................................................................................................................. 253 7.2.7 Service at 90.000€kilometers.................................................................................................................................................................. 254 7.2.8 Service at 105,000€kilometers................................................................................................................................................................. 254 7.2.9 Service at 120,000€kilometers................................................................................................................................................................. 255 7.2.10 Service at 135,000€kilometers................................................................................................................................................................ 256 7.2.11 Service at 150,000€kilometers................................................................................................................................................................ 257 7.2.12 Service at 165,000€kilometers................................................................................................................................................................ 257 7.2.13 Service at 180,000€kilometers................................................................................................................................................................ 258 7.3 MY 2009 Maintenance Intervals - Routan - USA........................................................................................................................................................ 259 7.3.1 Service at 6,000 miles........................................................................................................................................................................ 260 7.3.2 Service at 12,000 miles....................................................................................................................................................................... 260 7.3.3 Service at 18,000 miles....................................................................................................................................................................... 260 7.3.4 Service at 24,000 miles....................................................................................................................................................................... 261 7.3.5 Service at 30,000 miles....................................................................................................................................................................... 261 7.3.6 Service at 36,000 miles....................................................................................................................................................................... 261 7.3.7 Service at 42,000 miles....................................................................................................................................................................... 261 7.3.8 Service at 48,000 miles....................................................................................................................................................................... 261 7.3.9 Service at 54,000 miles....................................................................................................................................................................... 261 7.3.10 Service at 60,000 miles...................................................................................................................................................................... 261 7.3.11 Service at 66,000 miles...................................................................................................................................................................... 262 7.3.12 Service at 72,000 miles...................................................................................................................................................................... 262 7.3.13 Service at 78,000 miles...................................................................................................................................................................... 262 7.3.14 Service at 84,000 miles...................................................................................................................................................................... 262 7.3.15 Service at 90,000 miles...................................................................................................................................................................... 262 7.3.16 Service at 96,000 miles...................................................................................................................................................................... 262 7.3.17 Service at 102,000 miles..................................................................................................................................................................... 263 7.3.18 Service at 108,000 miles..................................................................................................................................................................... 263 7.3.19 Service at 114,000 miles..................................................................................................................................................................... 263 7.3.20 Service at 120,000 miles..................................................................................................................................................................... 263 7.3.21 Service at 126,000 miles..................................................................................................................................................................... 263 7.3.22 Service at 132,000 miles..................................................................................................................................................................... 263 7.3.23 Service at 138,000 miles..................................................................................................................................................................... 263 7.3.24 Service at 144,000 miles..................................................................................................................................................................... 264 7.3.25 Service at 150,000 miles..................................................................................................................................................................... 264 7.4 MY 2009 Maintenance Intervals - Routan - Canada..................................................................................................................................................... 264 7.4.1 Service at 10,000 kilometers.................................................................................................................................................................. 264 7.4.2 Service at 20,000 kilometers.................................................................................................................................................................. 265 7.4.3 Service at 30,000 kilometers.................................................................................................................................................................. 265 7.4.4 Service at 40,000 kilometers.................................................................................................................................................................. 265 7.4.5 Service at 50,000 kilometers.................................................................................................................................................................. 265 7.4.6 Service at 60,000 kilometers.................................................................................................................................................................. 265 7.4.7 Service at 70,000 kilometers.................................................................................................................................................................. 265 7.4.8 Service at 80,000 kilometers.................................................................................................................................................................. 265 7.4.9 Service at 90,000 kilometers.................................................................................................................................................................. 266 7.4.10 Service at 100,000 kilometers................................................................................................................................................................ 266 7.4.11 Service at 110,000 kilometers................................................................................................................................................................ 266 7.4.12 Service at 120,000 kilometers................................................................................................................................................................ 266 7.4.13 Service at 130,000 kilometers................................................................................................................................................................ 266 7.4.14 Service at 140,000 kilometers................................................................................................................................................................ 266 7.4.15 Service at 150,000 kilometers................................................................................................................................................................ 266 7.4.16 Service at 160,000 kilometers................................................................................................................................................................ 267 7.4.17 Service at 170,000 kilometers................................................................................................................................................................ 267 7.4.18 Service at 180,000 kilometers................................................................................................................................................................ 267 7.4.19 Service at 190,000 kilometers................................................................................................................................................................ 267 7.4.20 Service at 200,000 kilometers................................................................................................................................................................ 267 7.4.21 Service at 210,000 kilometers................................................................................................................................................................ 268 7.4.22 Service at 220,000 kilometers................................................................................................................................................................ 268 7.4.23 Service at 230,000 kilometers................................................................................................................................................................ 268 7.4.24 Service at 240,000 kilometers................................................................................................................................................................ 268 7.4.25 Service at 250,000 kilometers................................................................................................................................................................ 268 8 MY 2008 Maintenance Intervals............................................................................................................................................................................. 269 8.1 MY 2008 Maintenance Intervals - USA................................................................................................................................................................. 269 8.1.1 Time-Dependent Maintenance Items.............................................................................................................................................................. 269 8.1.2 Service at 5,000 miles........................................................................................................................................................................ 269 8.1.3 Service at 10,000 miles....................................................................................................................................................................... 270 8.1.4 Service at 20,000 miles....................................................................................................................................................................... 270 8.1.5 Service at 30,000 miles....................................................................................................................................................................... 271 8.1.6 Service at 40,000 miles....................................................................................................................................................................... 271 8.1.7 Service at 50,000 miles....................................................................................................................................................................... 273 8.1.8 Service at 60,000 miles....................................................................................................................................................................... 273 8.1.9 Service at 70,000 miles....................................................................................................................................................................... 274 8.1.10 Service at 80,000 miles...................................................................................................................................................................... 275 8.1.11 Service at 90,000 miles...................................................................................................................................................................... 276 8.1.12 Service at 100,000 miles..................................................................................................................................................................... 277 8.1.13 Service at 110,000 miles..................................................................................................................................................................... 278 8.1.14 Service at 120,000 miles..................................................................................................................................................................... 278 8.2 MY 2008 Maintenance Intervals - Canada.............................................................................................................................................................. 280 8.2.1 Time-Dependent Maintenance Items.............................................................................................................................................................. 280 8.2.2 Service at 8,000 kilometers................................................................................................................................................................... 280 8.2.3 Service at 16,000 kilometers.................................................................................................................................................................. 280 8.2.4 Service at 32,000 kilometers.................................................................................................................................................................. 281 8.2.5 Service at 48,000 kilometers.................................................................................................................................................................. 282 8.2.6 Service at 64,000 kilometers.................................................................................................................................................................. 282 8.2.7 Service at 80,000 kilometers.................................................................................................................................................................. 284 8.2.8 Service at 96,000 kilometers.................................................................................................................................................................. 284 8.2.9 Service at 112,000 kilometers................................................................................................................................................................. 285 8.2.10 Service at 128,000 kilometers................................................................................................................................................................ 286 8.2.11 Service at 144,000 kilometers................................................................................................................................................................ 287 8.2.12 Service at 160,000 kilometers................................................................................................................................................................ 287 8.2.13 Service at 176,000 kilometers................................................................................................................................................................ 288 8.2.14 Service at 180,000 kilometers................................................................................................................................................................ 289 9 MY 2007 Maintenance Intervals............................................................................................................................................................................. 291 9.1 MY 2007 Maintenance Intervals - USA................................................................................................................................................................. 291 9.1.1 Time-Dependent Maintenance Items.............................................................................................................................................................. 291 9.1.2 Service at 5,000 miles........................................................................................................................................................................ 292 9.1.3 Service at 10,000 miles....................................................................................................................................................................... 292 9.1.4 Service at 20,000 miles....................................................................................................................................................................... 292 9.1.5 Service at 30,000 miles....................................................................................................................................................................... 293 9.1.6 Service at 40,000 miles....................................................................................................................................................................... 293 9.1.7 Service at 50,000 miles....................................................................................................................................................................... 294 9.1.8 Service at 60,000 miles....................................................................................................................................................................... 295 9.1.9 Service at 70,000 miles....................................................................................................................................................................... 296 9.1.10 Service at 80,000 miles...................................................................................................................................................................... 296 9.1.11 Service at 90,000 miles...................................................................................................................................................................... 297 9.1.12 Service at 100,000 miles..................................................................................................................................................................... 298 9.1.13 Service at 110,000 miles..................................................................................................................................................................... 299 9.1.14 Service at 120,000 miles..................................................................................................................................................................... 299 9.2 MY 2007 Maintenance Intervals - Canada.............................................................................................................................................................. 301 9.2.1 Time-Dependent Maintenance Items.............................................................................................................................................................. 301 9.2.2 Service at 8,000 kilometers................................................................................................................................................................... 301 9.2.3 Service at 16,000 kilometers.................................................................................................................................................................. 302 9.2.4 Service at 32,000 kilometers.................................................................................................................................................................. 302 9.2.5 Service at 48,000 kilometers.................................................................................................................................................................. 303 9.2.6 Service at 64,000 kilometers.................................................................................................................................................................. 303 9.2.7 Service at 80,000 kilometers.................................................................................................................................................................. 304 9.2.8 Service at 96,000 kilometers.................................................................................................................................................................. 305 9.2.9 Service at 112,000 kilometers................................................................................................................................................................. 306 9.2.10 Service at 128,000 kilometers................................................................................................................................................................ 306 9.2.11 Service at 144,000 kilometers................................................................................................................................................................ 307 9.2.12 Service at 160,000 kilometers................................................................................................................................................................ 307 9.2.13 Service at 176,000 kilometers................................................................................................................................................................ 308 9.2.14 Service at 180,000 kilometers................................................................................................................................................................ 309 10 MY 2006 Maintenance Intervals............................................................................................................................................................................ 311 10.1 MY 2006 Maintenance Intervals - USA................................................................................................................................................................ 311 10.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 311 10.1.2 Service at 5,000 miles....................................................................................................................................................................... 312 10.1.3 Service at 10,000 miles...................................................................................................................................................................... 312 10.1.4 Service at 15,000 miles...................................................................................................................................................................... 312 10.1.5 Service at 20,000 miles...................................................................................................................................................................... 312 10.1.6 Service at 25,000 miles...................................................................................................................................................................... 313 10.1.7 Service at 30,000 miles...................................................................................................................................................................... 313 10.1.8 Service at 35,000 miles...................................................................................................................................................................... 314 10.1.9 Service at 40,000 miles...................................................................................................................................................................... 314 10.1.10 Service at 45,000 miles..................................................................................................................................................................... 315 10.1.11 Service at 50,000 miles..................................................................................................................................................................... 315 10.1.12 Service at 55,000 miles..................................................................................................................................................................... 316 10.1.13 Service at 60,000 miles..................................................................................................................................................................... 316 10.1.14 Service at 65,000 miles..................................................................................................................................................................... 317 10.1.15 Service at 70,000 miles..................................................................................................................................................................... 317 10.1.16 Service at 75,000 miles..................................................................................................................................................................... 317 10.1.17 Service at 80,000 miles..................................................................................................................................................................... 317 10.1.18 Service at 85,000 miles..................................................................................................................................................................... 319 10.1.19 Service at 90,000 miles..................................................................................................................................................................... 319 10.1.20 Service at 95,000 miles..................................................................................................................................................................... 319 10.1.21 Service at 100,000 miles.................................................................................................................................................................... 319 10.1.22 Service at 105,000 miles.................................................................................................................................................................... 320 10.2 MY 2006 Maintenance Intervals - Canada............................................................................................................................................................. 321 10.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 321 10.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 322 10.2.3 Service at 16,000 kilometers................................................................................................................................................................. 322 10.2.4 Service at 24,000 kilometers................................................................................................................................................................. 322 10.2.5 Service at 32,000 kilometers................................................................................................................................................................. 322 10.2.6 Service at 40,000 kilometers................................................................................................................................................................. 323 10.2.7 Service at 48,000 kilometers................................................................................................................................................................. 323 10.2.8 Service at 56,000 kilometers................................................................................................................................................................. 324 10.2.9 Service at 64,000 kilometers................................................................................................................................................................. 324 10.2.10 Service at 72,000 kilometers................................................................................................................................................................ 325 10.2.11 Service at 80,000 kilometers................................................................................................................................................................ 325 10.2.12 Service at 88,000 kilometers................................................................................................................................................................ 326 10.2.13 Service at 96,000 kilometers................................................................................................................................................................ 326 10.2.14 Service at 104,000 kilometers............................................................................................................................................................... 327 10.2.15 Service at 112,000 kilometers............................................................................................................................................................... 327 10.2.16 Service at 120,000 kilometers............................................................................................................................................................... 327 10.2.17 Service at 128,000 kilometers............................................................................................................................................................... 327 10.2.18 Service at 136,000 kilometers............................................................................................................................................................... 329 10.2.19 Service at 144,000 kilometers............................................................................................................................................................... 329 10.2.20 Service at 152,000 kilometers............................................................................................................................................................... 329 10.2.21 Service at 160,000 kilometers............................................................................................................................................................... 329 10.2.22 Service at 168,000 kilometers............................................................................................................................................................... 330 11 MY 2005 Maintenance Intervals............................................................................................................................................................................ 331 11.1 MY 2005 Maintenance Intervals - USA................................................................................................................................................................ 331 11.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 331 11.1.2 Service at 5,000 miles....................................................................................................................................................................... 332 11.1.3 Service at 10,000 miles...................................................................................................................................................................... 332 11.1.4 Service at 15,000 miles...................................................................................................................................................................... 332 11.1.5 Service at 20,000 miles...................................................................................................................................................................... 332 11.1.6 Service at 25,000 miles...................................................................................................................................................................... 333 11.1.7 Service at 30,000 miles...................................................................................................................................................................... 333 11.1.8 Service at 35,000 miles...................................................................................................................................................................... 334 11.1.9 Service at 40,000 miles...................................................................................................................................................................... 334 11.1.10 Service at 45,000 miles..................................................................................................................................................................... 335 11.1.11 Service at 50,000 miles..................................................................................................................................................................... 335 11.1.12 Service at 55,000 miles..................................................................................................................................................................... 335 11.1.13 Service at 60,000 miles..................................................................................................................................................................... 336 11.1.14 Service at 65,000 miles..................................................................................................................................................................... 337 11.1.15 Service at 70,000 miles..................................................................................................................................................................... 337 11.1.16 Service at 75,000 miles..................................................................................................................................................................... 337 11.1.17 Service at 80,000 miles..................................................................................................................................................................... 337 11.1.18 Service at 85,000 miles..................................................................................................................................................................... 338 11.1.19 Service at 90,000 miles..................................................................................................................................................................... 338 11.1.20 Service at 95,000 miles..................................................................................................................................................................... 339 11.1.21 Service at 100,000 miles.................................................................................................................................................................... 339 11.1.22 Service at 105,000 miles.................................................................................................................................................................... 340 11.2 MY 2005 Maintenance Intervals - Canada............................................................................................................................................................. 341 11.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 341 11.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 342 11.2.3 Service at 16,000 kilometers................................................................................................................................................................. 342 11.2.4 Service at 24,000 kilometers................................................................................................................................................................. 342 11.2.5 Service at 32,000 kilometers................................................................................................................................................................. 342 11.2.6 Service at 40,000 kilometers................................................................................................................................................................. 343 11.2.7 Service at 48,000 kilometers................................................................................................................................................................. 343 11.2.8 Service at 56,000 kilometers................................................................................................................................................................. 343 11.2.9 Service at 64,000 kilometers................................................................................................................................................................. 344 11.2.10 Service at 72,000 kilometers................................................................................................................................................................ 345 11.2.11 Service at 80,000 kilometers................................................................................................................................................................ 345 11.2.12 Service at 88,000 kilometers................................................................................................................................................................ 345 11.2.13 Service at 96,000 kilometers................................................................................................................................................................ 345 11.2.14 Service at 104,000 kilometers............................................................................................................................................................... 346 11.2.15 Service at 112,000 kilometers............................................................................................................................................................... 346 11.2.16 Service at 120,000 kilometers............................................................................................................................................................... 347 11.2.17 Service at 128,000 kilometers............................................................................................................................................................... 347 11.2.18 Service at 136,000 kilometers............................................................................................................................................................... 348 11.2.19 Service at 144,000 kilometers............................................................................................................................................................... 348 11.2.20 Service at 152,000 kilometers............................................................................................................................................................... 348 11.2.21 Service at 160,000 kilometers............................................................................................................................................................... 349 11.2.22 Service at 168,000 kilometers............................................................................................................................................................... 350 12 MY 2004 Maintenance Intervals............................................................................................................................................................................ 351 12.1 MY 2004 Maintenance Intervals - USA................................................................................................................................................................ 351 12.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 351 12.1.2 Service at 5,000 miles....................................................................................................................................................................... 352 12.1.3 Service at 10,000 miles...................................................................................................................................................................... 352 12.1.4 Service at 15,000 miles...................................................................................................................................................................... 352 12.1.5 Service at 20,000 miles...................................................................................................................................................................... 352 12.1.6 Service at 25,000 miles...................................................................................................................................................................... 353 12.1.7 Service at 30,000 miles...................................................................................................................................................................... 353 12.1.8 Service at 35,000 miles...................................................................................................................................................................... 353 12.1.9 Service at 40,000 miles...................................................................................................................................................................... 353 12.1.10 Service at 45,000 miles..................................................................................................................................................................... 354 12.1.11 Service at 50,000 miles..................................................................................................................................................................... 354 12.1.12 Service at 55,000 miles..................................................................................................................................................................... 355 12.1.13 Service at 60,000 miles..................................................................................................................................................................... 355 12.1.14 Service at 65,000 miles..................................................................................................................................................................... 356 12.1.15 Service at 70,000 miles..................................................................................................................................................................... 356 12.1.16 Service at 75,000 miles..................................................................................................................................................................... 356 12.1.17 Service at 80,000 miles..................................................................................................................................................................... 356 12.1.18 Service at 85,000 miles..................................................................................................................................................................... 357 12.1.19 Service at 90,000 miles..................................................................................................................................................................... 357 12.1.20 Service at 95,000 miles..................................................................................................................................................................... 358 12.1.21 Service at 100,000 miles.................................................................................................................................................................... 358 12.1.22 Service at 105,000 miles.................................................................................................................................................................... 358 12.2 MY 2004 Maintenance Intervals - Canada............................................................................................................................................................. 359 12.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 359 12.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 360 12.2.3 Service at 16,000 kilometers................................................................................................................................................................. 360 12.2.4 Service at 24,000 kilometers................................................................................................................................................................. 360 12.2.5 Service at 32,000 kilometers................................................................................................................................................................. 360 12.2.6 Service at 40,000 kilometers................................................................................................................................................................. 361 12.2.7 Service at 48,000 kilometers................................................................................................................................................................. 361 12.2.8 Service at 56,000 kilometers................................................................................................................................................................. 361 12.2.9 Service at 64,000 kilometers................................................................................................................................................................. 361 12.2.10 Service at 72,000 kilometers................................................................................................................................................................ 362 12.2.11 Service at 80,000 kilometers................................................................................................................................................................ 362 12.2.12 Service at 88,000 kilometers................................................................................................................................................................ 363 12.2.13 Service at 96,000 kilometers................................................................................................................................................................ 363 12.2.14 Service at 104,000 kilometers............................................................................................................................................................... 363 12.2.15 Service at 112,000 kilometers............................................................................................................................................................... 363 12.2.16 Service at 120,000 kilometers............................................................................................................................................................... 364 12.2.17 Service at 128,000 kilometers............................................................................................................................................................... 364 12.2.18 Service at 136,000 kilometers............................................................................................................................................................... 365 12.2.19 Service at 144,000 kilometers............................................................................................................................................................... 365 12.2.20 Service at 152,000 kilometers............................................................................................................................................................... 365 12.2.21 Service at 160,000 kilometers............................................................................................................................................................... 365 12.2.22 Service at 168,000 kilometers............................................................................................................................................................... 366 13 MY 2003 Maintenance Intervals............................................................................................................................................................................ 367 13.1 MY 2003 Maintenance Intervals - USA................................................................................................................................................................ 367 13.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 367 13.1.2 Service at 5,000 miles....................................................................................................................................................................... 367 13.1.3 Service at 10,000 miles...................................................................................................................................................................... 368 13.1.4 Service at 15,000 miles...................................................................................................................................................................... 368 13.1.5 Service at 20,000 miles...................................................................................................................................................................... 368 13.1.6 Service at 25,000 miles...................................................................................................................................................................... 369 13.1.7 Service at 30,000 miles...................................................................................................................................................................... 369 13.1.8 Service at 35,000 miles...................................................................................................................................................................... 369 13.1.9 Service at 40,000 miles...................................................................................................................................................................... 369 13.1.10 Service at 45,000 miles..................................................................................................................................................................... 370 13.1.11 Service at 50,000 miles..................................................................................................................................................................... 370 13.1.12 Service at 55,000 miles..................................................................................................................................................................... 370 13.1.13 Service at 60,000 miles..................................................................................................................................................................... 370 13.1.14 Service at 65,000 miles..................................................................................................................................................................... 371 13.1.15 Service at 70,000 miles..................................................................................................................................................................... 371 13.1.16 Service at 75,000 miles..................................................................................................................................................................... 371 13.1.17 Service at 80,000 miles..................................................................................................................................................................... 371 13.1.18 Service at 85,000 miles..................................................................................................................................................................... 372 13.1.19 Service at 90,000 miles..................................................................................................................................................................... 372 13.1.20 Service at 95,000 miles..................................................................................................................................................................... 373 13.1.21 Service at 100,000 miles.................................................................................................................................................................... 373 13.1.22 Service at 105,000 miles.................................................................................................................................................................... 373 13.2 MY 2003 Maintenance Intervals - Canada............................................................................................................................................................. 374 13.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 374 13.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 374 13.2.3 Service at 16,000 kilometers................................................................................................................................................................. 374 13.2.4 Service at 24,000 kilometers................................................................................................................................................................. 375 13.2.5 Service at 32,000 kilometers................................................................................................................................................................. 375 13.2.6 Service at 40,000 kilometers................................................................................................................................................................. 375 13.2.7 Service at 48,000 kilometers................................................................................................................................................................. 375 13.2.8 Service at 56,000 kilometers................................................................................................................................................................. 376 13.2.9 Service at 64,000 kilometers................................................................................................................................................................. 376 13.2.10 Service at 72,000 kilometers................................................................................................................................................................ 377 13.2.11 Service at 80,000 kilometers................................................................................................................................................................ 377 13.2.12 Service at 88,000 kilometers................................................................................................................................................................ 377 13.2.13 Service at 96,000 kilometers................................................................................................................................................................ 377 13.2.14 Service at 104,000 kilometers............................................................................................................................................................... 378 13.2.15 Service at 112,000 kilometers............................................................................................................................................................... 378 13.2.16 Service at 120,000 kilometers............................................................................................................................................................... 378 13.2.17 Service at 128,000 kilometers............................................................................................................................................................... 378 13.2.18 Service at 136,000 kilometers............................................................................................................................................................... 379 13.2.19 Service at 144,000 kilometers............................................................................................................................................................... 379 13.2.20 Service at 152,000 kilometers............................................................................................................................................................... 379 13.2.21 Service at 160,000 kilometers............................................................................................................................................................... 379 13.2.22 Service at 168,000 kilometers............................................................................................................................................................... 380 14 MY 2002 Maintenance Intervals............................................................................................................................................................................ 381 14.1 MY 2002 Maintenance Intervals - USA................................................................................................................................................................ 381 14.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 381 14.1.2 Service at 5,000 miles....................................................................................................................................................................... 381 14.1.3 Service at 10,000 miles...................................................................................................................................................................... 382 14.1.4 Service at 15,000 miles...................................................................................................................................................................... 382 14.1.5 Service at 20,000 miles...................................................................................................................................................................... 382 14.1.6 Service at 25,000 miles...................................................................................................................................................................... 383 14.1.7 Service at 30,000 miles...................................................................................................................................................................... 383 14.1.8 Service at 35,000 miles...................................................................................................................................................................... 383 14.1.9 Service at 40,000 miles...................................................................................................................................................................... 383 14.1.10 Service at 45,000 miles..................................................................................................................................................................... 384 14.1.11 Service at 50,000 miles..................................................................................................................................................................... 384 14.1.12 Service at 55,000 miles..................................................................................................................................................................... 384 14.1.13 Service at 60,000 miles..................................................................................................................................................................... 384 14.1.14 Service at 65,000 miles..................................................................................................................................................................... 385 14.1.15 Service at 70,000 miles..................................................................................................................................................................... 385 14.1.16 Service at 75,000 miles..................................................................................................................................................................... 385 14.1.17 Service at 80,000 miles..................................................................................................................................................................... 385 14.1.18 Service at 85,000 miles..................................................................................................................................................................... 386 14.1.19 Service at 90,000 miles..................................................................................................................................................................... 386 14.1.20 Service at 95,000 miles..................................................................................................................................................................... 387 14.1.21 Service at 100,000 miles.................................................................................................................................................................... 387 14.1.22 Service at 105,000 miles.................................................................................................................................................................... 387 14.2 MY 2002 Maintenance Intervals - Canada............................................................................................................................................................. 388 14.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 388 14.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 388 14.2.3 Service at 16,000 kilometers................................................................................................................................................................. 388 14.2.4 Service at 24,000 kilometers................................................................................................................................................................. 389 14.2.5 Service at 32,000 kilometers................................................................................................................................................................. 389 14.2.6 Service at 40,000 kilometers................................................................................................................................................................. 389 14.2.7 Service at 48,000 kilometers................................................................................................................................................................. 389 14.2.8 Service at 56,000 kilometers................................................................................................................................................................. 390 14.2.9 Service at 64,000 kilometers................................................................................................................................................................. 390 14.2.10 Service at 72,000 kilometers................................................................................................................................................................ 391 14.2.11 Service at 80,000 kilometers................................................................................................................................................................ 391 14.2.12 Service at 88,000 kilometers................................................................................................................................................................ 391 14.2.13 Service at 96,000 kilometers................................................................................................................................................................ 391 14.2.14 Service at 104,000 kilometers............................................................................................................................................................... 392 14.2.15 Service at 112,000 kilometers............................................................................................................................................................... 392 14.2.16 Service at 120,000 kilometers............................................................................................................................................................... 392 14.2.17 Service at 128,000 kilometers............................................................................................................................................................... 392 14.2.18 Service at 136,000 kilometers............................................................................................................................................................... 393 14.2.19 Service at 144,000 kilometers............................................................................................................................................................... 393 14.2.20 Service at 152,000 kilometers............................................................................................................................................................... 393 14.2.21 Service at 160,000 kilometers............................................................................................................................................................... 393 14.2.22 Service at 168,000 kilometers............................................................................................................................................................... 394 15 MY 2001 Maintenance Intervals............................................................................................................................................................................ 395 15.1 MY 2001 Maintenance Intervals - USA................................................................................................................................................................ 395 15.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 395 15.1.2 Service at 5,000 miles....................................................................................................................................................................... 396 15.1.3 Service at 10,000 miles...................................................................................................................................................................... 396 15.1.4 Service at 15,000 miles...................................................................................................................................................................... 396 15.1.5 Service at 20,000 miles...................................................................................................................................................................... 396 15.1.6 Service at 25,000 miles...................................................................................................................................................................... 397 15.1.7 Service at 30,000 miles...................................................................................................................................................................... 397 15.1.8 Service at 35,000 miles...................................................................................................................................................................... 397 15.1.9 Service at 40,000 miles...................................................................................................................................................................... 397 15.1.10 Service at 45,000 miles..................................................................................................................................................................... 398 15.1.11 Service at 50,000 miles..................................................................................................................................................................... 398 15.1.12 Service at 55,000 miles..................................................................................................................................................................... 398 15.1.13 Service at 60,000 miles..................................................................................................................................................................... 398 15.1.14 Service at 65,000 miles..................................................................................................................................................................... 399 15.1.15 Service at 70,000 miles..................................................................................................................................................................... 399 15.1.16 Service at 75,000 miles..................................................................................................................................................................... 399 15.1.17 Service at 80,000 miles..................................................................................................................................................................... 399 15.1.18 Service at 85,000 miles..................................................................................................................................................................... 400 15.1.19 Service at 90,000 miles..................................................................................................................................................................... 400 15.1.20 Service at 95,000 miles..................................................................................................................................................................... 400 15.1.21 Service at 100,000 miles.................................................................................................................................................................... 400 15.1.22 Service at 105,000 miles.................................................................................................................................................................... 401 15.2 MY 2001 Maintenance Intervals - Canada............................................................................................................................................................. 402 15.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 402 15.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 402 15.2.3 Service at 16,000 kilometers................................................................................................................................................................. 402 15.2.4 Service at 24,000 kilometers................................................................................................................................................................. 403 15.2.5 Service at 32,000 kilometers................................................................................................................................................................. 403 15.2.6 Service at 40,000 kilometers................................................................................................................................................................. 403 15.2.7 Service at 48,000 kilometers................................................................................................................................................................. 403 15.2.8 Service at 56,000 kilometers................................................................................................................................................................. 404 15.2.9 Service at 64,000 kilometers................................................................................................................................................................. 404 15.2.10 Service at 72,000 kilometers................................................................................................................................................................ 404 15.2.11 Service at 80,000 kilometers................................................................................................................................................................ 405 15.2.12 Service at 88,000 kilometers................................................................................................................................................................ 405 15.2.13 Service at 96,000 kilometers................................................................................................................................................................ 405 15.2.14 Service at 104,000 kilometers............................................................................................................................................................... 405 15.2.15 Service at 112,000 kilometers............................................................................................................................................................... 406 15.2.16 Service at 120,000 kilometers............................................................................................................................................................... 406 15.2.17 Service at 128,000 kilometers............................................................................................................................................................... 406 15.2.18 Service at 136,000 kilometers............................................................................................................................................................... 407 15.2.19 Service at 144,000 kilometers............................................................................................................................................................... 407 15.2.20 Service at 152,000 kilometers............................................................................................................................................................... 407 15.2.21 Service at 160,000 kilometers............................................................................................................................................................... 407 15.2.22 Service at 168,000 kilometers............................................................................................................................................................... 408 16 MY 2000 Maintenance Intervals............................................................................................................................................................................ 409 16.1 MY 2000 Maintenance Intervals - USA................................................................................................................................................................ 409 16.1.1 Time-Dependent Maintenance Items............................................................................................................................................................. 409 16.1.2 Service at 5,000 miles....................................................................................................................................................................... 409 16.1.3 Service at 10,000 miles...................................................................................................................................................................... 410 16.1.4 Service at 15,000 miles...................................................................................................................................................................... 410 16.1.5 Service at 20,000 miles...................................................................................................................................................................... 410 16.1.6 Service at 25,000 miles...................................................................................................................................................................... 411 16.1.7 Service at 30,000 miles...................................................................................................................................................................... 411 16.1.8 Service at 35,000 miles...................................................................................................................................................................... 411 16.1.9 Service at 40,000 miles...................................................................................................................................................................... 411 16.1.10 Service at 45,000 miles..................................................................................................................................................................... 412 16.1.11 Service at 50,000 miles..................................................................................................................................................................... 412 16.1.12 Service at 55,000 miles..................................................................................................................................................................... 412 16.1.13 Service at 60,000 miles..................................................................................................................................................................... 412 16.1.14 Service at 65,000 miles..................................................................................................................................................................... 413 16.1.15 Service at 70,000 miles..................................................................................................................................................................... 413 16.1.16 Service at 75,000 miles..................................................................................................................................................................... 413 16.1.17 Service at 80,000 miles..................................................................................................................................................................... 413 16.1.18 Service at 85,000 miles..................................................................................................................................................................... 414 16.1.19 Service at 90,000 miles..................................................................................................................................................................... 414 16.1.20 Service at 95,000 miles..................................................................................................................................................................... 414 16.1.21 Service at 100,000 miles.................................................................................................................................................................... 414 16.1.22 Service at 105,000 miles.................................................................................................................................................................... 415 16.2 MY 2000 Maintenance Intervals - Canada............................................................................................................................................................. 416 16.2.1 Time-Dependent Maintenance Items............................................................................................................................................................. 416 16.2.2 Service at 8,000 kilometers.................................................................................................................................................................. 416 16.2.3 Service at 16,000 kilometers................................................................................................................................................................. 416 16.2.4 Service at 24,000 kilometers................................................................................................................................................................. 417 16.2.5 Service at 32,000 kilometers................................................................................................................................................................. 417 16.2.6 Service at 40,000 kilometers................................................................................................................................................................. 417 16.2.7 Service at 48,000 kilometers................................................................................................................................................................. 417 16.2.8 Service at 56,000 kilometers................................................................................................................................................................. 418 16.2.9 Service at 64,000 kilometers................................................................................................................................................................. 418 16.2.10 Service at 72,000 kilometers................................................................................................................................................................ 418 16.2.11 Service at 80,000 kilometers................................................................................................................................................................ 419 16.2.12 Service at 88,000 kilometers................................................................................................................................................................ 419 16.2.13 Service at 96,000 kilometers................................................................................................................................................................ 419 16.2.14 Service at 104,000 kilometers............................................................................................................................................................... 419 16.2.15 Service at 112,000 kilometers............................................................................................................................................................... 420 16.2.16 Service at 120,000 kilometers............................................................................................................................................................... 420 16.2.17 Service at 128,000 kilometers............................................................................................................................................................... 420 16.2.18 Service at 136,000 kilometers............................................................................................................................................................... 421 16.2.19 Service at 144,000 kilometers............................................................................................................................................................... 421 16.2.20 Service at 152,000 kilometers............................................................................................................................................................... 421 16.2.21 Service at 160,000 kilometers............................................................................................................................................................... 421 16.2.22 Service at 168,000 kilometers............................................................................................................................................................... 422 00-04 Maintenance Procedures General................................................................................................................................................................................ 426 03 – Maintenance, Diagnosis..................................................................................................................................................................................... 430 1 General Information....................................................................................................................................................................................... 430 1.1 Engine Overview..................................................................................................................................................................................... 430 1.2 Oil Change Service.................................................................................................................................................................................. 434 1.3 Inspection Service through MY 99.................................................................................................................................................................... 434 1.4 Inspection Service from MY 00....................................................................................................................................................................... 434 1.5 Lifting Vehicle..................................................................................................................................................................................... 434 1.5.1 General Information........................................................................................................................................................................... 434 1.5.2 Vehicle Hoist Lifting Points.................................................................................................................................................................. 435 1.5.3 Golf R32, Lifting............................................................................................................................................................................. 435 1.5.4 Floor Jack Lifting Points..................................................................................................................................................................... 435 1.6 Labels.............................................................................................................................................................................................. 436 1.6.1 Attaching Data Label in the Luggage Compartment............................................................................................................................................... 436 1.7 Diagnostic Tool, Connecting......................................................................................................................................................................... 437 1.8 Severe Operating Conditions......................................................................................................................................................................... 439 1.9 Vehicle Identification Number....................................................................................................................................................................... 440 1.10 Vehicle Data Label................................................................................................................................................................................. 440 1.11 Hot Climate Countries.............................................................................................................................................................................. 441 1.12 Engine Code and Engine Identification.............................................................................................................................................................. 442 1.13 RME biodiesel...................................................................................................................................................................................... 442 1.14 Type Plate......................................................................................................................................................................................... 443 1.15 Glossary........................................................................................................................................................................................... 443 2 Maintenance Procedures.................................................................................................................................................................................... 446 2.1 Exhaust System, Inspect Visually For Leaks, Fasteners And Damage.................................................................................................................................... 448 2.2 Ball Joints, Checking............................................................................................................................................................................... 448 2.3 Automatic Transmission 01M, Changing ATF............................................................................................................................................................ 448 2.4 Automatic Transmission 01M, Replacing ATF Strainer.................................................................................................................................................. 448 2.5 Automatic Transmission 01M, Checking Final Drive Gear Oil........................................................................................................................................... 449 2.6 Automatic Transmission 01M, Checking ATF Level and Filling.......................................................................................................................................... 449 2.7 Automatic Transmission 09A, Checking ATF Level and Filling.......................................................................................................................................... 449 2.8 Battery Terminals, Checking for Secure Fit.......................................................................................................................................................... 449 2.9 Battery, Checking................................................................................................................................................................................... 450 2.10 Tires, Tire Condition, Wear Pattern, Inflation Pressure and Tread Depth............................................................................................................................ 451 2.10.1 General Information.......................................................................................................................................................................... 451 2.10.2 Checking..................................................................................................................................................................................... 451 2.10.3 Tires, Checking Wear Pattern................................................................................................................................................................. 452 2.10.5 Tires, Including Spare, Checking Pressure and Correcting..................................................................................................................................... 452 2.11 Brake System, Check for Leaks and Damage........................................................................................................................................................... 453 2.12 Front and Rear Brake Pads, Checking Thickness...................................................................................................................................................... 453 2.12.1 Front Disc Brake Pads........................................................................................................................................................................ 453 2.12.2 Rear Disc Brake Pads......................................................................................................................................................................... 454 2.12.3 Drum Brake Pads, Checking, Rear.............................................................................................................................................................. 455 2.13 Brake and Clutch System, Changing Brake Fluid...................................................................................................................................................... 457 2.13.1 Application Information and Safety Precautions............................................................................................................................................... 457 2.13.2 Brake Fluid Specifications................................................................................................................................................................... 457 2.13.3 Brake Fluid, Changing........................................................................................................................................................................ 457 2.14 Brake Fluid Level, Checking........................................................................................................................................................................ 460 2.15 DSG transmission 02E, Fluid and Filter Change, 6-Speed, AWD........................................................................................................................................ 461 2.16 Power Window Regulators, 8-Way Memory Seats, Performing Initialization............................................................................................................................. 461 2.16.1 Power Window Regulators, Performing Initialization........................................................................................................................................... 461 2.16.2 8-Way Memory Seat, Performing Initialization................................................................................................................................................. 462 2.17 Performing Vehicle System Test..................................................................................................................................................................... 462 2.18 Protective Joint Boots, Inspecting................................................................................................................................................................. 463 2.19 Noise Insulation, Installing, Golf R32............................................................................................................................................................. 463 2.20 Haldex Clutch Oil Filter, Removing and Installing, AWD............................................................................................................................................. 465 2.21 Haldex Clutch, AWD, Changing Oil................................................................................................................................................................... 465 2.22 First Aid Kit Expiration Date, Checking............................................................................................................................................................ 465 2.23 Fuel Filter, Diesel, Removing and Installing....................................................................................................................................................... 465 2.24 Fuel Filter, Diesel, Draining Water................................................................................................................................................................ 466 2.25 Ribbed Belt, Checking Condition.................................................................................................................................................................... 467 2.26 Cooling System, Checking Freeze Protection and Coolant Level....................................................................................................................................... 468 2.27 Air Filter, Cleaning Housing and Removing and Installing Air Filter................................................................................................................................ 471 2.27.1 Air Filter, Cleaning Housing, Replacing Filter, Cleaning Snow Screen If Equipped............................................................................................................. 471 2.28 Upper Engine Cover, Removing and Installing........................................................................................................................................................ 473 2.28.1 Engine Cover, Removing and Installing, 1.4L with Ignition Coil............................................................................................................................... 473 2.28.3 Engine Cover, 1.8L, Removing and Installing.................................................................................................................................................. 474 2.28.6 Engine Cover, Removing and Installing, 2.8L Fuel Injection Engines........................................................................................................................... 476 2.28.7 Engine Cover, Removing and Installing, 3.2L Fuel Injection Engines........................................................................................................................... 476 2.28.9 Engine Cover, Removing and Installing, 4-Cylinder TDI PD Engines............................................................................................................................. 477 2.29 Lower Engine Compartment Cover, Removing and Installing............................................................................................................................................ 478 2.30 Engine Oil Level, Checking......................................................................................................................................................................... 480 2.31 Engine Oil, Draining or Extracting and Filling; Replacing Oil Filter............................................................................................................................... 480 2.31.1 Engine Oil, Draining or Extracting and Filling............................................................................................................................................... 480 2.31.2 Oil Filter, Replacing........................................................................................................................................................................ 482 2.31.3 Engine Oil, Filling.......................................................................................................................................................................... 485 2.32 Engine and Engine Compartment Components, Checking for Leaks and Damage............................................................................................................................ 486 2.33 Perform a Road Test................................................................................................................................................................................ 486 2.34 Radio/Radio Navigation System, Attaching Serial Number and Code Number to Unit Card................................................................................................................ 487 2.35 Radio/Radio Navigation System, Activating Anti-Theft Coding........................................................................................................................................ 487 2.35.1 General Information.......................................................................................................................................................................... 487 2.35.2 ALPHA Radio Units, Activating Security Code.................................................................................................................................................. 487 2.35.4 On the Radio Navigation System activate the security code as follows:........................................................................................................................ 488 2.36 Wheel Bolts, Tightening Specifications............................................................................................................................................................. 489 2.37 Attaching Wheel Housing Liner to Front Apron (Anniversary Golf GTI with 132 kW only)............................................................................................................... 491 2.38 Tire Repair Kit, Checking.......................................................................................................................................................................... 492 2.39 Power Steering, Checking Fluid Level............................................................................................................................................................... 493 2.40 Sunroof, Checking Function, Cleaning and Lubricating Guide Rails................................................................................................................................... 494 2.41 Sunroof Water Drains, Checking and Cleaning........................................................................................................................................................ 495 2.42 Windshield and Headlamp Washer System, Checking for Damage, Function and Spray Nozzle Adjustment................................................................................................... 496 2.42.1 Windshield Wiper/Washer System Freeze Protection, Checking and Filling....................................................................................................................... 496 2.42.2 Windshield Washer System, Checking and Adjusting Spray Nozzle Position....................................................................................................................... 498 2.42.3 Headlamp Washer System, Checking Spray Nozzles............................................................................................................................................... 500 2.43 Windshield Wiper Blades, Checking for Damage, End Position and Adjustment Angle.................................................................................................................... 500 2.43.1 Windshield Wiper Blades Parked Position, Adjusting........................................................................................................................................... 500 2.43.2 Windshield Wiper Blades, Checking Angle and Adjusting........................................................................................................................................ 501 2.44 Manual Transmission/Final Drive, Checking Oil Level................................................................................................................................................ 502 2.45 Headlamps, Checking and Adjusting.................................................................................................................................................................. 502 2.45.1 General Information.......................................................................................................................................................................... 502 2.45.2 Headlamps, Checking Adjustment with New Test Screen without 15° Adjustment Line.............................................................................................................. 503 2.45.3 Adjusting Headlamps for the Golf............................................................................................................................................................. 504 2.45.4 Headlamps, Adjusting, Jetta.................................................................................................................................................................. 504 2.45.5 Headlamps, Checking Headlamp with Gas Discharge Lamps........................................................................................................................................ 505 2.46 Service Interval Display, Resetting................................................................................................................................................................ 506 2.47 Service Interval Display, Coding................................................................................................................................................................... 508 2.48 Tie Rod Ends, Checking Play, Security and Joint Boots.............................................................................................................................................. 509 2.49 Language, Selecting................................................................................................................................................................................ 509 2.50 Dust and Pollen Filter, Cleaning Housing and Removing and Installing Filter Element................................................................................................................ 510 2.51 Transport Protection, Removing Locking Pieces from Front Axle Struts............................................................................................................................... 510 2.52 Door Arrester, Lubricating......................................................................................................................................................................... 511 2.53 Clock, Setting..................................................................................................................................................................................... 512 2.54 Underbody Components, Checking for Damage.......................................................................................................................................................... 512 2.55 Toothed Belt and Camshaft Drive Tensioner, Replacing............................................................................................................................................... 513 2.55.1 Toothed Belt and Camshaft Drive Tensioning Roller, Removing and Installing, Diesel, Engine Codes ALH and BEW................................................................................. 513 2.55.2 Camshaft Drive Toothed Belt, Removing and Installing, 4-Cylinder, 5-Valve Gasoline, Engine Code AWP.......................................................................................... 513 2.56 Camshaft Drive Toothed Belt, Checking, 4-Cylinder Gasoline Engine.................................................................................................................................. 513 2.57 Toothed Belt, Diesel, Checking for Wear............................................................................................................................................................ 514 2.58 Camshaft Drive Toothed Belt, Checking Condition and Tension, Diesel, Engine Codes ALH with Automatic Transmission.................................................................................. 514 2.58.1 Checking Toothed Belt Condition.............................................................................................................................................................. 514 2.58.2 Toothed Belt, Checking Tension............................................................................................................................................................... 515 2.58.3 Toothed Belt, Tensioning..................................................................................................................................................................... 515 2.59 Spark Plugs, Removing and Installing............................................................................................................................................................... 515 2.59.1 Spark Plugs, Removing and Installing, 1.4L Engines with Ignition Coil........................................................................................................................ 515 2.59.2 Spark Plugs, Removing and Installing, 2.8L Engines, 4-Valve, with Ignition Coil.............................................................................................................. 516 2.59.3 Spark Plugs, Replacing, 2.8L and 3.2L Engines, 4-Valve with Ignition Coil with Power Output Stage............................................................................................ 517 2.59.4 Spark Plugs, 1.8L with Ignition Transformer, Replacing....................................................................................................................................... 518 2.59.5 Spark Plugs, Replacing, 1.8L Engines with Threaded Ignition Coils with Power Output Stages................................................................................................... 519 2.59.6 Spark Plugs, Replacing, 1.8L Engines with Connected Ignition Coils with Power Output Stages.................................................................................................. 520 2.59.7 Spark Plugs, 2.0L Engines, Replacing......................................................................................................................................................... 522 2.60 Rear Lid, Lubricating Multi-Joint Hinges........................................................................................................................................................... 523 3 Special Tools............................................................................................................................................................................................. 526 4 Revision History.......................................................................................................................................................................................... 527 00-05 Maintenance Procedures Variant................................................................................................................................................................................ 531 1 Engine Overview............................................................................................................................................................................................... 535 2 Service Work.................................................................................................................................................................................................. 539 2.1 Oil Change Service...................................................................................................................................................................................... 539 2.2 Inspection Service through MY 99........................................................................................................................................................................ 539 2.3 Inspection Service from MY 00........................................................................................................................................................................... 539 3 General Information........................................................................................................................................................................................... 540 3.1 Lifting Vehicle......................................................................................................................................................................................... 540 3.1.1 General Information............................................................................................................................................................................... 540 3.1.2 Vehicle Hoist Lifting Points...................................................................................................................................................................... 541 3.1.3 Golf R32, Lifting................................................................................................................................................................................. 541 3.1.4 Floor Jack Lifting Points......................................................................................................................................................................... 541 3.2 Labels.................................................................................................................................................................................................. 542 3.2.1 Attaching Data Label in the Luggage Compartment................................................................................................................................................... 542 3.3 Diagnostic Tool, Connecting............................................................................................................................................................................. 543 3.4 Severe Operating Conditions............................................................................................................................................................................. 545 3.5 Vehicle Identification Number........................................................................................................................................................................... 545 3.6 Vehicle Data Label...................................................................................................................................................................................... 546 3.7 Hot Climate Countries................................................................................................................................................................................... 547 3.8 Engine Code and Engine Identification................................................................................................................................................................... 548 3.9 RME Biodiesel........................................................................................................................................................................................... 548 3.10 Type Plate............................................................................................................................................................................................. 549 4 Work Descriptions............................................................................................................................................................................................. 551 4.1 Exhaust System, Inspect Visually For Leaks, Fasteners And Damage........................................................................................................................................ 553 4.2 Ball Joints, Checking................................................................................................................................................................................... 553 4.3 Automatic Transmission 01M, Changing ATF................................................................................................................................................................ 553 4.4 Automatic Transmission 01M, Replacing ATF Strainer...................................................................................................................................................... 553 4.5 Automatic Transmission 01M, Checking Final Drive Gear Oil............................................................................................................................................... 554 4.6 Automatic Transmission 01M, Checking ATF Level and Filling.............................................................................................................................................. 554 4.7 Automatic Transmission 09A, Checking ATF Level and Filling.............................................................................................................................................. 554 4.8 Battery Terminals, Checking for Secure Fit.............................................................................................................................................................. 554 4.9 Battery, Checking....................................................................................................................................................................................... 555 4.10 Tires, Tire Condition, Wear Pattern, Inflation Pressure and Tread Depth................................................................................................................................ 556 4.10.1 General Information.............................................................................................................................................................................. 556 4.10.2 Checking......................................................................................................................................................................................... 556 4.10.3 Tires, Checking Wear Pattern..................................................................................................................................................................... 557 4.10.5 Tires, Including Spare, Checking Pressure and Correcting......................................................................................................................................... 557 4.11 Brake System, Check for Leaks and Damage............................................................................................................................................................... 558 4.12 Front and Rear Brake Pads, Checking Thickness.......................................................................................................................................................... 558 4.12.1 Front Disc Brake Pads............................................................................................................................................................................ 558 4.12.2 Rear Disc Brake Pads............................................................................................................................................................................. 559 4.12.3 Drum Brake Pads, Checking, Rear.................................................................................................................................................................. 560 4.13 Brake and Clutch System, Changing Brake Fluid.......................................................................................................................................................... 562 4.13.1 Application Information and Safety Precautions................................................................................................................................................... 562 4.13.2 Brake Fluid Specifications....................................................................................................................................................................... 562 4.13.3 Brake Fluid, Changing............................................................................................................................................................................ 562 4.14 Brake Fluid Level, Checking............................................................................................................................................................................ 565 4.15 Direct Shift Gearbox (DSG) Transmission 02E, Fluid and Filter Change, 6-Speed, AWD..................................................................................................................... 566 4.16 Power Window Regulators, 8-Way Memory Seats, Performing Initialization................................................................................................................................. 566 4.16.1 Power Window Regulators, Performing Initialization............................................................................................................................................... 566 4.16.2 8-Way Memory Seat, Performing Initialization..................................................................................................................................................... 567 4.17 Performing Vehicle System Test......................................................................................................................................................................... 567 4.18 Protective Joint Boots, Inspecting..................................................................................................................................................................... 568 4.19 Noise Insulation, Installing, Golf R32................................................................................................................................................................. 568 4.20 Haldex Clutch Oil Filter, Removing and Installing, All Wheel Drive (AWD)............................................................................................................................... 570 4.21 Haldex Clutch, All Wheel Drive (AWD), Changing Oil..................................................................................................................................................... 570 4.22 First Aid Kit Expiration Date, Checking................................................................................................................................................................ 570 4.23 Fuel Filter, Diesel, Removing and Installing........................................................................................................................................................... 570 4.24 Fuel Filter, Diesel, Draining Water.................................................................................................................................................................... 571 4.25 Ribbed Belt, Checking Condition........................................................................................................................................................................ 572 4.26 Cooling System, Checking Freeze Protection and Coolant Level........................................................................................................................................... 573 4.27 Air Filter, Cleaning Housing and Removing and Installing Air Filter.................................................................................................................................... 576 4.27.1 Air Filter, Cleaning Housing, Replacing Filter, Cleaning Snow Screen If Equipped................................................................................................................. 576 4.28 Upper Engine Cover, Removing and Installing............................................................................................................................................................ 578 4.28.1 Engine Cover, Removing and Installing, 1.4L with Ignition Coil................................................................................................................................... 578 4.28.3 Engine Cover, 1.8L, Removing and Installing...................................................................................................................................................... 579 4.28.6 Engine Cover, Removing and Installing, 2.8L Fuel Injection Engines............................................................................................................................... 581 4.28.7 Engine Cover, Removing and Installing, 3.2L Fuel Injection Engines............................................................................................................................... 581 4.28.9 Engine Cover, Removing and Installing, 4-Cylinder TDI PD Engines................................................................................................................................. 582 4.29 Lower Engine Compartment Cover, Removing and Installing................................................................................................................................................ 583 4.30 Engine Oil Level, Checking............................................................................................................................................................................. 585 4.31 Engine Oil, Draining or Extracting and Filling; Replacing Oil Filter................................................................................................................................... 585 4.31.1 Engine Oil, Draining or Extracting and Filling................................................................................................................................................... 585 4.31.2 Oil Filter, Replacing............................................................................................................................................................................ 587 4.31.3 Engine Oil, Filling.............................................................................................................................................................................. 590 4.32 Engine and Engine Compartment Components, Checking for Leaks and Damage................................................................................................................................ 591 4.33 Perform a Road Test.................................................................................................................................................................................... 591 4.34 Radio/Radio Navigation System, Attaching Serial Number and Code Number to Unit Card.................................................................................................................... 592 4.35 Radio/Radio Navigation System, Activating Anti-Theft Coding............................................................................................................................................ 592 4.35.1 General Information.............................................................................................................................................................................. 592 4.35.2 ALPHA Radio Units, Activating Security Code...................................................................................................................................................... 592 4.35.4 On the Radio Navigation System activate the security code as follows:............................................................................................................................ 593 4.36 Wheel Bolts, Tightening Specifications................................................................................................................................................................. 594 4.37 Attaching Wheel Housing Liner to Front Apron (Anniversary Golf GTI with 132 kW only)................................................................................................................... 596 4.38 Tire Repair Kit, Checking.............................................................................................................................................................................. 597 4.39 Power Steering, Checking Fluid Level................................................................................................................................................................... 598 4.40 Sunroof, Checking Function, Cleaning and Lubricating Guide Rails....................................................................................................................................... 599 4.41 Sunroof Water Drains, Checking and Cleaning............................................................................................................................................................ 600 4.42 Windshield and Headlamp Washer System, Checking for Damage, Function and Spray Nozzle Adjustment....................................................................................................... 601 4.42.1 Windshield Wiper/Washer System Freeze Protection, Checking and Filling........................................................................................................................... 601 4.42.2 Windshield Washer System, Checking and Adjusting Spray Nozzle Position........................................................................................................................... 603 4.42.3 Headlamp Washer System, Checking Spray Nozzles................................................................................................................................................... 605 4.43 Windshield Wiper Blades, Checking for Damage, End Position and Adjustment Angle........................................................................................................................ 605 4.43.1 Windshield Wiper Blades Parked Position, Adjusting............................................................................................................................................... 605 4.43.2 Windshield Wiper Blades, Checking Angle and Adjusting............................................................................................................................................ 606 4.44 Manual Transmission/Final Drive, Checking Oil Level.................................................................................................................................................... 607 4.45 Headlamps, Checking and Adjusting...................................................................................................................................................................... 607 4.45.1 General Information.............................................................................................................................................................................. 607 4.45.2 Headlamps, Checking Adjustment with New Test Screen without 15° Adjustment Line.................................................................................................................. 608 4.45.3 Adjusting Headlamps for the Golf................................................................................................................................................................. 609 4.45.4 Headlamps, Adjusting, Jetta...................................................................................................................................................................... 609 4.45.5 Headlamps, Checking Headlamp with Gas Discharge Lamps............................................................................................................................................ 610 4.46 Service Interval Display, Resetting.................................................................................................................................................................... 611 4.47 Service Interval Display, Coding....................................................................................................................................................................... 613 4.48 Tie Rod Ends, Checking Play, Security and Joint Boots.................................................................................................................................................. 614 4.49 Language, Selecting.................................................................................................................................................................................... 614 4.50 Dust and Pollen Filter, Cleaning Housing and Removing and Installing Filter Element.................................................................................................................... 615 4.51 Transport Protection, Removing Locking Pieces from Front Axle Struts................................................................................................................................... 615 4.52 Door Arrester, Lubricating............................................................................................................................................................................. 616 4.53 Clock, Setting......................................................................................................................................................................................... 617 4.54 Underbody Components, Checking for Damage.............................................................................................................................................................. 617 4.55 Toothed Belt and Camshaft Drive Tensioner, Replacing................................................................................................................................................... 618 4.55.1 Toothed Belt and Camshaft Drive Tensioning Roller, Removing and Installing, Diesel, Engine Codes ALH and BEW..................................................................................... 618 4.55.2 Camshaft Drive Toothed Belt, Removing and Installing, 4-Cylinder, 5-Valve Gasoline, Engine Code AWP.............................................................................................. 618 4.56 Camshaft Drive Toothed Belt, Checking, 4-Cylinder Gasoline Engine...................................................................................................................................... 618 4.57 Toothed Belt, Diesel, Checking for Wear................................................................................................................................................................ 619 4.58 Camshaft Drive Toothed Belt, Checking Condition and Tension, Diesel, Engine Codes ALH with Automatic Transmission...................................................................................... 619 4.58.1 Checking Toothed Belt Condition.................................................................................................................................................................. 619 4.58.2 Toothed Belt, Checking Tension................................................................................................................................................................... 620 4.58.3 Toothed Belt, Tensioning......................................................................................................................................................................... 620 4.59 Spark Plugs, Removing and Installing................................................................................................................................................................... 620 4.59.1 Spark Plugs, Removing and Installing, 1.4L Engines with Ignition Coil............................................................................................................................ 620 4.59.2 Spark Plugs, Removing and Installing, 2.8L Engines, 4-Valve, with Ignition Coil.................................................................................................................. 621 4.59.3 Spark Plugs, Replacing, 2.8L and 3.2L Engines, 4-Valve with Ignition Coil with Power Output Stage................................................................................................ 622 4.59.4 Spark Plugs, 1.8L with Ignition Transformer, Replacing........................................................................................................................................... 623 4.59.5 Spark Plugs, Replacing, 1.8L Engines with Threaded Ignition Coils with Power Output Stages....................................................................................................... 624 4.59.6 Spark Plugs, Replacing, 1.8L Engines with Connected Ignition Coils with Power Output Stages...................................................................................................... 625 4.59.7 Spark Plugs, 2.0L Engines, Replacing............................................................................................................................................................. 627 4.60 Rear Lid, Lubricating Multi-Joint Hinges............................................................................................................................................................... 628 5 Glossary...................................................................................................................................................................................................... 631 00-06 VW Fluid Capacity Charts...................................................................................................................................................................................... 636 00-07 Fluid Capacity Tables All..................................................................................................................................................................................... 645 03 – Maintenance, Diagnosis..................................................................................................................................................................................... 649 1 New Beetle/New Beetle Convertible......................................................................................................................................................................... 649 2 Golf/GTI/Jetta/Jetta Wagon................................................................................................................................................................................ 651 3 new Jetta................................................................................................................................................................................................. 653 4 Passat.................................................................................................................................................................................................... 654 5 Phaeton................................................................................................................................................................................................... 655 6 Touareg................................................................................................................................................................................................... 656 00-08 VW Maintenance Labor Operations Times......................................................................................................................................................................... 660 00-09 Towing Guide.................................................................................................................................................................................................. 669 01-Engine Mechanical & Systems.pdf (p.783-3293)......................................................................................................................................................................... 783 01-01A Engine Mechanical AFP........................................................................................................................................................................................ 783 01-01B Fuel Injection & Ignition AFP................................................................................................................................................................................ 949 01-02A Engine Mechanical ALH........................................................................................................................................................................................1132 01-02B Fuel Injection & Glow Plug ALH...............................................................................................................................................................................1274 01-03A Engine Mechanical AWD-AWW-AWP................................................................................................................................................................................1426 01-03B Fuel_Injection & Ignition AWP, AWW...........................................................................................................................................................................1617 01-03C Fuel Injection & Ignition AWD................................................................................................................................................................................1930 01-04A Engine Mechanical BDF........................................................................................................................................................................................2141 01-04B Fuel_Injection & Ignition BDF................................................................................................................................................................................2328 01-05 Engine Mechanical, Fuel Injection & Ignition BJS.............................................................................................................................................................2631 01-06 Engine Mechanical, Fuel Injection & Ignition 1999 AEG-AVH-AZG.................................................................................................................................................2825 01-07 Engine Mechanical Fuel Injection & Glow Plug BEW..............................................................................................................................................................3115 02-Engine Performance.pdf (p.3294-4841).................................................................................................................................................................................3294 02-00A Gasoline Quality.............................................................................................................................................................................................3294 02-00B 1.9L Pump Values TDI-BEW & BRM...............................................................................................................................................................................3300 02-01A Generic Scan Tool AFP........................................................................................................................................................................................3324 02-01B-Generic Scan Tool ALH, BEW...................................................................................................................................................................................3457 02-01C Generic Scan Tool AWP, AWW, AWD..............................................................................................................................................................................3596 02-01D Generic Scan Tool AVH, AZG, BBW, BEV.........................................................................................................................................................................3800 02-01E Generic Scan Tool BJS........................................................................................................................................................................................4046 02-02A VW Engine & Transmission Fault Codes.........................................................................................................................................................................4239 02-02B DTC List Complete 1998-2004..................................................................................................................................................................................4263 P Codes.........................................................................................................................................................................................................4263 U Codes.........................................................................................................................................................................................................4321 02-02C DTC List-Engine & Transmission...............................................................................................................................................................................4327 02-02D Simos 6 OBD System Strategy..................................................................................................................................................................................4355 1. CATALYST MONITORING .........................................................................................................................................................................................4357 1.01 Diagnostic Overview:...................................................................................................................................................................................4357 1.02 General description....................................................................................................................................................................................4357 1.03 Monitoring Structure...................................................................................................................................................................................4357 1.04 Flow Chart Catalyst Monitoring .......................................................................................................................................................................4358 2. HEATED CATALYST MONITORING...................................................................................................................................................................................4359 3. MISFIRE MONITORING...........................................................................................................................................................................................4359 3.01 General Description....................................................................................................................................................................................4359 3.02 Monitoring function description........................................................................................................................................................................4359 3.04 Chart and Flow Chart(s)................................................................................................................................................................................4362 3.05 Paths for misfire and catalyst damaging misfire rate.................................................................................................................................4363 4 EVAPORATIVE SYSTEM DIAGNOSIS.................................................................................................................................................................................4364 4.04 Leakage Check / Reed Sensor ...........................................................................................................................................................................4364 4.04.01 General description ............................................................................................................................................................................4364 4.04.02 Monitoring function description ..............................................................................................................................................................4364 4.04.03 Chart(s) and flow chart(s) ....................................................................................................................................................................4365 4.05 Purge Check ...........................................................................................................................................................................................4367 4.05.01 General description.............................................................................................................................................................................4367 4.05.02 Monitoring function description................................................................................................................................................................4368 4.05.03 Chart(s) and flow chart(s) .....................................................................................................................................................................4368 5 SECONDARY/ AIR SYSTEM MONITORING..............................................................................................................................................................................4369 6 FUEL SYSTEM MONITORING........................................................................................................................................................................................4369 6.04 General Description....................................................................................................................................................................................4369 6.05 Monitoring function description........................................................................................................................................................................4369 6.05.01 Adaptive pilot control..........................................................................................................................................................................4369 6.05.02 Fuel trim.......................................................................................................................................................................................4369 6.06 Chart(s) and flowchart(s)..............................................................................................................................................................................4370 7 OXYGEN SENSOR AND HEATER MONITORING..........................................................................................................................................................................4373 7.04.01 Open circuit (UN)...................................................................................................................................................................................4373 7.04.02 Open circuit (VM)...............................................................................................................................................................................4373 7.04.03 Open circuit (IP)...............................................................................................................................................................................4373 7.04.04 Open circuit (IA)...............................................................................................................................................................................4373 8. EGR MONITORING...........................................................................................................................................................................................4384 9. PCV MONITORING............................................................................................................................................................................................4384 10. ENGINE COOLANT SYSTEM MONITORING ..........................................................................................................................................................................4384 7.15 General description ..................................................................................................................................................................................4384 7.16 Monitor Functional Description........................................................................................................................................................................4385 7.16.01 Cooling System Performance (P2081)..............................................................................................................................................................4386 7.16.02 Engine Coolant Temperature Sensor Rationality (P3081)..........................................................................................................................................4388 7.16.03 Engine Coolant Temperature Sensor Stuck Low (P0116)............................................................................................................................................4390 7.16.04 Engine Coolant Temperature Sensor Stuck High (P0116)............................................................................................................................................4392 7.16.05 Engine Coolant Temperature Sensor Out of Range Check (P0118 / P0117)............................................................................................................................4394 10. COLD START EMISSION REDUCTION STRATEGY MONITORING ........................................................................................................................................................4395 11. AIR CONDITIONING (A/C) SYSTEM COMPONENT MONITORING ........................................................................................................................................................4395 12. VARIABLE VALVE TIMING AND/OR CONTROL (VVT) SYSTEM MONITORING .............................................................................................................................................4395 13. DIRECT OZON REDUCTION (DOR) SYSTEM MONITORING..............................................................................................................................................................4395 14. PARTICULATE MATER (PM) TRAP MONITORING ...................................................................................................................................................................4395 15. COMPREHENSIVE COMPONENTS MONITORING........................................................................................................................................................................4395 15.01 Electrical checks for Sensor signals...........................................................................................................................................................4396 15.02 Electrical checks for Actuators.......................................................................................................................................................................4396 15.03 Camshaft position sensor and variable valve actuator ..................................................................................................................................4397 15.03.01 Signal activity and rationality check..........................................................................................................................................................4397 15.04 Variable valve actuator functional check.............................................................................................................................................4398 15.05 Engine speed sensor ...............................................................................................................................................................4399 15.05.01 Electrical check..............................................................................................................................................................................4399 15.05.02 Signal activity and rationality check.........................................................................................................................................................4400 15.06 Knock sensor.....................................................................................................................................................................4401 15.06.01 Signal activity check..........................................................................................................................................................................4401 15.07 Vehicle speed sensor..............................................................................................................................................................4402 15.07.01 Rationality check..............................................................................................................................................................................4402 15.08 MAP and altitude sensor..........................................................................................................................................................4403 15.08.01 Rationality check..............................................................................................................................................................................4403 15.2.1 Rationality check................................................................................................................................................................................4405 15.3 Idle controller ......................................................................................................................................................................................4406 15.3.1 Out of range check...............................................................................................................................................................................4406 15.4 Accelerator pedal position sensor ....................................................................................................................................................................4407 15.4.1 Out of Range / Rationality check.................................................................................................................................................................4407 15.5 Injection valve check .................................................................................................................................................................................4408 15.19 Automatic Transmission Monitor.........................................................................................................................................................4408 16 OTHER EMISSION CONTROL OR SOURCE SYSTEM MONITORING..........................................................................................................................................................4409 .17.01.01 Intake manifold runner flap ..........................................................................................................................................................4409 .17.01.02 Out of range low / high......................................................................................................................................................................4409 .17.01.03 Stuck open / close.....................................................................................................................................................................4410 18. PARAMETERS AND CONDITIONS TO BEGIN CLOSED LOOP OPERATION.................................................................................................................................................4411 02-02E DTC & Mode 6 Summary Tables 2004-2005 1.9L TDI BEW...........................................................................................................................................................4416 .01.00.00 – MODE 06 REQUEST ON - BOARD MONITORING TEST RESULTS..................................................................................................................................................4417 Mode 06 - TID 01 Oxygen Sensor Monitoring...................................................................................................................................................................4417 Mode 06 - TID 09 Dynamic plausibility of coolant temperature sensor.........................................................................................................................................4417 Mode 06 - TID 10 Start-Stop positions test of quantity adjuster.............................................................................................................................................4418 Mode 06 - TID 11 Dynamic plausibility of fuel temperature sensor............................................................................................................................................4418 Mode 06 - TID 12 Plausibility of boost pressure sensor with atmospheric pressure sensor.....................................................................................................................4418 Mode 06 - TID 31 Exhaust Gas Recirculation (EGR)............................................................................................................................................................4419 .............................................................................................................................................................................................................4419 .02.00.00 ( OBD DTC SUMMARY TABLE ..............................................................................................................................................................................4420 02-03A Glow Plug Fault Diagnosis for Engines BEW....................................................................................................................................................................4435 02-03B How to Set Readiness Code 2005 All Models with 2.0L AVH......................................................................................................................................................4440 02-03C How to Set Readiness Code 2002-2005 Golf & Jetta 2.8L BDF & AFP..............................................................................................................................................4444 02-03D How to Set Readiness Code 2002-2006 All Models with 1.8L engine-except BKF...................................................................................................................................4448 02-03E How to Set Readiness Code 2004-2005 All Models with Diesel BHW BEW BKW.......................................................................................................................................4452 02-03F How to Set Readiness Code 2005 All Models with 2.0L BEV......................................................................................................................................................4456 02-03G VW New OBD II Drive Cycle Procedure..........................................................................................................................................................................4460 02-04A Immobilizer Self Study Program...............................................................................................................................................................................4463 02-04B Immobilizer Theory...........................................................................................................................................................................................4518 02-04C Immobilizer Service Requirements - Vehicle Keys..............................................................................................................................................................4535 02-04D Immobilizer Service Requirements - Guided Fault Finding......................................................................................................................................................4546 02-05A Bosch Motronic ME 7, ME 7.1, ME 7.1.1, ME 7.5 System Strategy................................................................................................................................................4566 ...............................................................................................................................................................................................................4568 .01.00.00 CATALYST MONITORING ..................................................................................................................................................................................4569 .01.01.00 Passive measurement of amplitude ratio............................................................................................................................................................4569 .01.01.01 General description...........................................................................................................................................................................4569 .......................................................................................................................................................................................................4570 .01.01.02 Monitoring Structure..........................................................................................................................................................................4570 .01.01.03 Flow Chart Catalyst Monitoring ...............................................................................................................................................................4570 ...........................................................................................................................................................................................................4571 .01.02.00 Active measurement of OSC.........................................................................................................................................................................4571 .01.02.01 General description...........................................................................................................................................................................4571 .01.02.02 Monitoring Structure..........................................................................................................................................................................4572 Main-catalyst.......................................................................................................................................................................................4573 Catalyst-system.................................................................................................................................................................................4573 .......................................................................................................................................................................................................4575 .01.02.03 Flow Chart Catalyst Monitoring................................................................................................................................................................4575 .02.00.00 HEATED CATALYST MONITORING............................................................................................................................................................................4576 .03.00.00 MISFIRE MONITORING....................................................................................................................................................................................4576 .03.00.01 General Description...............................................................................................................................................................................4576 .......................................................................................................................................................................................................4577 .03.01.02 Monitoring function description...............................................................................................................................................................4577 ...........................................................................................................................................................................................................4578 ...........................................................................................................................................................................................................4579 .03.00.03 Chart(s) and Flow Chart(s)....................................................................................................................................................................4580 ...............................................................................................................................................................................................................4582 .04.00.00 EVAPORATIVE SYSTEM DIAGNOSIS..........................................................................................................................................................................4582 .04.01.00 Leakage Check ....................................................................................................................................................................................4582 .04.01.01 General description ..........................................................................................................................................................................4582 .04.01.02 Monitoring function description ............................................................................................................................................................4582 .......................................................................................................................................................................................................4583 .04.01.03 Chart(s) and flow chart(s) ...................................................................................................................................................................4583 .04.02.00 Purge Check ......................................................................................................................................................................................4585 .04.02.01 General description...........................................................................................................................................................................4585 .......................................................................................................................................................................................................4586 .04.02,02 Monitoring function description...............................................................................................................................................................4586 .04.02.03 Chart(s) and flow chart(s) ...................................................................................................................................................................4586 ...............................................................................................................................................................................................................4587 .05.00.00 SECONDARY AIR SYSTEM MONITORING.......................................................................................................................................................................4587 .05.01.00 Via lambda deviation .............................................................................................................................................................................4587 .05.01.01 General Description...........................................................................................................................................................................4587 .......................................................................................................................................................................................................4588 .05.01.02 Monitoring Structure..........................................................................................................................................................................4588 .05.01.03 Chart(s) and flow chart(s) ...................................................................................................................................................................4590 .05.02.00 Via exhaust temperature sensor ...................................................................................................................................................................4592 .05.02.01 General Description...........................................................................................................................................................................4592 .05.02.02 Monitor function description .................................................................................................................................................................4592 .......................................................................................................................................................................................................4593 .05.02.03 Chart(s) and flow chart(s)....................................................................................................................................................................4593 ...............................................................................................................................................................................................................4594 .06.00.00 Fuel System Monitoring................................................................................................................................................................................4594 .06.00.01 General Description...............................................................................................................................................................................4594 .06.00.02 Monitoring function description...............................................................................................................................................................4594 ...........................................................................................................................................................................................................4595 .06.00.03 Chart(s) and flow chart(s) ...................................................................................................................................................................4595 .07.00.00 OXYGEN SENSOR MONITORING............................................................................................................................................................................4598 .07.01.00 Calibrations with ASIC CJ 110.....................................................................................................................................................................4598 .07.01.01 General Description...........................................................................................................................................................................4598 .07.01.02 Monitoring function description...............................................................................................................................................................4598 .07.01.03 Chart(s) and flow chart(s)....................................................................................................................................................................4600 .07.02.00 Oxygen Sensor Heater Monitoring .................................................................................................................................................................4605 .07.03.01 General description (ASIC CJ 110).............................................................................................................................................................4605 .07.02.02 Monitor function description .................................................................................................................................................................4605 .......................................................................................................................................................................................................4606 07.02.03 Chart(s) and Flow Chart(s) ...................................................................................................................................................................4606 .07.03.01 General Description...........................................................................................................................................................................4608 .07.03.02 Monitor function description..................................................................................................................................................................4608 .......................................................................................................................................................................................................4610 .07.03.03 Chart(s) and Flow Chart(s)....................................................................................................................................................................4610 .07.04.00 Oxygen Sensor Heater Monitoring (ASIC CJ 125/120)................................................................................................................................................4612 .07.04.01 General description ..........................................................................................................................................................................4612 .07.04.02 Monitor function description..................................................................................................................................................................4612 .07.04.03 Chart(s) and Flow Chart(s)....................................................................................................................................................................4613 .07.05.00 SULEV applications................................................................................................................................................................................4614 .07.05.01 General description...........................................................................................................................................................................4614 .07.05.02 Monitor function description..................................................................................................................................................................4614 .07.05.03 Chart(s) and flow chart(s)....................................................................................................................................................................4616 .07.06.00 Oxygen Sensor Heater Monitoring (SULEV).........................................................................................................................................................4621 .07.06.01 General description ..........................................................................................................................................................................4621 .07.06.02 Monitor function description).................................................................................................................................................................4621 .......................................................................................................................................................................................................4623 .07.06.03 Chart(s) and Flow Chart(s)...................................................................................................................................................................4623 ...............................................................................................................................................................................................................4625 .08.00.00 EGR Monitoring........................................................................................................................................................................................4625 .09.00.00 PCV MONITORING........................................................................................................................................................................................4625 .10.00.00 ENGINE COOLANT SYSTEM MONITORING .....................................................................................................................................................................4625 .10.01.00 General description .............................................................................................................................................................................4625 .......................................................................................................................................................................................................4626 .10.01.02 Monitor Functional Description...............................................................................................................................................................4626 .10.03.00 Charts and Flow Charts........................................................................................................................................................................4627 .11.00.00 COLD START EMISSION REDUCTION STRATEGY MONITORING ...................................................................................................................................................4638 .12.00.00 AIR CONDITIONING (A/C) SYSTEM COMPONENT MONITORING ...................................................................................................................................................4638 .13.00.00 VARIABLE VALVE TIMING AND/OR CONTROL (VVT) SYSTEM MONITORING ........................................................................................................................................4638 .14.00.00 DIRECT OZON REDUCTION (DOR) SYSTEM MONITORING.........................................................................................................................................................4638 .15.00.00 PARTICULATE MATER (PM) TRAP MONITORING ..............................................................................................................................................................4638 .16.00.00 COMPREHENSIVE COMPONENTS MONITORING...................................................................................................................................................................4638 .16.01.00 Injection Valve...................................................................................................................................................................................4638 .16.02.00 Fuel Pump Relay...................................................................................................................................................................................4638 .16.03.00 Idle Controller .................................................................................................................................................................................4639 .16.04.00 Engine Speed Sensor:..............................................................................................................................................................................4640 .16.05.00 Warm-up Bypass valve:.............................................................................................................................................................................4640 ...........................................................................................................................................................................................................4641 .16.06.00 Signal Range Check for different sensor ..........................................................................................................................................................4641 ...........................................................................................................................................................................................................4642 .16.07.00 Rationality Mass Air Flow Sensor (MAF)............................................................................................................................................................4642 ...........................................................................................................................................................................................................4644 .16.08.00 Vehicle Speed Sensor (VSS)........................................................................................................................................................................4644 ...........................................................................................................................................................................................................4645 .16.09.00 Throttle Position Sensor (throttle unit with E-gas actuator).....................................................................................................................................4645 .16.10.00 Accelerator pedal position sensor (APPS)..........................................................................................................................................................4646 .16.11.00 Camshaft Position Sensor..........................................................................................................................................................................4647 .16.12.00 Boost Pressure Control Valve .....................................................................................................................................................................4648 ...........................................................................................................................................................................................................4649 .16.13.00 Engine Start Delay Relay (SULEV)..................................................................................................................................................................4649 ...........................................................................................................................................................................................................4650 .16.14.00 Exhaust Temperature Sensor (SULEV)...............................................................................................................................................................4650 .16.14.01 General Monitoring Description ...............................................................................................................................................................4650 .16.14.02 Monitor function description..................................................................................................................................................................4650 ...........................................................................................................................................................................................................4650 .16.14.03 Chart(s) and Flow Chart (s)...................................................................................................................................................................4651 .16.15.00 reserved.........................................................................................................................................................................................4652 .16.16.00 reserved.........................................................................................................................................................................................4652 .16.17.00 reserved.........................................................................................................................................................................................4652 .16.18.00 reserved.........................................................................................................................................................................................4652 .16.19.00 reserved.........................................................................................................................................................................................4652 ...........................................................................................................................................................................................................4653 .16.20.00 Automatic Transmission Monitor....................................................................................................................................................................4653 .16.21.00 Output Stage Check ...............................................................................................................................................................................4653 ...............................................................................................................................................................................................................4654 .17.00.00 OTHER EMISSION CONTROL OR SOURCE SYSTEM MONITORING...................................................................................................................................................4654 .18.00.00 EXEMPTIONS TO MONITOR REQUIREMENTS .................................................................................................................................................................4654 .19.00.00 RESERVED ............................................................................................................................................................................................4654 .20.00.00 PARAMETERS AND CONDITIONS FOR CLOSED LOOP OPERATION...................................................................................................................................................4655 ...............................................................................................................................................................................................................4658 .21.00.00 PARAMETERS / CONDITIONS FOR 2ND CLOSED LOOP OPERATION.................................................................................................................................................4658 ...............................................................................................................................................................................................................4660 .22.00.00 PARAMETERS / CONDITIONS FOR CLOSED LOOP OPERATION ON SULEV............................................................................................................................................4660 02-05B Bosch Motronic ME 9.1 System Strategy........................................................................................................................................................................4668 ..............................................................................................................................................................................................................4670 .01.00.00 Catalyst Monitoring .................................................................................................................................................................................4671 ...........................................................................................................................................................................................................4671 .01.01.00 Passive measurement of amplitude ratio ...........................................................................................................................................................4671 .01.01.01 General description ..........................................................................................................................................................................4671 ...........................................................................................................................................................................................................4671 ......................................................................................................................................................................................................4672 .......................................................................................................................................................................................................4672 .01.01.02 Monitoring Structure .........................................................................................................................................................................4672 .......................................................................................................................................................................................................4672 .......................................................................................................................................................................................................4672 .01.01.03 Flow Chart Catalyst Monitoring .............................................................................................................................................................4672 .......................................................................................................................................................................................................4672 ..........................................................................................................................................................................................................4673 .01.02.00 Active measurement of OSC ........................................................................................................................................................................4673 .01.02.01 General description ..........................................................................................................................................................................4673 .01.02.02 Monitoring Structure .........................................................................................................................................................................4674 main-catalyst.......................................................................................................................................................................................4675 catalyst-system.................................................................................................................................................................................4675 ......................................................................................................................................................................................................4677 .01.02.03 Flow Chart Catalyst Monitoring ..............................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4677 ...........................................................................................................................................................................................................4678 .02.00.00 Heated Catalyst Monitoring .......................................................................................................................................................................4678 .03.00.00 Misfire Monitoring ...............................................................................................................................................................................4678 .03.00.01 General Description ..........................................................................................................................................................................4678 ..................................................................................................................................................................................................4679 .03.01.02 Monitoring function description ..........................................................................................................................................................4679 ......................................................................................................................................................................................................4680 ......................................................................................................................................................................................................4681 .03.00.03 Chart(s) and Flow Chart(s) ...............................................................................................................................................................4682 ..........................................................................................................................................................................................................4684 .04.00.00 Evaporative System Diagnosis .....................................................................................................................................................................4684 .04.01.00 Leakage Check ..............................................................................................................................................................................4684 .04.01.01 General description .....................................................................................................................................................................4684 ..................................................................................................................................................................................................4685 ...................................................................................................................................................................................................4685 .04.01.02 Monitoring function description .......................................................................................................................................................4685 ..................................................................................................................................................................................................4686 ...................................................................................................................................................................................................4686 .04.01.03 Chart(s) and flow chart(s) ..............................................................................................................................................................4686 ......................................................................................................................................................................................................4687 ......................................................................................................................................................................................................4687 .04.02.00 Purge Check .................................................................................................................................................................................4688 .04.02.01 General description ......................................................................................................................................................................4688 ..................................................................................................................................................................................................4689 .04.02,02 Monitoring function description ..........................................................................................................................................................4689 .04.02.03 Chart(s) and flow chart(s) ..............................................................................................................................................................4689 .05.00.00 Secondary Air System Monitoring ..................................................................................................................................................................4690 .06.00.00 Fuel System Monitoring ...........................................................................................................................................................................4690 .06.01.00 General Description ..........................................................................................................................................................................4690 .06.00.02 Monitoring function description ..........................................................................................................................................................4690 .......................................................................................................................................................................................................4690 ......................................................................................................................................................................................................4691 .06.00.03 Chart(s) and flow chart(s) ..............................................................................................................................................................4691 .....................................................................................................................................................................................................4693 .06.04.00 Fuel Pressure Monitoring .........................................................................................................................................................................4694 .06.05.00 General Description ..........................................................................................................................................................................4694 .06.05.00 Monitoring function description ..........................................................................................................................................................4695 ......................................................................................................................................................................................................4697 .07.00.00 Oxygen Sensor Monitoring .......................................................................................................................................................................4697 .07.01.00 Calibrations with ASIC CJ 110 ...............................................................................................................................................................4697 .07.01.01 General Description ......................................................................................................................................................................4697 .07.01.02 Monitoring function description ..........................................................................................................................................................4697 .07.01.03 Chart(s) and flow chart(s) ...............................................................................................................................................................4699 .07.02.00 Oxygen Sensor Heater Monitoring ............................................................................................................................................................4704 .07.03.01 General description (ASIC CJ 110) ........................................................................................................................................................4704 .07.02.02 Monitor function description ............................................................................................................................................................4704 ..................................................................................................................................................................................................4705 ...................................................................................................................................................................................................4705 07.02.03 Chart(s) and Flow Chart(s) ..............................................................................................................................................................4705 ...................................................................................................................................................................................................4707 .07.03.01 General Description ......................................................................................................................................................................4707 .07.03.02 Monitor function description .............................................................................................................................................................4707 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ...................................................................................................................................................................................................4708 ..................................................................................................................................................................................................4709 ...................................................................................................................................................................................................4709 .07.03.03 Chart(s) and Flow Chart(s) ...............................................................................................................................................................4709 .......................................................................................................................................................................................................4710 .......................................................................................................................................................................................................4710 .......................................................................................................................................................................................................4710 .......................................................................................................................................................................................................4710 .......................................................................................................................................................................................................4710 .......................................................................................................................................................................................................4710 .......................................................................................................................................................................................................4710 .......................................................................................................................................................................................................4710 .07.04.00 Oxygen Sensor Heater Monitoring (ASIC CJ 125/120) ...........................................................................................................................................4711 .07.04.01 General description .....................................................................................................................................................................4711 .07.04.02 Monitor function description .............................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ...................................................................................................................................................................................................4711 ..................................................................................................................................................................................................4712 .07.04.03 Chart(s) and Flow Chart(s) ...............................................................................................................................................................4712 .07.05.00 SULEV applications ...........................................................................................................................................................................4713 .07.05.01 General description ......................................................................................................................................................................4713 .07.05.02 Monitor function description .............................................................................................................................................................4713 .07.05.03 Chart(s) and flow chart(s) ...............................................................................................................................................................4715 .07.06.00 Oxygen Sensor Heater Monitoring (SULEV) ....................................................................................................................................................4720 .07.06.01 General description .....................................................................................................................................................................4720 .07.06.02 Monitor function description) ............................................................................................................................................................4720 .................................................................................................................................................................................................4722 ...................................................................................................................................................................................................4722 .07.06.03 Chart(s) and Flow Chart(s) ...............................................................................................................................................................4722 .08.00.00 EGR MONITORING ...................................................................................................................................................................................4724 .09.00.00 PCV Monitoring ...................................................................................................................................................................................4724 ..........................................................................................................................................................................................................4725 .10.00.00 Engine Coolant System Monitoring ................................................................................................................................................................4725 .10.01.00 General description ........................................................................................................................................................................4725 ..................................................................................................................................................................................................4726 ...................................................................................................................................................................................................4726 .10.01.02 Monitor Functional Description ..........................................................................................................................................................4726 ...................................................................................................................................................................................................4727 .10.03.00 Charts and Flow Charts ...................................................................................................................................................................4727 .......................................................................................................................................................................................................4727 .......................................................................................................................................................................................................4727 .......................................................................................................................................................................................................4727 .......................................................................................................................................................................................................4727 .......................................................................................................................................................................................................4727 .......................................................................................................................................................................................................4727 .......................................................................................................................................................................................................4727 .......................................................................................................................................................................................................4727 .......................................................................................................................................................................................................4727 ...................................................................................................................................................................................................4728 .......................................................................................................................................................................................................4730 .11.00.00 Cold Start Emission Reduction Strategy Monitoring ..............................................................................................................................................4738 .11.01.00 General Description ..........................................................................................................................................................................4738 .11.02.00 Monitoring function description ..........................................................................................................................................................4739 ..................................................................................................................................................................................................4740 ...................................................................................................................................................................................................4740 .11.03.00 Charts and flow charts ...................................................................................................................................................................4740 ...................................................................................................................................................................................................4740 .12.00.00 Air Conditioning (A/C) System Component Monitoring ..............................................................................................................................................4741 .13.00.00 Variable Valve Timing and/or Control (VVT) System Monitoring ...................................................................................................................................4741 .13.01.00 General Description ..........................................................................................................................................................................4741 .13.02.00 Monitor function description ............................................................................................................................................................4741 ...................................................................................................................................................................................................4742 .13.03.00 Charts and flow charts ..................................................................................................................................................................4742 .14.00.00 Direct Ozone Reduction (DOR) System Monitoring ...................................................................................................................................................4743 .15.00.00 Particulate Mater (PM) Trap Monitoring .........................................................................................................................................................4743 .16.00.00 Comprehensive Components Monitoring .............................................................................................................................................................4743 .16.01.00 Injection Valve ..............................................................................................................................................................................4743 .16.02.00 Fuel Pump Relay .............................................................................................................................................................................4743 .16.03.00 Idle Controller ............................................................................................................................................................................4744 .16.04.00 Engine Speed Sensor: .........................................................................................................................................................................4745 .16.05.00 Warm-up Bypass valve: ........................................................................................................................................................................4746 .16.06.00 Signal Range Check for different sensor ....................................................................................................................................................4746 .......................................................................................................................................................................................................4746 .......................................................................................................................................................................................................4746 .......................................................................................................................................................................................................4746 ......................................................................................................................................................................................................4747 .16.07.00 Rationality Mass Air Flow Sensor (MAF) ......................................................................................................................................................4747 ......................................................................................................................................................................................................4749 .16.08.00 Vehicle Speed Sensor (VSS) ...................................................................................................................................................................4749 ......................................................................................................................................................................................................4750 .16.09.00 Throttle Position Sensor (throttle unit with E-gas actuator) ................................................................................................................................4750 .16.10.00 Accelerator pedal position sensor (APPS) .....................................................................................................................................................4751 .16.11.00 Camshaft Position Sensor .....................................................................................................................................................................4752 .......................................................................................................................................................................................................4752 .......................................................................................................................................................................................................4752 .......................................................................................................................................................................................................4752 .......................................................................................................................................................................................................4752 ......................................................................................................................................................................................................4753 .16.12.00 Boost Pressure Control Valve ................................................................................................................................................................4753 ......................................................................................................................................................................................................4754 .16.13.00 Engine Start Delay Relay (SULEV) .............................................................................................................................................................4754 ......................................................................................................................................................................................................4755 .16.14.00 Exhaust Temperature Sensor (SULEV) ..........................................................................................................................................................4755 .16.14.01 General Monitoring Description ..........................................................................................................................................................4755 .16.14.02 Monitor function description .............................................................................................................................................................4755 ......................................................................................................................................................................................................4755 ...................................................................................................................................................................................................4756 .16.14.03 Chart(s) and Flow Chart (s) ..............................................................................................................................................................4756 .16.15.00 reserved ....................................................................................................................................................................................4757 .16.16.00 reserved ....................................................................................................................................................................................4757 .16.17.00 reserved ....................................................................................................................................................................................4757 .16.18.00 reserved ....................................................................................................................................................................................4757 .16.19.00 reserved ....................................................................................................................................................................................4757 ......................................................................................................................................................................................................4758 .......................................................................................................................................................................................................4758 .16.20.00 Automatic Transmission Monitor ...............................................................................................................................................................4758 .16.21.00 Output Stage Check ..........................................................................................................................................................................4758 .17.00.00 Other Emission Control or Source System Monitoring ..............................................................................................................................................4759 .17.01.00 Intake manifold runner flap monitoring ..........................................................................................................................................................4759 ...........................................................................................................................................................................................................4759 .17.01.01 General Description ..........................................................................................................................................................................4759 .17.01.02 Monitoring function description ..........................................................................................................................................................4759 .17.01.03 Charts and flow charts ...................................................................................................................................................................4760 ..................................................................................................................................................................................................4762 .18.00.00 Exemptions to Monitor Requirements ...........................................................................................................................................................4762 .19.00.00 reserved .......................................................................................................................................................................................4762 .20.00.00 Parameters and conditions for closed loop operation ..............................................................................................................................................4762 ..........................................................................................................................................................................................................4765 ...........................................................................................................................................................................................................4765 .21.00.00 Parameters / conditions for 2nd closed loop operation ..........................................................................................................................................4765 ..........................................................................................................................................................................................................4767 .22.00.00 Parameters / conditions for closed loop operation on SULEV .......................................................................................................................................4767 02-06A 2004-2006 VW ECM Calibrations IDs............................................................................................................................................................................4775 02-06B 2005-2010 VW diesel ECM Calibration IDs and CVNs.............................................................................................................................................................4777 VW Q3-09 Diesel.................................................................................................................................................................................................4777 02-06C 2005-2010 VW Gas ECM Calibration IDs and CVNS................................................................................................................................................................4778 VW Q3-09 Gasoline...............................................................................................................................................................................................4778 02-06D VW ECM Part Numbers..........................................................................................................................................................................................4786 03-Manual Transmission.pdf (p.4842-5444)................................................................................................................................................................................4842 03-01 Manual Transmission 1998......................................................................................................................................................................................4842 03-02 Manual Transmission 1999......................................................................................................................................................................................4988 03-03 Manual Transmission BJS.......................................................................................................................................................................................5152 04-Automatic Transmission.pdf (p.5445-6065).............................................................................................................................................................................5445 04-01 Automatic Transmission 1998-99................................................................................................................................................................................5445 04-02 Automatic Transmission 1999-2001..............................................................................................................................................................................5697 04-03 Automatic Transmission 2000-01................................................................................................................................................................................5812 04-04 Automatic Transmission OBD R32-1..............................................................................................................................................................................5933 04-05 Automatic Transmission OBD R32-2..............................................................................................................................................................................6005 05-Steering & Suspension.pdf (p.6066-7145)..............................................................................................................................................................................6066 05-01 Suspension, Wheels & Steering.................................................................................................................................................................................6066 05-02 Wheel and Tire Guide..........................................................................................................................................................................................6341 06-Brakes Systems.pdf (p.7146-7423).....................................................................................................................................................................................7146 06-01 Brake System..................................................................................................................................................................................................7146 06-02 Brake System OBD..............................................................................................................................................................................................7290 07-HVAC Systems.pdf (p.7424-7777).......................................................................................................................................................................................7424 07-01 HVAC..........................................................................................................................................................................................................7424 07-02 HVAC Refrigerant R134a Servicing..............................................................................................................................................................................7567 08-Body.pdf (p.7778-8599)...............................................................................................................................................................................................7778 08-01 Body Repair...................................................................................................................................................................................................7778 08-02 Body Repair-Body Collision Repair.............................................................................................................................................................................7959 08-03 Body Interior.................................................................................................................................................................................................8030 08-04 Body Exterior.................................................................................................................................................................................................8316 09-Electrical Equipment.pdf (p.8600-9384)...............................................................................................................................................................................8600 09-01 Electrical Equipment General Information......................................................................................................................................................................8600 09-02 Electrical Equipment..........................................................................................................................................................................................8745 09-03 Electrical Equipment OBD......................................................................................................................................................................................9020 09-04 Body OBD-SRS & Central Locking................................................................................................................................................................................9097 09-05 Communication-Radio & Controls................................................................................................................................................................................9269 10-Electrical Wiring Diagrams.pdf (p.9385-9578).........................................................................................................................................................................9385 006-Automatic transmission, 4 speed automatic.......................................................................................................................................................................9385 Automatic transmission, 4 speed automatic, from September 1998..................................................................................................................................................9385 Park/neutral position (PNP) relay...........................................................................................................................................................................9386 Transmission control module (TCM), multi-function transmission range (TR) switch............................................................................................................................9387 Transmission control module (TCM), solenoid valves, transmission vehicle speed sensor (VSS), kick down switch...............................................................................................9388 Transmission control module (TCM), vehicle speed sensor (VSS)...............................................................................................................................................9389 Transmission control module (TCM), shift lock solenoid......................................................................................................................................................9390 011-Coolant Fan-single speed........................................................................................................................................................................................9391 Coolant Fan (single speed), from September 1998.................................................................................................................................................................9391 Coolant fan, coolant fan control (FC) thermal switch........................................................................................................................................................9392 038-Air conditioning (manual control)...............................................................................................................................................................................9393 Air conditioning (manual control), from May 1999................................................................................................................................................................9393 Fresh air blower switch, fresh air/recirculating flap switch, fresh air blower, servo motor for fresh-/recirculating air flap...............................................................................9394 Coolant fan control (FC) control module, A/C switch, ambient temperature switch.............................................................................................................................9395 Coolant fan control (FC) control module, A/C clutch, coolant fan, after-run coolant pump....................................................................................................................9396 Coolant fan control (FC) control module, coolant fan control (FC) thermal switch, high pressure sensor......................................................................................................9397 041-1.8L Engine-Motronic Multiport Fuel Injection (MFI) 110kW code AWD..............................................................................................................................................9398 1.8L - Engine - Motronic Multiport Fuel Injection (MFI)/110 kW, code AWD, from November 1999....................................................................................................................9398 Generator (GEN), starter....................................................................................................................................................................................9399 Motronic engine control module (ECM), power supply relay....................................................................................................................................................9400 Motronic engine control module (ECM), ignition system.......................................................................................................................................................9401 Motronic engine control module (ECM)........................................................................................................................................................................9402 Motronic engine control module (ECM), (ECT) sensor, charge air pressure sensor, camshaft position (CMP) sensor 2, wastegate bypass regulator valve, recirculating valve for turbocharger...................9403 Motronic engine control module (ECM), angle sensor for throttle drive (power accelerator actuation), intake air temperature (IAT) sensor, knock sensor (KS) 1, leak detection pump (LDP)....................9404 Motronic engine control module (ECM), pressure switch, power steering, engine speed (RPM) sensor, knock sensor (KS) 2.......................................................................................9405 Motronic engine control module (ECM), heated oxygen sensor (H02S), injectors................................................................................................................................9406 Motronic engine control module (ECM), throttle position (TP) sensor, oxygen sensor (O2S) behind three way catalytic converter (TWC), evaporative emission (EVAP) canister purge.............................9407 Motronic engine control module (ECM), fuel pump (FP) relay, cruise control switch, mass air flow (MAF) sensor...............................................................................................9408 Motronic engine control module (ECM), secondary air injection (AIR) pump system, break light switch, clutch vacuum vent valve switch, brake vacuum vent valve switch........................................9409 Fuel pump (FP), fuel level sensor, engine coolant level (ECL) sensor........................................................................................................................................9410 Instrument cluster, oil pressure switch, speedometer vehicle speed sensor, oil pressure warning light.......................................................................................................9411 Instrument cluster, multi-function indicator (MFI), fuel gauge, tachometer, speedometer, generator (GEN) warning light......................................................................................9412 Instrument cluster, multi-function indicator (MFI), outside air temperature sensor, electronic power control (EPC) warning lamp.............................................................................9413 052-Standard Equipment-Golf, Jetta..................................................................................................................................................................................9414 52 - Golf/Jetta - Standard Equipment, from January 2001.........................................................................................................................................................9414 Battery, ignition/starter switch............................................................................................................................................................................9415 Instrument cluster, clutch pedal position (CPP) switch, starting interlock relay............................................................................................................................9416 Instrument cluster, tachometer, speedometer, odometer display, anti-theft immobilizer, warning light for anti-theft immobilizer sensor......................................................................9417 Instrument cluster, generator (GEN) warning light, low fuel level warning light, warning light for rear lid unlocked/door ajar indicator lamp...............................................................9418 Instrument cluster, left front brake padwear sensor, brake padwear indicator light,headlight highbeam indicator light, digital clock........................................................................9419 Instrument cluster, parking brake warning light switch, brake fluid level warning switch, low windshield washer fluid level indication, left and right turn signal indicator lights.........................9420 Turn signal switch, headlight dimmer/flasher switch, left front turn signal light, light for side marker front left, left headlight.........................................................................9421 Emergency flasher switch, turn signal relay, right front turn signal light, light for side marker front right, right headlight..............................................................................9422 Left rear turn signal light, left back-up light, left brake/tail light, high-mount brake light (Golf only)..................................................................................................9423 Back-up light switch, brake light switch, right rear turn signal light, right back-up light, right brake/tail light.........................................................................................9424 Data Link Connector (DLC)...................................................................................................................................................................................9425 Radio connection, cigarette lighter, instrument panel vent illumination.....................................................................................................................................9426 Light switch................................................................................................................................................................................................9427 License plate light, glove compartment light................................................................................................................................................................9428 Dual tone horn, fuel tank door remote.......................................................................................................................................................................9429 Instrument panel light dimmer switch, rearwindow defogger switch, heated rear window........................................................................................................................9430 Fresh air blower switch, fresh air/recirculating flap switch, fresh air blower..............................................................................................................................9431 Motor for rear windshield wiper, windshield and rear window washer pump.....................................................................................................................................9432 Windshield wiper/washer switch, windshield wiper intermittent regulator, windshield wiper motor, wiper/washer intermittent relay............................................................................9433 056-Comfort system-Jetta Wagon with power windows...................................................................................................................................................................9434 Comfort system (vehicles with power windows), from May 2001.....................................................................................................................................................9434 Door control module (driver side), switch for window regulator, safety switch for window regulator rear, switch for interior lock (driver side).............................................................9435 Door control module (driver side), lock unit for central locking (driver side), warning light for central locking -SAFE-, left door warning light...........................................................9436 Door control module (driver side), mirror adjustment switch, mirror selector switch, switch for outside mirror heating......................................................................................9437 Door control module (driver side), switch for remote/fuel tank door, motor for fuel tank lid unlock, power mirror (driver side), heated outside mirror (driver side)........................................9438 Switch for remote unlock rear lid (driver side), key switch for switching off remote unlock rear lid........................................................................................................9439 Door control module (passenger side), switch for window regulator (passenger side), lock unit for central locking (passenger side)..........................................................................9440 Door control module (passenger side), switch for interior lock (passenger side), right door warning light, power mirror (passenger side), heated outside mirror............................................9441 Door control module (rear left), left rear window switch (in LR door), lock unit for central locking (rear left), motor for window regulator (rear left)....................................................9442 Door control module (rear right), right rear window switch (in RR door), lock unit for central locking (rear right), motor for window regulator (rear right)................................................9443 Interior lights, make-up mirror lights......................................................................................................................................................................9444 Central control module for comfort system...................................................................................................................................................................9445 Central control module for comfort system, switch for unlocking (rear lid handle), motor to unlock rear lid.................................................................................................9446 Central control module for comfort system, trunk lid release switch, luggage compartment light..............................................................................................................9447 Central control module for comfort system, power sunroof control module, sunroof regulator, sunroof motor...................................................................................................9448 Central control module for comfort system, antitheft warning system, antenna wire for central locking and antitheft warning system..........................................................................9449 Central control module for comfort system...................................................................................................................................................................9450 057-Comfort system-Golf, Jetta without power windows................................................................................................................................................................9451 Comfort system (vehicles without power windows), from May 2001..................................................................................................................................................9451 Switch for remote/fuel tank door, motor for fuel tank lid unlock............................................................................................................................................9452 Central control module for comfort system, switch for interior lock (driver side), switch for remote unlock rear lid........................................................................................9453 Central control module for comfort system, lock unit for central locking, warning light for central locking -SAFE-..........................................................................................9454 Central control module for comfort system, switch for interior lock (passenger side), left door warning light, heated outside mirrors.......................................................................9455 Central control module for comfort system, locking unit for central locking (passenger side), right door warning light......................................................................................9456 Central control module for comfort system, lock unit for central locking (rear left)........................................................................................................................9457 Central control module for comfort system, lock unit for central locking (rear right), trunk lock alarm/central locking switch, decklid central locking system motor........................................9458 Central control module for comfort system, trunk lid release switch, luggage compartment light switch.......................................................................................................9459 Central control module for comfort system, power sunroof control module, sunroof regulator, sunroof motor...................................................................................................9460 Central control module for comfort system, interior lights, make-up mirror lights...........................................................................................................................9461 Central control module for comfort system, antitheft warning system, antenna wire for central locking and antitheft warning system..........................................................................9462 Central control module for comfort system...................................................................................................................................................................9463 058-Comfort system-Golf, Jetta with power windows...................................................................................................................................................................9464 Comfort system (vehicles with power windows), from May 2001.....................................................................................................................................................9464 Door control module (driver side), switch for window regulator, safety switch for window regulator rear, switch for interior lock (driver side).............................................................9465 Door control module (driver side), lock unit for central locking (driver side), warning light for central locking -SAFE-, left door warning light...........................................................9466 Door control module (driver side), mirror adjustment switch, mirror selector switch, switch for outside mirror heating......................................................................................9467 Door control module (driver side), switch for remote/fuel tank door, motor for fuel tank lid unlock, power mirror (driver side), heated outside mirror (driver side)........................................9468 Switch for remote unlock rear lid (driver side), key switch for switching off remote unlock rear lid........................................................................................................9469 Door control module (passenger side), switch for window regulator (passenger side), lock unit for central locking (passenger side)..........................................................................9470 Door control module (passenger side), switch for interior lock (passenger side), right door warning light, power mirror (passenger side), heated outside mirror............................................9471 Door control module (rear left), left rear window switch (in LR door), lock unit for central locking (rear left), motor for window regulator (rear left)....................................................9472 Door control module (rear right), right rear window switch (in RR door), lock unit for central locking (rear right), motor for window regulator (rear right)................................................9473 Interior lights, make-up mirror lights......................................................................................................................................................................9474 Central control module for comfort system...................................................................................................................................................................9475 Central control module for comfort system, switch for unlocking (rear lid handle), motor to unlock rear lid.................................................................................................9476 Central control module for comfort system, trunk lid release switch, luggage compartment light switch.......................................................................................................9477 Central control module for comfort system, power sunroof control module, sunroof regulator, sunroof motor...................................................................................................9478 Central control module for comfort system, antitheft warning system, antenna wire for central locking and antitheft warning system..........................................................................9479 Central control module for comfort system...................................................................................................................................................................9480 059-Headlight washer................................................................................................................................................................................................9481 Headlight washer, from May 2000.................................................................................................................................................................................9481 Wiper/washer intermittent relay, windshield wiper internmittent regulator, windshield washer fluid level sensor, headlight washer pump, instrument cluster..................................................9482 Wiper/washer intermittent relay, windshield wiper/washer switch, windshield wiper motor, windshield and rear window washer pump.............................................................................9483 060-Fog lights......................................................................................................................................................................................................9484 Fog lights, from May 2000.......................................................................................................................................................................................9484 Left headlight light, light for side marker front left, fog light relay, left front fog light, left parking light...........................................................................................9485 Right headlight light, light for side marker front right, fog light relay, right front fog light, right parking light.......................................................................................9486 Light switch, fog light switch..............................................................................................................................................................................9487 Instrument cluster, headlight high beam indicator light, turn signal indicator lights.......................................................................................................................9488 061-Daytime running lights..........................................................................................................................................................................................9489 Daytime running lights, from May 2000...........................................................................................................................................................................9489 Instrument cluster, left and right turn signal indicator lights, parking brake indicator light, warning light for brake system, headlight high beam indicator light.........................................9490 Turn signal switch, headlight dimmer/flasher switch, left front turn signal light, light for side marker front left, left headlight.........................................................................9491 Daytime running lights change-over relay, parking brake warning light switch, right front turn signal light, light for side marker front right, right headlight.............................................9492 Light switch................................................................................................................................................................................................9493 Left rear turn signal light, left back-up light, left brake/tail light, high-mount brake light (Jetta Wagon/Golf)...........................................................................................9494 Right rear turn signal light, right back-up light, right brake/tail light, high-mount brake light (Jetta Sedan).............................................................................................9495 068-Heated seats....................................................................................................................................................................................................9496 Heated seats, from May 1999.....................................................................................................................................................................................9496 Driver's heated seat control module, driver's heated seat temperature sensor, driver's seat heating element, driver's backrest heating element..............................................................9497 Passenger's heated seat control module, passenger's heated seat temperature sensor, passenger's seat heating element, passenger's backrest heating element..................................................9498 074-CAN-Bus, Powertrain and Comfort System..........................................................................................................................................................................9499 74 - CAN-Bus, Powertrain and Comfort System, from May 2001......................................................................................................................................................9499 CAN connection for: door control module (driver side, passenger side), door control module (rear, left and rear, right), central control module for comfort system..........................................9500 CAN connection for: telematic control module, control module for multi-function steering wheel, radio.......................................................................................................9501 instrument cluster, Data Link Connector (DLC)...............................................................................................................................................................9502 instrument cluster, data bus on board diagnostic interface, CAN connection for: airbag control module, ABS control module (w/EDL)...........................................................................9503 CAN connection for: transmission control module (TCM), motronic engine control module (ECM), diesel direct fuel injection (DFI) engine control module (ECM), all-wheel drive control module.................9504 077-Heated power mirrors (Canada)...................................................................................................................................................................................9505 77 - Heated power mirrors (Canada), from May 2002...............................................................................................................................................................9505 Mirror adjustment switch, mirror selector switch, switch for outside mirror heating, motor for mirror adjustment (driver side), heated outside mirror (driver side).........................................9506 Heated mirror relay, motor for mirror adjustment (passenger side), heated outside mirror (passenger side)...................................................................................................9507 078-1.8L Engine - Motronic MFI code AWW, 1.8L code AWP..............................................................................................................................................................9508 78 - 1.8L - Engine - Motronic Multiport Fuel Injection (MFI)/132 kW, code AWP, from May 2002....................................................................................................................9508 Generator (GEN), starter....................................................................................................................................................................................9509 Power supply relay..........................................................................................................................................................................................9510 Motronic engine control module (ECM), ignition system.......................................................................................................................................................9511 Motronic engine control module (ECM)........................................................................................................................................................................9512 Charge air pressure sensor, camshaft position (CMP) sensor,wastegate bypass regulator valve, recirculating valve for turbocharger, valve for camshaft adjustment............................................9513 Motronic engine control module (ECM), angle sensor for throttle drive (power accelerator actuation), intake air temperature (IAT) sensor, (ECT) sensor, leak detection pump (LDP)...........................9514 Motronic engine control module (ECM), engine speed (RPM) sensor, knock sensor (KS) 1, knock sensor (KS) 2...................................................................................................9515 Motronic engine control module (ECM), pressure switch/power steering, injectors.............................................................................................................................9516 Motronic engine control module (ECM), heated oxygen sensor (HO2S), oxygen sensor (O2S) behind three way catalytic converter (TWC), (EVAP) canister purge regulator valve....................................9517 Motronic engine control module (ECM), brake booster control module, brake system vacuum pump................................................................................................................9518 Motronic engine control module (ECM), secondary air injection (AIR) pump system, brake light switch, brake pedal switch.....................................................................................9519 Motronic engine control module (ECM), cruise control switch, mass air flow (MAF) sensor, clutch vacuum vent valve switch....................................................................................9520 Motronic engine control module (ECM), throttle position (TP) sensor, fuel pump (FP) relay...................................................................................................................9521 Fuel pump (FP), fuel level sensor, engine coolant level (ECL) sensor........................................................................................................................................9522 Instrument cluster, oil pressure switch, speedometer vehicle speed sensor (VSS),oil pressurewarning light...................................................................................................9523 Instrument cluster, engine coolant temperature (ECL/ECT) gauge, fuel gauge, tachometer, speedometer, generator (GEN) warning light, low fuel level warning light............................................9524 Instrument cluster, multi-function indicator (MFI), outside air temperature sensor, electronic power control (EPC)warning lamp, cruise control indicator light, malfunction indicator lamp..................9525 082-1.9L Turbo Diesel PD Fuel Injection (DFI) 74 kW, code BEW.......................................................................................................................................................9526 82 - 1.9L - Engine - Turbo Diesel PD Fuel Injection (DFI)/74 kW, code BEW, (with automatic transmission),.......................................................................................................9526 Generator (GEN), starter....................................................................................................................................................................................9527 Glow plug activation control module, engine glow............................................................................................................................................................9528 Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9529 Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9530 Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9531 Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9532 Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9533 Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9534 Diesel direct fuel injection (DFI) engine control...........................................................................................................................................................9535 Diesel direct fuel injection (DFI) engine control module ...................................................................................................................................................9536 Diesel direct fuel injection (DFI) engine controlmodule.....................................................................................................................................................9537 Fuel pump (FP) relay, fuel pump (FP), Fuel level Sensor.....................................................................................................................................................9538 Instrument cluster, oil pressure switch, speedometer........................................................................................................................................................9539 Instrument cluster, engine coolant temperature..............................................................................................................................................................9540 Instrument cluster, multi-function indicator (MFI),.........................................................................................................................................................9541 085-Telematics......................................................................................................................................................................................................9542 85 - Telematics, from May 2003..................................................................................................................................................................................9542 Telematic Control Module, Dual tone horn, Dual horn auxiliary relay.........................................................................................................................................9543 Telematic Control Module, warning lamp auxiliary relay, auxiliary emergency flasher relay...................................................................................................................9544 Telematic Control Module, Emergency Flasher Switch..........................................................................................................................................................9545 Telematic Control Module, Lock unit for central locking (driver side).......................................................................................................................................9546 Telematic Control Module, Telematic Control Head, Roadside Assistance Button, Emergency Call Button, End Conversation Button (Telematic USA), Telematics Indicator Lamp.....................................9547 Telematic Control Module, Antenna, Antenna for Navigation System (GPS), Telephone Microphone................................................................................................................9548 092-Heated rear window with timer...................................................................................................................................................................................9549 Heated rear window with timer, from May 1999 Additional Fuse, Relay, Control Module and Connector locations -> Compontent Locations Troubleshooting Procedures -> Guided Fault Finding using VAS 5051/5052 ....9549 Relay location on thirteen position auxiliary relay panel, above relay panel:...............................................................................................................................9549 Fuse 26 in fuse holder......................................................................................................................................................................................9550 Rear windowdefogger switch, heated rear window..............................................................................................................................................................9551 501-Threaded connection -2- (30) on the relay plate.................................................................................................................................................................9552 C-Generator (GEN)...................................................................................................................................................................................................9553 F220-Lock unit for central locking driver side......................................................................................................................................................................9554 G2-Engine Coolant Temperature (ECT) sensor (1.9L TDI)...............................................................................................................................................................9555 G17-Outside Air Temperature Sensor (vehicles without Multi-Function Indicator MFI)..................................................................................................................................9556 G22-Speedometer Vehicle Speed Sensor (VSS) (5 spd. Manual transmission).............................................................................................................................................9557 G39-Heated Oxygen Sensor (HO2S) (3.2L engine).......................................................................................................................................................................9558 G62-Engine Coolant Temperature (ECT) sensor (1.8L engine)...........................................................................................................................................................9559 G68-Vehicle Speed Sensor (VSS)......................................................................................................................................................................................9560 G130-Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC)_(1.8L engine)...................................................................................................................................9561 G163-Camshaft Position (CMP) sensor 2...............................................................................................................................................................................9562 N112-Secondary Air Injection (AIR) solenoid valve (2.0L engine).....................................................................................................................................................9563 N112-Secondary Air Injection (AIR) solenoid valve (2.8L VR6)........................................................................................................................................................9564 N205-Valve 1 for camshaft adjustment................................................................................................................................................................................9565 N292-Ignition Coil 4 with Power Output Stage........................................................................................................................................................................9566 R12-Amplifier Sedan only............................................................................................................................................................................................9567 S164-Fuse 3 (30) in fuse bracket battery............................................................................................................................................................................9568 T3b-3 pin connector (1.8L engine)...................................................................................................................................................................................9569 T3b-3 pin connector.................................................................................................................................................................................................9570 T4c-4 Pin Connector (3.2L engine)...................................................................................................................................................................................9571 T4e-4-pin connector.................................................................................................................................................................................................9572 T10a-10 pin connector (2.0L engine).................................................................................................................................................................................9573 TA10 A-10-pin connector (2.8L VR6)..................................................................................................................................................................................9574 V51-After-run coolant pump..........................................................................................................................................................................................9575 V60-Throttle Position (TP) actuator.................................................................................................................................................................................9576 V139-Motor for remote unlock rear lid...............................................................................................................................................................................9577 V148-Motor for window regulator passenger side......................................................................................................................................................................9578
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1997-2004 Volkswagen Golf MK4 Service Manual
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