1999-2005 Volkswagen Golf, Jetta, GTI Service Manual – PDF DOWNLOAD
SAMPLE PAGES FROM THE MANUAL:
1999-2005 Volkswagen Golf, Jetta, GTI Service Manual – PDF DOWNLOAD
Volkswagen
Jetta, Golf, GTI
1999, 2000, 2001, 2002, 2003, 2004, 2005
1.8L turbo, 1.9L TDI and PD diese!
2.0L gasoline, 2.8L VR6
Engine number :
The engine number (engine code and serial number) are located next to the vibration damper on the cylinder block. The engine number consists of up to nine characters (alphanumeric). The first part (maximal 3 characters) makes up the engine code and the second part (6 characters), the serial number. If more than 999,999 engines with the same engine code are produced, the first of the six characters is replaced with a letter. Additionally there is a sticker on the intake manifold with the engine code and serial number. The engine code is additionally included on the vehicle data plate.
TABLE OF CONTENTS:
1999-2005 Volkswagen Golf, Jetta, GTI Service Manual – PDF DOWNLOAD
Capa..................................................................................................................... 1 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF.................................................................. 3 Technical data....................................................................................................... 4 Engine, removing and installing...................................................................................... 7 Engine, disassembling and assembling................................................................................. 29 Sealing flanges and dualmass flywheel, removing and installing....................................................... 60 Crankshaft, removing and installing.................................................................................. 74 Piston and connecting rod, disassembling and assembling.............................................................. 83 Cylinder head, servicing............................................................................................. 96 Valve gear, servicing................................................................................................ 154 Lubrication system components, servicing............................................................................. 203 Cooling system components, servicing................................................................................. 227 Components of fuel supply system, servicing.......................................................................... 270 Evaporative Emissions................................................................................................ 312 Electronic Power Control (EPC)....................................................................................... 341 Exhaust system components, servicing................................................................................. 354 Secondary air system................................................................................................. 379 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF.......................................................... 414 On Board Diagnostic (OBD)............................................................................................ 417 DTC memory........................................................................................................... 439 DTC table: SAE P0 codes.............................................................................................. 446 DTC table: SAE P1 codes.............................................................................................. 475 DTC table: SAE P2 codes.............................................................................................. 516 DTC table: SAE P3 codes.............................................................................................. 517 Output Diagnosis Test Mode (DTM)..................................................................................... 518 Readiness code....................................................................................................... 563 Readiness code....................................................................................................... 600 Measured value (data) blocks......................................................................................... 637 Fuel injection system, servicing..................................................................................... 723 Components, checking................................................................................................. 781 Functions, checking.................................................................................................. 868 Motronic Engine Control Module (ECM) -J220-.......................................................................... 905 Additional signals, checking......................................................................................... 931 Ignition system, servicing........................................................................................... 971 5 & 6 Spd. Manual Transmission 02M.......................................................................................1022 Transmission identification..........................................................................................1024 Transmission layout..................................................................................................1029 Calculating overall ratio "i"........................................................................................1031 General repair instructions..........................................................................................1032 Clutch mechanism, repairing..........................................................................................1036 Clutch release mechanism, servicing..................................................................................1060 Clutch, servicing....................................................................................................1063 Clutch, servicing....................................................................................................1071 Gear selector mechanism, servicing...................................................................................1079 Transmission, removing and installing................................................................................1110 Transmission gear oil, checking......................................................................................1137 Transmission, disassembling and assembling...........................................................................1139 Transmission housing, servicing......................................................................................1163 Clutch housing, servicing............................................................................................1177 Transmission selector mechanism, disassembling and assembling........................................................1189 Selector forks, disassembling and assembling.........................................................................1195 Input shaft, disassembling and assembling............................................................................1198 Input shaft, adjusting...............................................................................................1213 Output shaft, 1st-4th gear, disassembling and assembling.............................................................1220 Output shaft for 1st-4th gears, adjusting............................................................................1251 Output shaft for 5th, 6th and reverse gear, disassembling and assembling.............................................1259 Output shaft for 5th, 6th and reverse gear, adjusting................................................................1285 Oil seals for flanged shafts, replacing..............................................................................1293 Differential, disassembling and assembling...........................................................................1299 Adjustment overview..................................................................................................1320 Differential, adjusting..............................................................................................1322 Brake System On Board Diagnostic (OBD)...................................................................................1330 ABS ITT Mark 20 IE On Board Diagnostic (OBD).........................................................................1332 Electrical/electronic components and locations.......................................................................1340 ABS ITT Mk 20 IE On Board Diagnostic (OBD) program...................................................................1356 ABS, ABS/EDL and ABS/EDL/ASR ITT Mark 20 IE, electrical check........................................................1415 ABS Mark 60 On Board Diagnostic (OBD), vehicles from my 10.00........................................................1448 Electrical/electronic components and installing locations............................................................1458 Diagnostic Trouble Codes (DTCs) displayed by warning lights -K47-, -K118- and -K155-.................................1476 On Board Diagnostic (OBD), performing................................................................................1480 Electrical check of Mark 60..........................................................................................1540 Definitions..........................................................................................................1580 Brake System.............................................................................................................1586 Technical data.......................................................................................................1589 Technical data, brakes...............................................................................................1595 Anti-lock brake system (ABS) and antilock brake system with electronic differential lock (ABS/EDL) ITT Mark 20 IE....1602 Hydraulic unit, brake booster/master cylinder, overview..............................................................1606 ABS system components for front axle, removing and installing........................................................1622 Anti-lock brake system (ABS) Mark 60.................................................................................1639 VAS 5051 Vehicle Diagnostic, Testing and Information System, connecting and electing functions......................1645 Electrical/electronic components and installing locations (ABS) Mark 6...............................................1648 Hydraulic unit, brake booster/brake master cylinder Mark 60, assembly overview.......................................1657 DTCs displayed by (ABS) Mark 60 warning lights -K32-, -K47-, -K118-, and -K155-......................................1676 ABS system components for front and rear axles, removing and installing..............................................1682 ESP system components, removing and installing.......................................................................1718 Front brakes.........................................................................................................1735 Rear wheel brakes (disc brakes - front wheel drive), assembly overview...............................................1788 Rear wheel brakes/disc brakes (allwheel drive), servicing............................................................1807 Parking brake cables for disc brakes - front wheel drive, removing and installing....................................1823 Parking brake cables for disc brakes - all wheel drive, removing and installing......................................1827 Parking brake lever, assembly overview...............................................................................1831 Brake pedal assembly overview........................................................................................1834 Front brake calipers, servicing......................................................................................1846 FN 3 front brake calipers, servicing.................................................................................1852 Rear brake caliper, servicing........................................................................................1868 Brake pressure regulator, assembly overview..........................................................................1879 Brake system, bleeding...............................................................................................1884 Brake booster/brake master cylinder for vehicles with ABS/EDL/ASR/ESP, servicing for vehicles up to my 10.00.........1894 Brake booster/brake master cylinder for vehicles with ABS/EDL/ASR/ESP Mark 60 from m.y. 10.00, assembly overview.....1903 Brake master cylinder, removing and installing.......................................................................1936 Brake booster, removing and installing...............................................................................1939 Definitions..........................................................................................................1942 Suspension, Wheels, Steering.............................................................................................1944 Technical data.......................................................................................................1948 Check list for evaluating the suspension of accident vehicles........................................................1949 Evaluation of accident vehicles......................................................................................1952 Electrical/electronic components and installation locations..........................................................1953 Front suspension, servicing..........................................................................................1964 Front suspension R32, servicing......................................................................................2015 Front drive axle, servicing..........................................................................................2058 Evaluation of accident vehicles......................................................................................2119 Rear axle, servicing.................................................................................................2120 Wheel bearing, servicing.............................................................................................2152 Rear axle, servicing (all wheel drive vehicles)......................................................................2164 Trailing arm and transverse links (allwheel drive vehicles), assembly overview.......................................2192 Subframe with final drive, assembly overview.........................................................................2236 Rear drive axle, servicing...........................................................................................2251 Evaluation of accident vehicles......................................................................................2264 Tightening torques for wheel bolts...................................................................................2265 Protecting wheel centering seat against corrosion....................................................................2266 Wheels, tires........................................................................................................2267 Wheel alignment......................................................................................................2270 Wheels, tires........................................................................................................2284 Evaluation of accident vehicles......................................................................................2285 Connecting VAS 5051 and selecting functions..........................................................................2286 Airbag...............................................................................................................2289 Steering column......................................................................................................2290 Power steering, servicing............................................................................................2310 Power steering pump, reservoir and hydraulic lines...................................................................2329 Definitions..........................................................................................................2362 Body Collision Repair....................................................................................................2364 Technical data.......................................................................................................2367 Body foam insulation.................................................................................................2372 Reinforced body sheet metal..........................................................................................2374 Laser welding........................................................................................................2375 Galvanized body panels...............................................................................................2376 Body panel gaps/mating lines.........................................................................................2377 Body dimensions......................................................................................................2383 Straightening fixture................................................................................................2406 50 40 55 50 Engine mount bracket, replacing..........................................................................2424 50 52 55 50 Intermediate piece, replacing............................................................................2426 50 53 55 50 fender connecting plate, replacing.......................................................................2428 50 72 55 50 long member for upper wheel house, replacing.............................................................2431 50 74 55 00 Front wheel house, partial replacing.....................................................................2434 50 75 55 50 Front inner fender, replacing............................................................................2436 50 79 55 00 Front long member, replacing.............................................................................2438 50 79 55 02 Front long member, partial replacing.....................................................................2441 50 80 55 00 Long member front section, replacing.....................................................................2444 51 03 55 00 Roof, replacing (Golf)...................................................................................2447 51 03 55 00 Roof, replacing (Jetta)..................................................................................2452 51 03 55 20 Roof, replacing (Jetta wagon)............................................................................2456 51 07 55 50 Front roof cross member, replacing.......................................................................2464 51 08 55 50 Roof reinforcement, replacing............................................................................2466 51 09 55 50 Rear roof cross member, replacing (Golf).................................................................2468 51 09 55 50 Rear cross member, replacing (Jetta).....................................................................2470 51 09 55 70 Rear roof crossmember, replacing (Jetta wagon)...........................................................2472 51 09 55 70 Rear roof crossmember, replacing (Jetta wagon)...........................................................2474 51 37 55 00 Apillar, inner, replacing................................................................................2476 51 38 55 50 Apillar, inner, replacing................................................................................2480 51 41 55 62 B-pillar, replacing (4 door), 51 41 55 52 B-pillar, replacing (Jetta)....................................2485 51 42 55 50 Inner B-pillar, replacing (2-door).......................................................................2489 51 42 55 60 Inner B-pillar, replacing (4-door), 51 42 55 50 inner B-pillar, replacing (Jetta)........................2493 51 45 55 00 Outer side member, replacing (2-door)....................................................................2500 51 45 55 10 Outer side member, replacing (4-door), 51 45 55 00 outer side member, replacing (Jetta)..................2503 51 49 55 50 Side member reinforcement, replacing.....................................................................2506 51 73 55 50 Floor plate, partial replacement.........................................................................2510 53 05 55 50 Rear cross panel, replacing..............................................................................2514 53 05 55 20 Rear cross panel, exterior, replacing (Jetta wagon)......................................................2515 53 05 55 23 Rear cross panel, complete, replacing (Jetta wagon)......................................................2520 53 10 55 50 Tail light mount, replacing (Golf).......................................................................2536 53 05 55 50 Rear center cross panel carrier, replacing (Jetta).......................................................2541 53 05 55 50 Rear cross panel, replacing (Jetta)......................................................................2545 53 16 55 00 End cross panel, replacing (Golf)........................................................................2548 53 16 55 00 Outer wheel house, replacing (Jetta).....................................................................2550 53 29 55 70 Reinforcement for C-pillar, replacing (Jetta wagon)......................................................2552 53 48 55 50 Rear long member, replacing (Jetta)......................................................................2554 53 47 55 52 Long member, partial replacement (Jetta).................................................................2556 53 55 55 10 Quarter panel, partial replacement (Golf 4-door).........................................................2558 53 55 55 00 Quarter panel, partial replacement (Jetta)...............................................................2563 53 55 55 20 Side panel, partial replacement (Jetta wagon)............................................................2569 53 69 55 50 Quarter panel, partial replacement (Golf)...............................................................2577 53 69 55 50 Wheel house connecting panel, partial replacement (Jetta)................................................2579 53 36 55 50 Connecting panel, replacing (Jetta)......................................................................2581 53 69 55 70 Rear wheelhousing, outer, replacing - partial section- (Jetta wagon).....................................2583 53 80 55 50 Spare wheel well, replacing (Golf).......................................................................2587 53 80 55 52 Spare wheel well, partial replacement (Golf).............................................................2589 53 80 55 50 Spare wheel well, replacing (Jetta)......................................................................2591 Body Exterior............................................................................................................2595 Body, front..........................................................................................................2600 Hood.................................................................................................................2609 Rear lid (Golf)......................................................................................................2618 Rear lid (Jetta).....................................................................................................2630 Rear lid, (Jetta Wagon)..............................................................................................2641 Tank flap unit.......................................................................................................2651 Front door...........................................................................................................2655 Central locking system...............................................................................................2683 Rear doors...........................................................................................................2700 Sunroof..............................................................................................................2723 Sunroof with glass panel (Webasto)...................................................................................2727 Sunroof with glass panel (Meritor)...................................................................................2749 Front bumper.........................................................................................................2770 Rear bumper..........................................................................................................2782 Flush-bonded windows.................................................................................................2796 Door windows.........................................................................................................2832 Wheelhousing liner, removing and installing..........................................................................2870 Outside rear view mirror.............................................................................................2873 Roof moldings........................................................................................................2878 Roof rail............................................................................................................2880 Trim.................................................................................................................2883 Protective side moldings.............................................................................................2886 Rear spoiler with integrated stoplight...............................................................................2888 Special components of Golf "GTI 337 Edition"/Jetta GLI Sport and Golf R32............................................2896 Body Interior............................................................................................................2919 Seatbelts............................................................................................................2925 Seatbelts, inspecting................................................................................................2940 Inspecting child seat anchors after accident (ISOFIX)................................................................2945 Airbag...............................................................................................................2946 Crash sensors........................................................................................................3001 Instrument panel.....................................................................................................3008 Door trim............................................................................................................3023 Pillar and side trim.................................................................................................3036 Luggage compartment trim.............................................................................................3106 Rear lid trim........................................................................................................3131 Headliner............................................................................................................3144 Front seats..........................................................................................................3158 Rear seats...........................................................................................................3185 Front seat cushion and cover.........................................................................................3197 Seat heating elements................................................................................................3211 Rear seat upholstery and cover.......................................................................................3214 Body On Board Diagnostic (OBD)...........................................................................................3219 On Board Diagnostic (OBD)............................................................................................3221 Airbag system, On Board Diagnostic (OBD).............................................................................3225 Convenience system (vehicles with power windows), On Board Diagnostic (OBD)..........................................3310 Central locking system (vehicles without power windows), On Board Diagnostic (OBD)...................................3524 Driver's side seat adjustment, On Board Diagnostic (OBD).............................................................3606 Heating and Air Conditioning.............................................................................................3659 On Board Diagnostic (OBD) through m.y. 2001..........................................................................3661 On Board Diagnostic (OBD) from m.y. 2002.............................................................................3665 Climatronic On Board Diagnostic (OBD) through m.y. 2001..............................................................3666 Heating and ventilation system, servicing............................................................................3718 Manual A/C...........................................................................................................3754 Climatronic..........................................................................................................3788 A/C refrigerant system...............................................................................................3849 A/C refrigerant system, servicing....................................................................................3870 A/C refrigerant system, troubleshooting..............................................................................3921 A/C refrigerant system, capacities...................................................................................3931 Compressor bracket, removing and installing..........................................................................3935 Refrigerant R134a - Servicing............................................................................................3970 General information for A/C system...................................................................................3972 General information on refrigerant circuit...........................................................................3991 Laws and regulations.................................................................................................4012 Refrigerant circuit..................................................................................................4018 Complaints...........................................................................................................4029 Service station, connecting..........................................................................................4031 Pressures, checking on vehicles......................................................................................4032 Components, replacing................................................................................................4065 Testing equipment and tools..........................................................................................4072 Electrical Equipment On Board Diagnostic (OBD)...........................................................................4080 On Board Diagnostic (OBD) through m.y. 2001..........................................................................4082 On Board Diagnostic (OBD) from m.y. 2002.............................................................................4086 Instrument cluster through m.y. 1999, On Board Diagnostic (OBD)......................................................4087 Instrument cluster m.y. 2000 through m.y. 2001, On Board Diagnostic (OBD)............................................4150 Data Bus On Board Diagnostic Interface -J533- ("Gateway") m.y. 2000 through m.y. 2001, On Board Diagnostic (OBD).....4225 Anti-theft immobilizer, On Board Diagnostic (OBD)....................................................................4246 Electrical Equipment.....................................................................................................4247 Battery..............................................................................................................4253 Battery, checking....................................................................................................4260 Battery, charging....................................................................................................4288 Battery, disconnecting and reconnecting..............................................................................4293 Battery, removing and installing.....................................................................................4306 Battery, tightening torques..........................................................................................4315 Starter..............................................................................................................4316 Starter, tightening torques..........................................................................................4325 Generator (GEN)......................................................................................................4326 Generator (GEN) through 04.99........................................................................................4327 Generator (GEN) from 05.99...........................................................................................4331 Generator (GEN) -4- cylinder gasoline engines........................................................................4337 Generator (GEN) -6- cylinder gasoline engines........................................................................4348 Generator (GEN) -4- cylinder TDI engines.............................................................................4360 Generator (GEN) -4- cylinder TDI - PD engines........................................................................4377 Generator (GEN), tightening torques..................................................................................4390 Cruise Control System (CCS) through m.y. 2001........................................................................4395 Cruise Control System (CCS) from m.y. 2002...........................................................................4409 Instrument cluster...................................................................................................4410 Windshield wiper system..............................................................................................4430 Windshield wiper system, tightening torques..........................................................................4448 Washer system........................................................................................................4449 Rear window wiper & washer system....................................................................................4459 Rear window wiper system, tightening torques.........................................................................4469 Washer hoses, repairing..............................................................................................4470 Headlights - Golf....................................................................................................4474 Headlights - Jetta...................................................................................................4494 Side mounted turn signals............................................................................................4511 Rear lights..........................................................................................................4513 Rear lights, tightening torques......................................................................................4524 License plate lights.................................................................................................4525 High-mount brake light...............................................................................................4526 Steering column switches.............................................................................................4532 Ignition/starter switch and lock cylinder............................................................................4540 Interior lights and switches.........................................................................................4547 Anti-theft Immobilizer...............................................................................................4574 Fuse holder and relay carriers.......................................................................................4582 Fuse holder and relay carriers, tightening torques...................................................................4591 Wiring harnesses and connectors, repairing...........................................................................4592 Antenna cables, replacing............................................................................................4599 Communication............................................................................................................4603 Radio system - "Premium IV" and "Premium V" (including "Monsoon") through 11.01, On Board Diagnostic (OBD)...........4606 Radio system - "Premium VI" (including "Monsoon) from 12.01, On Board Diagnostic (OBD)...............................4632 Multi-function steering wheel through 11.01, On Board Diagnostic (OBD)...............................................4661 Multi-function steering wheel from 12.01, On Board Diagnostic (OBD)..................................................4688 Communication........................................................................................................4691 Radio systems........................................................................................................4694 Radio, "Premium IV"..................................................................................................4695 Radio, "Premium V" & "Premium V - Monsoon"...........................................................................4705 Radio, "Premium VI" & "Premium VI - Monsoon".........................................................................4715 Amplifier system - "Monsoon".........................................................................................4727 Speaker system.......................................................................................................4733 Antenna systems......................................................................................................4737 CD Changer / CD Player...............................................................................................4748 Multi-function steering wheel........................................................................................4758 Telematics...........................................................................................................4769 Mobile telephone and two-way radio operation, notes..................................................................4804 Maintenance..............................................................................................................4815 Engine overview......................................................................................................4818 Service work.........................................................................................................4819 Oil change service...................................................................................................4820 Delivery inspection..................................................................................................4821 Maintenance service..................................................................................................4822 General..............................................................................................................4823 Description of work (part 1 of 2)....................................................................................4846 Description of work (part 2 of 2)....................................................................................4896
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