golf odrzavanje maintenance

7/29/2019 Golf Odrzavanje Maintenance

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opyrightbyVolkswagenAG.

MaintenanceBora 1999 Bora Variant 1999 Golf 1998 Golf Variant 1998 Edition 05.2012

Service

Service Department. Technical Information


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Maintenance

Heading1. Engine list

2. Service work

3. General

4. Descriptions of work

5. Exhaust emissions test

6. Glossary

Technical information should always be available to the foremen and mechanics, because theircareful and constant adherence to the instructions is essential to ensure vehicle road-worthiness andsafety. In addition, the normal basic safety precautions for working on motor vehicles must, as a

matter of course, be observed.

Service

All rights reserved.No reproduction without prior agreement from publisher.Copyright 2012 Volkswagen AG, Wolfsburg K0451015020


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.

Contents1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.1 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.2 Delivery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.3 Oil change service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.4 Inspection service 1999 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.5 Inspection service 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.6 Additional work on natural gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.1 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.2 Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.3 Connecting vehicle diagnosis tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.4 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.5 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.6 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343.7 Information on long-life service or time- or distance-dependent service . . . . . . . . . . . . . . 35

3.8 Countries with elevated sulphur content in diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.9 Countries with hot climate includes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.10 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.11 RME fuel (biodiesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.12 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394.1 Exhaust system: Perform visual check for leaks, security and damage . . . . . . . . . . . . . . . . 41

4.2 Swivel joints: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.3 Automatic gearbox: Change ATF (01M gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.4 Automatic gearbox: Change ATF strainer (01M gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.5 Automatic gearbox: Check gear oil in final drive (01M gearbox) . . . . . . . . . . . . . . . . . . . . 42

4.6 Automatic gearbox: Check ATF level, top-up if necessary (01M gearbox) . . . . . . . . . . . . 42

4.7 Automatic gearbox: Check ATF level, top-up if necessary (09A gearbox) . . . . . . . . . . . . 42

4.8 Battery: Check battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . . . 42

4.9 Battery: Check using battery tester with printer VAS 5097A or VAS 6161 . . . . . . . . . . . . . . 44

4.10 Front airbag for the front passenger: Check activation / deactivation . . . . . . . . . . . . . . . . 44

4.11 Checking tyres: Condition, wear pattern, tyre pressure and tread depth . . . . . . . . . . . . . . 45

4.12 Brake system: Perform visual check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . 61

4.13 Front and rear brake pads/linings: Check thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.14 Brake and clutch system: Change brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

4.15 Brake fluid level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.16 6-speed dual clutch gearbox 02E (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4.17 Electric windows, 8-way memory seat: Perform initialisation (activation) . . . . . . . . . . . . . . 69

4.18 Vehicle system test: Perform test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4.19 Protective bellows: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.20 Installing noise insulation: Golf R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.21 Haldex coupling: Renew oil filter (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.22 Haldex coupling: Change oil (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.23 Checking first aid box expiry date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.24 Rear lid: Lubricate left and right multi-joint hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.25 Fuel filter: Renew (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.26 Fuel filter: Drain water (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.27 Poly V-belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.28 Cooling system: Check frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.29 Air filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.30 Engine cover panel -top-: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4.31 Engine compartment cover (noise insulation) -bottom-: Removing and installing . . . . . . . . 90

Bora 1999 , Bora Variant 1999 , Golf 1998 , Golf Variant 1998

Maintenance - Edition 05.2012

Contents i


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4.32 Engine oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4.33 Engine oil: Drain or extract and replenish; renew oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4.34 Engine and components in engine compartment (from above and below): Perform visualcheck for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.35 Performing road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.36 Radio and radio-navigation system: Stick serial number and code number onto unit card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

4.37 Radio/radio-navigation system: Activate anti-theft coding . . . . . . . . . . . . . . . . . . . . . . . . . . 99

4.38 Wheel securing bolts: Tighten to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.39 Securing wheel housing liner to front apron (only Golf Anniversary GTI with 132 kW) . . . . 103

4.40 Tyre repair set: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4.41 Power assisted steering: Check oil/fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

4.42 Sunroof: Check function, clean and grease guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

4.43 Sliding sunroof drains: Checking for blockage, cleaning if necessary . . . . . . . . . . . . . . . . 107

4.44 Windscreen wash/wipe system and headlight washer system: Check for damage, functionand spray jet settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4.45 Wiper blades: Check for damage, park position and setting angle if wiper blades judder . . 112

4.46 Manual gearbox/final drive: Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1134.47 Headlight adjustment: Check and adjust as necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.48 Service interval display: Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

4.49 Service interval display: Recode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

4.50 Track rod ends: Check clearance, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4.51 Dash panel insert: Adapt to required language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4.52 Dust and pollen filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . 122

4.53 Transportation device: Remove blocking pieces from front axle springs . . . . . . . . . . . . . . 122

4.54 Door arrester: Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

4.55 Clock: Set to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4.56 Underbody: Visual check for damage to underbody sealant, underbody panels, routing oflines, plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4.57 Toothed belt and camshaft drive tensioning roller: Renew . . . . . . . . . . . . . . . . . . . . . . . . 1254.58 Camshaft drive toothed belt: Check (4-cylinder petrol engine) . . . . . . . . . . . . . . . . . . . . . . 125

4.59 Toothed belt: Check for wear (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

4.60 Camshaft drive toothed belt: Check condition and tension (diesel engine code ALH withautomatic gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

4.61 Additional work on natural gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

4.62 Spark plugs: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

5 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1485.1 Exhaust emissions test for petrol engines without OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

5.2 Exhaust emissions test for petrol engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

5.3 Exhaust emissions test for diesel engines without OBD . . . . . . . . . . . . . . . . . . . . . . . . . . 174

5.4 Exhaust emissions test for diesel engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

6 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Bora 1999 , Bora Variant 1999 , Golf 1998 , Golf Variant 1998

Maintenance - Edition 05.2012

ii Contents

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