33

Work procedures
Driver's and passenger's airbag units,
visually checking
Driver's side airbag:
- Visually check airbag cover on steering wheel for signs of exterior damage.
WARNING!
The covers of the airbag units on the steering wheel, instrument panel, and
side airbags must not be covered or have any objects affixed to them.
Inform the customer once more about the importance of this point.
Do not apply any chemical treatment to airbag covers. Clean with dry or
water-moistened cloth only.

34

Front passenger's airbag:

- Visually check airbag cover on instrument panel for signs of exterior damage.
WARNING!
The covers of the airbag units on the steering wheel, instrument panel, and
side airbags must not be covered or have any objects affixed to them.
Inform the customer once more about the importance of this point.
Do not apply any chemical treatment to airbag covers. Clean with dry or
water-moistened cloth only.

35

On Board Diagnostic (OBD), checking

all systems
Check OBD Diagnostic Trouble Codes (DTC) in
two ways:
With V.A.G 1551 Scan Tool

Page 36

or with
Vehicle Diagnosis, Testing and Information
System VAS 5051 Page 38 .

36

On Board Diagnostic (OBD) Diagnostic

Trouble Codes (DTC), checking with V.A.G
1551 Scan Tool:
Special tools and equipment
V.A.G 1551 Scan Tool

V.A.G 1551/3 A adapter cable

37

Diagnostic Trouble Code (DTC), checking:

- Connect V.A.G 1551 Scan Tool

Page 15 .

- Start engine and run at idle.

- Switch on printer with printer button (indicator
light comes on).
V.A.G. On Board Diagnostic

HELP

Indicated on display

1 - Rapid data transfer*

- Press button 1 for to select "Rapid data transfer".

2 - Blink code output*

Rapid data transfer

HELP

Indicated on display

Input address word XX

- Press buttons 0 and 0 to select address word "Automatic test sequence".

Rapid data transfer

Indicated on display

00 - Automatic test sequence

- Confirm entry with Q-button. The V.A.G 1551 Scan Tool now sends all known
address words.
If the control module answers with its identification code, the display shows the
number of DTCs and or, if no DTC was found, the display will show"No DTC
found".
Possible DTCs that are stored for a system will be shown one after the other and

printed. After that the V.A.G 1551 sends the next address word.

38

V.A.G. On Board Diagnostic

HELP

The automatic test sequence is ended when the following is displayed:

1 - Rapid data transfer*

2 - Blink code output*

* appears alternately
- Switch ignition off.
If DTCs are found, a repair is necessary. Attach the DTC print-out to the repair
order.
Note:
The scan tool V.A.G 1551 may have to stay connected for the emission control
service.
Vehicle Diagnosis, Testing and Information System VAS 5051, checking DTC
memory for all systems:
Special tools and equipment
VAS 5051 Vehicle Diagnosis, Testing and Information System
VAS 5051/3 adapter cable

39

- Connect Vehicle Diagnosis, Testing and

Information System VAS 5051 Page 16 .
- Switch ignition on.
Indicated on display
Select function:
- On the display press button for "On Board Diagnostic" -arrow-.
Note:
If the display does not show the function:
Operating Manual for Vehicle Diagnosis, Testing and Information System VAS
5051.
Indicated on display
Select vehicle system:
- On display press on "00 - Check Diagnostic Trouble Code (DTC)" -arrow-.
VAS 5051 will send all known address words one after the other.
If one of the control modules answers with its identification code, the display will
show the number of DTCs or "0 DTCs recognized" will appear.

40

Possible DTCs of a system are shown one after

the other. The VAS 5051 will then show the next
address word.
The automatic test sequence is ended when this is displayed
- On display press button "Print" -1- and on print menu press "Screen Print".
The VAS 5051 will print out all DTCs or "0 DTC recognized". If a DTC was
recognized, a repair is necessary. Attach the print-out to the repair order.
- Press "Go to" button -2-.

Indicated on display
- Press "Exit" button -arrow-.
- In exit menu press "Exit" button.
- Switch ignition off and disconnect Data Link Connector (DLC).

41

Door check and securing bolts,

lubricating
- Lubricate door check at points shown -arrows-.
Lubricant: grease G 000 400

42

Power roof, checking function, cleaning

and lubricating guide rails
- Check function of power roof.
- Lubricate guide rails -arrows- with grease G 000 450 02.

43

Power windows, activating

Note:
After disconnecting and connecting the battery,
the up and down motion of the windows does not
function. Before delivery of the vehicle, the power
windows must be activated. After activation, the
battery must not be disconnected.
WARNING!
After disconnecting and connecting the
battery, the "pinch protection" is deactivated.
Damage and personal injury can result!
To activate the power windows:
- Completely close all windows and doors.
- Lock vehicle from the outside either from the
driver's or passenger's doors.
- Unlock vehicle.
- Again lock vehicle either from the driver's or
passenger's door while holding key in the locked
position for at least 1 second.

44

8-way memory seats, activating

Note:
After disconnecting and connecting the battery,
the memory system for the power seat
adjustment does not function. Before delivery of
the vehicle, the power seats must be activated
again. After activation, the battery must not be
disconnected.
To activate the power seats:
- Open driver's door.
- Switch ignition on.
- Move seat forward to stop and up.
- Move seat backrest forward to stop.

45

Clock, adjusting
Digital clock
Adjusting hours:
- Turn knob -1- counter-clockwise. The knob is located on the lower right side next
to the tachometer.
Slightly turning the knob once advances the clock by one hour. Turning and holding
the knob advances the hours continuously.
Adjusting minutes:
- Turn knob -1- clockwise.
Slightly turning the knob once advances the clock by one minute. Turning and
holding the knob advances the minutes continuously.
With knob -1- , the clock can be precisely adjusted to the second:
- Turn knob clockwise until the clock is one minute short of the exact time.
- Turn knob clockwise the moment the second hand of another correctly adjusted
watch reaches a full minute.

46

Analog clock
Adjust the clock as follows:
Note:
In the instrument cluster on the lower right next
to the tachometer is the adjustment knob. Pull
the knob to adjust the clock.
To adjust the clock one minute at a time:
- Briefly pull knob.
To move the pointer slowly and then gradually
faster:
- Pull knob and hold.

47

Climatronic, adjusting temperature to 22

C (72 F)
Note:
By adjusting the temperature to 22 C (72 F), a
comfortable climate is created for the vehicle's
interior.
- Switch ignition on.
- Check whether 22 C (72 F) was adjusted - 3- in the display.
If necessary, adjust the temperature as follows:
- Press knob -1- for automatic operation. In the display AUTO -2-will appear.
- By pressing knob -4- for "cooler" or button -5- for "warmer" adjust the
temperature to 22 C (72 F).

48

Radio anti-theft security code, inputting

"Premium III"
inputting

10.97 anti-theft security code,

The security code is "fixed", meaning the radio is

programmed by the radio manufacturer to accept
only one code. This code must be input during
the new vehicle delivery inspection, into newly
installed or existing units that have been
removed and reinstalled.
Prerequisites:
Obtain security code, either from code card or
from customer.
Fuse 37 OK (S 237 in wiring diagram)
Inputting code / cancelling electronic lock-up
- Switch on radio
"SAFE" appears in radio display
- Press "Seek" and "Scan" buttons simultaneously
until radio display indicates "1000".

Note:
Release the "Seek" and "Scan" buttons
immediately after "1000" appears in display. Do
Not continue to hold buttons down or press them
again. This may cause the radio to consider 1000
to be the input code number.

49

- Input the security code found on the radio card

using the station preset buttons on the radio.
Button "1" corresponds to the first number in the
security code, "2" the second and so on. Press
the applicable button repeatedly until the desired
number appears in the display (eg.: press button
"2" three times if the second number in the code
is 3).
Note:
For technical reasons, the first number in the
security code can only be a "1" or left blank. The
following three digits may be any number from 1
to 9.
- When the entire code has been input and
appears on the display, press "Seek" and "Scan"
buttons simultaneously.
The code is input properly when the display
indicates "SAFE" and then a radio frequency
(ready for use). When the radio is switched off
and the ignition key removed, a flashing LED on
the radio faceplate indicates the radio is security
protected.
Incorrect code number

If an incorrect code is entered, "SAFE" will

appear in the display (first blinking and then
continuous) and the radio will not function. The
entire coding procedure can only be repeated
one more time immediately (the number of
attempts is displayed).
If during the second attempt an incorrect code is
entered, the radio will lock-up for approximately
one hour. Leave radio switched on for 1 hour and
attempt coding again when the number of
attempts on display goes out (ensure proper
code is available).
Cycle: 2 attempts - 1 hour lock-up still applies.

50

"Premium IV" 10.97

code, inputting

08.99 anti-theft security

The security code is "fixed", meaning the radio is

programmed by the radio manufacturer to accept
only one code. This code must be input during
the new vehicle delivery inspection, into newly
installed or existing units that have been
removed and reinstalled.
Prerequisites:
Obtain security code, either from code card or
from customer.
Fuse 37 OK (S 237 in wiring diagram)
Inputting code / cancelling electronic lock-up
- Switch on radio
"SAFE" appears in radio display, followed by
"1000" approximately 3 seconds later.
-

Input the security code found on the radio card

using the station preset buttons on the radio.
Button "1" corresponds to the first number in the

security code, "2" the second and so on. Press

the applicable button repeatedly until the desired
number appears in the display (eg.: press button
"1" three times if the first number in the code is
3).
- When the entire code has been input and
appears on the display, press the right side of
the "Seek" button (">") for longer than 2 seconds
until an audible signal is heard.

51

The code is input properly when the display

indicates a radio frequency (ready for use).
When the radio is switched off and the ignition
key removed, a flashing LED on the radio
faceplate indicates the radio is security
protected.
Incorrect code number
If an incorrect code is entered, "SAFE" will
appear in the display (first blinking and then
continuous) and the radio will not function. The
entire coding procedure can only be repeated
one more time immediately (the number of
attempts is displayed).
If during the second attempt an incorrect code is
entered, the radio will lock-up for approximately
one hour. Leave key in ignition, radio switched
on for 1 hour and attempt coding again when the
number of attempts on display goes out (ensure
proper code is available).
Cycle: 2 attempts - 1 hour lock-up still applies.

52

"Premium V" (incl. "Monsoon") 08.99

theft security code, inputting

anti-

The security code is "fixed", meaning the radio is

programmed by the radio manufacturer to accept
only one code. This code must be input during
the new vehicle delivery inspection, into newly
installed or existing units that have been
removed and reinstalled.
Prerequisites:
Obtain security code, either from code card or
from customer.
Fuse 37 OK (S 237 in wiring diagram)
Inputting code / cancelling electronic lock-up
- Switch on radio
"SAFE" appears in radio display, followed by
"1000" approximately 3 seconds later.
-

Input the security code found on the radio card

using the station preset buttons on the radio.
Button "1" corresponds to the first number in the

security code, "2" the second and so on. Press

the applicable button repeatedly until the desired
number appears in the display (eg.: press button
"1" three times if the first number in the code is
3).
- When the entire code has been input and
appears on the display, press the right side of
the "Seek" button (">") for longer than 2 seconds
until an audible signal is heard.

53

The code is input properly when the display

indicates "LSM" (ready for use). When the radio
is switched off and the ignition key removed, a
flashing LED on the radio faceplate indicates the
radio is security protected.
Incorrect code number
If an incorrect code is entered, "SAFE" will
appear in the display (first blinking and then
continuous) and the radio will not function. The
entire coding procedure can only be repeated
one more time immediately (the number of
attempts is displayed).
If during the second attempt an incorrect code is
entered, the radio will lock-up for approximately
one hour. Leave key in ignition, radio switched
on for 1 hour and attempt coding again when the
number of attempts on display goes out (ensure
proper code is available).
Cycle: 2 attempts - 1 hour lock-up still applies.

54

Windshield wiper and washer system,

checking function
Note:
When checking the function, if the wiper blades
skip or cause noise, check the contact angle of
the blades Page 62 .
Wiper/washer system, checking or toppingup antifreeze
Special tools and equipment
T10007 Refractometer
Note:
Read the exact value for the following test at the light/dark line. To better recognize
the light/dark line, apply a drop of water with the pipette (dropping glass) onto the
glass. The light/dark line should now be clearly visible at the "WATERLINE".
- Check concentration of antifreeze with refractometer T10007 (see operating
instructions).
Scale -1- of refractometer applies to factory-filled antifreeze G 052 164.
Scale -2- applies to commercially available anti-freeze as well as to a mixture of
commercial anti-freeze and G 052 164.

55

Mixing ratio:
Anti-freeze protection to Anti-freeze

Water

G 052 164
-18 C (0 F)

1 Part

3 Parts

-23 C (-9 F)

1 Part

2 Parts

-38 C (-36 F)

1 Part

1 Part

The fluid reservoir must be filled to the top.

Use washer fluid VW G 052 164or equivalent all
year round.
All vehicles equipped with fan spray jets must
be filled with VW G 052 164 or equivalent.
These fluids have a low viscosity below freezing
which helps to prevent the complicated sprayer
system to be clogged with crystallized washer
fluid. This would interfere with the fan-effect of
the spray jets.
Also during the warm season fill the reservoir
with VW G 052 164 or equivalent. The strong
cleaning effect cleans the wax-like and oily film
from the window glass.

The anti-freeze protection must be provided for

about -15 C (9 F). For arctic climates the
protection must be for about -35 C (-31 F).

56

Windshield washer system, checking and

adjusting spray jets
Note:
Do not clean spray jets against the spray flow by
blowing air into the jets from the front.
Spray jets without pre-adjustment
The spray jets are pre-adjusted and have no
height adjustment.
If both spray fields are not at the same level:
- Remove spray jet with lower spray field and replace it with one that has height
adjustment (repair procedure).
The spray jets ar pre-adjusted, however allow slight compensation of differences in
height.
If the spray fields are not at the same level, correct the spray filed up or down as
follows:
Note:
Two different spray jet types were used in the production.

57

- Turn eccentric at spray jets in direction of arrow with a screwdriver to adjust

spray upward.
- Turn screwdriver against direction of the arrow to adjust spray downward.
or

- Adjust spray at adjustment -1- by hand either up or down.

58

Rear window (Wagon)

Special tools and equipment
3125 A Adjustment tool for spray jet adjustment
Notes:
If the washer spray is uneven or if the jet cannot be adjusted to the desired
area, replace the spray jet (repair procedure).
Never use a needle or similar tool because the water channel of the spray jet
can be damaged.
- Check adjustment of spray jet:
Spray jet specification for rear window:
The spray must hit the middle of the wipe area.
- If necessary adjust spray jet with special tool 3125 A.

59

Headlight washer system, checking and

adjusting spray jets
Special tools and equipment
3019 A Adjustment device
Vehicles before production date 09.00

Spray jet adjustment for left headlight. Adjustment for right headlight is identical but
reversed.
Spray jets, measurements
a - 60 mm
b - 205 mm
c - 75 mm
d - 80 mm
If necessary, adjust spray jets as follows:

60

- Pull spray jets out to stop and adjust spray to the applicable points using
adjustment tool 3019 A.
Note:
If the spray is uneven or if it cannot be adjusted to specifications, the spray jet must
be replaced (repair procedure).
Vehicles after production date 10.00

Spray jet adjustment for left headlight. Adjustment for right headlight is identical but
reversed
Spray jets, measurements
a - 110 mm
b - 75 mm
c - 230 mm
d - 50 mm
If necessary, adjust spray jets as follows:

61

- Pull spray jets out to stop and adjust spray to applicable points using adjustment
tool 3019 A.
Note:
If the spray is uneven or if it cannot be adjusted to specifications, the spray jet must
be replaced (repair procedure).

62

Wiper blades, checking park position,

adjusting contact angle
Wiper blade park position, checking and
adjusting
Special tools and equipment
V.A.G 1331 Torque wrench (5 to 50 Nm)

63

Windshield
Driver's side
Distance -A- between blade rubber insert and windshield lower edge must be 20
mm .
- If necessary adjust park position by resetting wiper arm.
Tightening torque for wiper blade: 20 Nm (15 ft lb)

Passenger's side:
Distance -A- between blade rubber insert and windshield lower edge must be 20
mm
- If necessary adjust park position by resetting wiper arm.
Tightening torque for wiper blade: 20 Nm (15 ft lb)

64

Rear window (wagon):

Distance -a- between blade rubber insert and window lower edge must be 25 mm .
- f necessary adjust park position by resetting wiper arm.
Tightening torque for wiper blade: 15 Nm (11 ft lb)
Wiper blade contact angle, checking and adjusting
Note:
Check contact angle only when wiper blades are noisy or skip.
Special tools and equipment
3358 B Adjustment tool for wiper blades

65

- Run wiper blades to park position.

- Remove wiper blade.
- Insert wiper arm -2- in adjustment tool 3358 B and lock with locking screw -3-.
- Check contact angle.
Contact angle (specified values) for
Left-hand drive vehicles Right-hand drive vehicles
Driver's side

-3

+3

Passenger's side

-5

+5

Rear window

Tolerance

66

If necessary adjust contact angle to specified

value as follows:
- Apply 24 mm open end wrench -1-on adjustment device and set wiper arm -2- to
specified value -arrows-.
- Release wiper arm -2- from adjustment fixture and again tighten lock screw -3-.
- Compare adjusted value with specified value. If necessary repeat procedure until
specified value is reached.
- Remove adjustment fixture and reinstall wiper blade.
- Check wiper blade operation.

67

Wheel bolts, checking torque

Special tools and equipment
V.A.G 1332 Torque wrench (40 - 200 Nm)
Wheel cover, removing
The removal hook is part of the vehicle's tool kit.
Wheel bolts
The adapter for loosening and tightening of anti-theft wheel bolts is part of the
vehicle's tool kit.
Note:
Be sure to tighten wheel bolts dioganally an alternately to the following specified
torque:
Tightening torque: 120 Nm (88 ft lb)
- After completion of work, return adapter and hook for wheel cover to vehicle tool
kit.
Full wheel cover, installing
- Install full wheel cover with tire valve positioned in the cut-out -arrow-.

68

Tire condition, inflation pressure and

tread depth, checking
Notes:
For safety reasons, all tires on the vehicle
should be of the same make and tread design.
For vehicles with all-wheel drive, the tires on
the vehicle must be of the same make and
tread design, otherwise the center differential
may be damaged.
Condition, checking
Pre-delivery inspection:
- Check tire tread surface and side walls for
damage. If necessary remove imbedded foreign
objects.
Note:
When detecting damage it must be determined
whether the tire must be replaced.
Inspection Service:

- Check tire tread and side walls for damage, If

necessary remove imbedded foreign objects.
- Check tire treads for cupping, feathering, onesided tread wear, porous side walls, cracks,
cuts, and rim damage.
Note:
Report any damage to customer and mark repair
order accordingly.

69

Tread, checking
From the wear pattern of the tread it is possible
to determine whether toe or camber needs to be
checked.
Feathered edges of the treads may indicate
faulty toe adjustment.
One-sided tread wear is mostly caused by
faulty camber.
If such wear patterns are found, determine the
causes by checking the wheel alignment (repair
procedure).
Tread depth (including spare wheel),
checking
- Check tread depth.
Minimum tread depth: 1.6 mm (1/16 in.)
Notes:
This specification may be different for some
states or provinces. Always follow local or
federal regulations.

The minimum tread depth has been reached

when the depth of 1,6 mm (1/16 in.) can be
measured at several points of the wheel
circumference or when the tread has worn
down to the wear indicators located at several
points on the circumference of the tire.
If the tread wear is close to the wear limits,
inform customer and note findings on the repair
order.

70

Tire pressure (including spare tire), checking

and correcting
Special tools and equipment
Tire pressure gauge
Notes:
Tire specifications as well as inflation pressure
specifications are listed on the tire label located
inside the fuel filler flap.
The inflation pressure specifications refer to the
air pressure of cold tires. Do not reduce tire
pressure when the tires are warm.

71

Transportation protection devices,

removing from front axle springs (if
installed)
For some models the front suspension struts have transportation protection devices
installed. Such vehicles are provided with a tag attached to the rear view mirror arrow-.
Note:
The transportation devices are designed to prevent damage to the vehicle when
driven onto railroad cars or road transport vehicles.
WARNING!
The transportation protection devices must be removed before delivery of the
vehicle. The tag attached to the inside rear view mirror is a reminder of this
important procedure.
Note:
It is not necessary to remove the wheels.
- Release tension of strut springs by lifting vehicle with lift.
- Remove transportation protection devices from struts.

72

Engine oil level, checking

After stopping the engine, wait for at least 3
minutes for the oil to flow back into the oil pan.
- Pull out oil dipstick and wipe with clean rag.
Replace dipstick and push down to stop.
- Pull out dipstick again and read oil level:
If the dipstick appears as illustrated:
Area a- Oil must be topped up. It is sufficient when oil level is within area -bafter topping up.
Area b - Oil does not have tobe topped up.
Area c - Oil must not be topped up.

73

Note:
If oil level is above area -c- , the catalytic converter can be damaged.

If the dipstick appears as illustrated:

The oil level must be between min.- and max.-markings Be sure that the oil level is
not above the max.-mark.
Notes:
If the oil level is above the max. mark, the catalytic converter can be damaged.
If the oil level is below the min.-mark, fill up with oil according to specifications
Page 77 .

74

Engine oil, draining or siphoning; oil

filter, removing and installing
Special tools and equipment
V.A.G 1358 A Used oil siphoning equipment

V.A.G 1331 Torque wrench 5 to 50 Nm (44 in. lb to 37 ft lb)

75

Notes:
If the oil is drained and not siphoned, replace
the gasket on the oil drain plug to prevent leaks
(See Parts Catalog for correct application. In
some cases, seal and drain plug are combined;
do not interchange with separate seal and drain
plug).
Don't pollute. Dispose of old oil properly.
Turbo engines: After replacing the oil and filter,
do the following after the first engine start:
- While oil pressure warning light in instrument
cluster is on, run engine at idle speed only. Do
not accelerate. Acceleration bursts can either
damage turbocharger or cause it to fail
completely.
Only when the oil pressure warning light has
gone out, full oil pressure has been reached and
accelerating the engine is allowed.
Oil Capacities up to MY 2000
From my 2001

Fluid Capacity Chart

Oil quantity with oil filter change:

Engine code AUG, ATW

AHA

AWM, AEB

ATQ

Oil capacity

3.9 Liters

With filter

(4.3 qt)

5.0 Liters
(5.7 qt)

76

- Remove sealing ring from oil drain plug, if

necessary cut with side cutter.
- Drain engine oil.
- Install new seal on oil drain plug and tighten plug
by hand.
Torque specifications for oil drain plug -arrow-:
Note:
Be mindful that the following torque specifications are not exceeded. A torque figure
that is too high may lead to leaks or even damage the oil pan.
4-cyl. engines: 30 Nm (22 ft lb)
6-cyl. engine: 30 Nm (22 ft lb)
Replace if leaking. See Parts Catalog for correct application. In some cases, seal
and drain plug are combined; do not interchange with separate seal and drain plug.

77

Because of the positive properties, only use the

following oils:
Oil specifications for gasoline engines:
Multi-viscosity energy conserving oils such as
VW 500 00, or VW 502 00
Multi-viscosity oil VW 501 01
Multi viscosity oils according to API-SJor APISL, SAE 5W-40 or SAE 10W-40
Note:
For vehicles after m. y. 1999, engine oil VW
503 00 must not be used, otherwise the engine
may be damaged.

78

Engine oil properties

Multi-viscosity oils VW 501 01 and 505 00
have the following properties:
For all-year use in temperate climates
Excellent cleaning ability
Safe lubrication during all engine temperatures
and load conditions
High service life
Multi-viscosity energy conserving oil VW 501
00 has the additional properties:
For all-year use in almost all climates
Little energy loss through friction
Best possible starting ability, also at very low
temperatures.

79

Multi-viscosity energy conserving oil VW 502

00:
This engine oil specifically formulated for
gasoline engines fulfilling specifications for VW
501 01 as well as 500 00 provides for the
following additional advantages:
This oil is especially suited for extreme driving
conditions, such as difficult road conditions,
trailer towing, driving predominately in
mountainous regions and in hot climates.
Notes:
Single viscosity oils are not normally suitable for
year-round driving because of their limited
viscosity range. Therefore such oil must only be
used in extreme climate zones.
When using multi-viscosity oils with the
specification SAE 5 W-30, avoid prolonged
driving with high engine rpm and prolonged
high loads. This restriction does not apply to
energy conserving oils.
- After filling the engine with the appropriate
amount of oil, wait for at least 3 minutes before
checking the oil level with the oil dipstick.

- Remove oil dipstick, wipe with clean rag and

insert dipstick again to stop.

80

Note:
Don't pollute! Return used oil to collection
centers.
- Pull out oil dipstick again and read oil level.
For illustrated dipstick:
Area a- Oil must be topped up. It is sufficient when oil level is within area -bafter topping up.
Area b - Oil does not have to be topped up.
Area c - Oil must not be topped up.

Note:
If oil level is above area -c- , the catalytic converter may be damaged.
If the dipstick appears as illustrated:
The oil level must be within the area between min. and max.-marks. The oil level
must not go over the max.-mark.
Note:
If the oil level is above the max. mark, the catalytic converter may be damaged.

81

Oil filter, removing and installing

Special tools and equipment
V.A.G 1331 Torque wrench 5 to 50 Nm (44 in. lb to 37 ft lb)
Oil filter wrench
or
Oil filter strap wrench
Shop rag
4-cyl and 6-cyl engines:
- Cover hole -1- of engine/transmission carrier with rag. This prevents old oil from
entering carrier.
Note:
Don't pollute! Return used oil to collection centers.

82

Engine and components in engine

compartment (from above and below),
visually checking for leaks and damage
- Check engine and components in engine
compartment for leaks and damage.
- Check lines, hoses and connections for leaks,
chafing, porosity and breaks of:
Fuel system
Cooling and heating systems
Brake system
Notes:
Report all faults for subsequent repairs.
For fluids that are missing for reasons other
than normal depletion, determine cause and
repair (repair procedure).

83

V-belt, removing and installing (4-cyl.

engine)
Special tools and equipment
3204 drift

V.A.G 1331 Torque wrench 5 to 50 Nm (44 in. lb to 37 ft lb)

Drift 5 mm (0.19 in.) dia.

84

Removing
- Set lock carrier to service position:

Repair Manual Body Exterior, Repair Group

50
- Mark running direction of belt if it is to be used
again.
Note:
Be sure to install the belt in the correct running
direction. If installed against the running
direction, the belt will be damaged.
- To slacken belt, move wrench in direction of arrow.
- Lock tensioning device using drift 3204.

85

- Remove ribbed belt.

- Remove fan from viscous fan pulley.
- Lock belt pulley to viscous fan pulley using drift -1-.
- Remove bolt for viscous fan pulley with 8 mm socket-head wrench -2- and
remove viscous fan pulley together with belt pulley.
- Mark installation position of two-part belt pulley in relation to cooling pump.

- Lock belt pulley of power steering pump with drift.

- Remove two-part belt pulley of coolant pump and remove belt.
Installing
- Attach 2-part belt pulley to coolant pump and install new belt between coolant
pump and power steering pump.
- Tighten belt pulley evenly until belt has moved to outside of its running surface. If
necessary turn power steering pulley or coolant pump pulley.

86

- Lock power steering pump with drift.

- Tighten belt pulley with 25 Nm (18 ft lb) to
coolant pump.
Note:
Adding shims to tighten belt tension is not
necessary.
- Push on viscous fan and install ribbed belt on
fan.
- Tighten belt pulley to viscous fan pulley with 30
Nm (22 ft lb).
- Tighten viscous fan pulley to 45 Nm (33 ft lb).
- Install ribbed belt.
- Tension belt by removing pin 3204.
Note:
When installing belt be sure it fits properly in pulleys.

- Start engine and check belt performance.

87

Ribbed belt, checking

- Turn engine at vibration damper/ belt pulley -2- with socket wrench .
- Check belt -1- with raised vehicle from below for:
Belt substrata breaks or cracks
Separation (cover layer, belt cords)
Breaks at lower layer
Fraying of cords
Wear at flanks (material wear, frayed flanks, hardening or glazing of flanks,
surface cracks)
Oil or grease contamination
Note:
Replace the belt if any damage is found. Replacing the belt is a repair procedure.

88

Axle boots, checking

- Visually check outside axle boots -1- and outside axle boots -2- for leaks and
damage.
Note:
For vehicles with all-wheel-drive also check boots at rear axle.

89

Manual transmission and final drive,

checking oil level
Special tools and equipment
3357 socket wrench (only for 012/01W transmission)

V.A.G 1331 Torque wrench 5 to 50 Nm (44 in. lb to 37 ft lb))

90

Transmission code is located on vehicle data

sticker Page 19 .
5-Gear manual transmission 012/01W/01A
- Remove oil plug with socket wrench 3357.
- Check oil level: Oil level must be at lower edge of oil plug hole.
- If necessary top up with transmission oil G 052 911 A SAE 75W90 (synthetic oil)
to lower edge of oil filler hole.
- Reinstall oil plug and tighten to 25 Nm (18 ft lb).

91

Automatic transmission final drive oil

level, checking
Special tools and equipment
V.A.G 1331 Torque wrench (5 to 50 Nm)
The transmission code is listed on the vehicle data sticker

Page 19 .

Automatic transmission 01V

- Remove oil filler plug -arrow-.

- Replace seal of oil filler plug.
- Check oil level: Oil level must be at lower edge of oil filler hole.
- If necessary top up with SAE 75 W 90 (synthetic).
- Tighten oil filler plug to 30 Nm (22 ft lb).

92

Brake system, checking

Check components for leaks and damage:
Main brake cylinder
Brake booster (for ABS check hydraulic unit)
Brake pressure regulator
Calipers
- Check that brake hoses are not twisted.
- Turn steering to left stop and to right stop.
During this operation no brake hose must touch
any vehicle components.
- Check brake hoses for porosity and cracks.
- Check brake hoses for chafing.
- Check all brake connections for tight fit, leaks or
corrosion.

WARNING!
Eliminate any faults (repair procedure).

93

Brake pads (front and rear), checking

thickness
Special tools and equipment
3314 Pliers

V.A.G 1332 Torque wrench 40 to 200 Nm (30 to 148 ft lb)

Flashlight and mirror

94

Remove full wheel cover

The removal hook is part of the vehicle's tool kit.
Wheel bolts
The adapter for loosening and tightening theft
protection wheel bolts is part of the vehicle's tool
kit
Brake pads front:
To better check thickness of brake pads, remove
wheel on driver's side.
- If necessary, remove wheel lug covers with pliers 3314 or remove full wheel
cover.
- Mark installation position of wheel in relation to brake rotor.
- Remove wheel lug bolts and remove wheel.
- Measure thickness of inner and outer brake pad.

95

a - Pad thickness including backing plate

Wear limit 7 mm (0.27 in.)
With pad thickness (including backing plate) of 7 mm (0.27 in.), the bake pads have
reached their wear limit and must be replaced (repair procedure). Be sure to notify
customer and mark findings on repair order.
- Install wheel in previously marked position.
- Tighten wheel bolts dioganally and alternately to:
Tightening torque: 120 Nm (89 ft lb)
- After completing work store tools in vehicle tool kit.
- If necessary install wheel bolt caps.
Full wheel cover, installing
- Install wheel cover with opening -arrow- lining up with tire valve.

96

Brake pads, rear:

- If necessary remove full wheel cover.
- Using a flashlight and looking through opening,
check brake pads.
- Check thickness of outer pads visually.
- With flashlight light up inner brake pad and position mirror.
- Check thickness of inner pads visually.
a - Pad thickness including backing plate;
Wear limit 7 mm (0.27 in.)
With pad thickness (including backing plate) of 7 mm (0.27 in.), the bake pads have
reached their wear limit and must be replaced (repair procedure). Be sure to notify
customer and mark findings on repair order.
- If necessary install full wheel covers

Page 95 .

97

Underbody sealant, checking

When checking the underbody sealant also
check wheel wells and sill panels.
Note:
Any damage found must be corrected to prevent
corrosion (repair procedure).

98

Tie rod ends, checking

- With vehicle raised (wheels off ground) check tie
rods by moving tie rods and wheels. There must
be no play.
- Check attachments
- Check upper control arm boots -1- and tie rod boots -2- for damage and proper
seating.

99

Control arm joints, checking

- Check boots -arrows- for damage and leaks.

100

Engine coolant level and anti-freeze,

checking
Note:
All engine coolant systems are filled with G 12
according to TL VW 774 D. Be sure to only use
G 12 (color red) when topping up.
CAUTION!
Engine coolant -G12- must not be mixed with
other coolant anti-freeze. Mixing with other
coolants can cause serious engine damage.
When the coolant has been mixed (color:
brown), it must be changed (repair
procedure).
Engine coolant level, checking
- Check coolant level at coolant expansion tank
when engine is cold.
Pre-delivery inspection: engine coolant level must be at max. mark
Inspection Service: Coolant level must be between min.- and max. -marks

- If coolant level is too low, top up according to mixing ratio.

Note:
If coolant loss is not caused by normal evaporation, check cause and repair (repair
procedure).

101

Mixture ratios:
Frost protection G 12 antifreeze
to
amount

Water

-25 C (-13 F)

approx.. 40%

approx.
60%

-35 C (-31 F)

approx. 50%

approx.
50%

-40 C (-40 F)

approx. 60%

approx.
40%

Notes:
G12 coolant additive according to TL VW 774 D
prevents frost and corrosion damage, scaling
and also raises the boiling point of the coolant.
For this reason the system must be filled with
G12 coolant additive all year.
Especially in countries with tropical climates or
when vehicle is driven under heavy load, the
coolant improves the engine reliability by its
increased boiling point.

The coolant concentration must not be reduced

by adding water, even during the warmer

season. The anti-freeze ratio must be at least

40% .

102

Mixture ratio, checking

Special tools and equipment
T10007 Refractometer
Note:
Read the exact value for the following test at the "light/dark" line. To see the
light/dark line, apply a little water using the drop glass on the glass. The light/dark
line should now be clearly visible at the "WATERLINE".
- Check mixture ratio with refractometer T10007 (see user instructions)

Scale -1- of refractor applies to coolant additive G 12 according to TL VW 774 D

and -G 11- according to TL VW 774 C.
Scale -2- refers to coolant additive G 13.
Notes:
Coolant additive G 13 is presently used only in vehicles of model "L 80".
Anti-freeze protection must be for approx. -25 C (-13 F). In cold climates the
protection must be for about -35 C (-31 F).
If climate conditions make greater anti-freeze protection necessary, the amount
of G 12 can be increased up to 60 % (anti-freeze protection to not more than. 40 C (-40 F). Adding more anti-freeze reduces the protection again and also

reduces the cooling protection.

103

- If anti-freeze ratio is too low, drain listed amount

and replace it with G 12.
Note:
Don't pollute! Dispose of used coolant according
to local regulations.
Mixing ratios
Anti-freeze to
C
Actual Specified

-5

-10

-15

Difference amount in liters.

(Drain this amount and
replace with G 12)
4-cyl

6-cyl

engine

engine

-25

3.5

5.0

-35

4.0

6.0

-25

3.0

4.5

-35

3.5

5.5

-25

2.0

3.5

-35

3.0

4.5

-25

1.5

2.5

-35

2.0

3.5

Continued on next page

104

Anti-freeze to
C
Actual Specified

Difference amount in liters.

(Drain this amount and
replace with G 12)
4-cyl

6-cyl

engine

engine

-25

1.0

1.5

-35

1.5

2.5

-25

-35

1.0

1.5

-30

-35

0.5

1.0

-35

-40

0.5

0.5

-20

- Check anti-freeze ratio once more after road

test.

105

Spark plugs, removing and installing

Special tools and equipment
3122 B Spark plug wrench

T10029 Removal/installation tool

106

V.A.G 1331 Torque wrench 5 to 50 Nm (44 in. lb to 37 ft lb)

- If covers for cylinder heads are installed, remove screws -arrows- and remove
covers upward.

107

- If spark plug connector is equipped with tool for removal of spark plug
connectors -arrow-, remove it.

- Remove spark plug connector -1- with tool -2- . If there is no tool, remove
connectors with removal/installation tool T10029.

108

- Remove spark plugs with spark plug wrench 3122 B.

Note:
Observe local regulations regarding disposal of spark plugs.
- Install new spark plugs with wrench 3122 B.
- Install spark plug connectors.
- Check ignition cables and connectors for proper connections.
- Install engine covers.

109

Dust and pollen filter element, replacing

Vehicles before production date 09.00
Filter is located on right side in plenum chamber under cover -arrow-.
Removing
- Remove bolt -1- and remove cover.

- Pull retainer -1- up.

- Push up filter and pull forward to remove.
Note:
Observe local regulations for disposal of filter elements.

110

Installing
Note:
When installing be sure that marking "TOPOBEN"on filter element points upward.
- Install new filter element -1- in bracket -2-.
- Push filter element under retainer -3- to stop.

- Push retainer -1- into spring clip -2-.

Note:
Both retainers hold the filter insert in the frame bracket.

111

- Install cover -arrow- with bolt -1-.

Vehicles after production date 10.00
Filter is located on right side in plenum chamber under cover -arrow-.
Removing

- Remove plenum cover seal -1- toward front.

- Carefully remove plenum chamber cover -2- upward.

112

- Pull up retainer -1- upward.

- Push filter element upward and pull out toward front.
Note:
Observe local disposal regulations of filter elements.
Installing

- Insert new filter element -1- into frame -2-.

Note:
When installing filter observe installation position.
- Insert retainer -3- and push down to stop.

113

- Install plenum chamber cover -2-.

- Push on seal -1- for plenum chamber cover.

114

Camshaft belt, checking (4-cyl. engine)

Camshaft belt condition, checking
- Open clamps of upper belt cover and remove
cover.
- Check condition of camshaft for:
Cracks
Separation of layers (belt body, cords)
Breaks at belt body
Fraying of belt cords
Surface cracks (plastic cover)
Traces of oil or grease
- Also check belt tensioner for wear or damage.

115

Note:
If belt damage is found, the camshaft belt must
be replaced to avoid serious engine damage.
Replacing the camshaft belt is a separate repair
procedure.
When checking belt condition, the following is especially important:
A - Cracks at the cover side
B - Chafing marks at the edges of the belt
C - Fraying
D - Cracks at the gear side
Camshaft belt, replacing
Repair Manual, Engine Mechanical, Repair Group 13

116

Air cleaner, cleaning housing and

replacing filter element
- Lift up cover -1- (if installed) and remove.
Note:
For some vehicles the cover -1- is bolted down.
- Remove air intake hose -2-.

- Remove screws -arrows- and remove heat shield.

Note:
The heat shield is not installed in all vehicles.

117

- Open clamps -1- .

- Release hose clamp -2- and remove air intake hose.
Note:
For some vehicle the air intake hose does not need to be removed.
- Lift up air cleaner housing upper part or lay aside.

- Remove old filter insert -1- .

Note:
Observe disposal regulations of filter elements.

118

Depending on the model, a screen -1- is installed in lower part close to the air
intake channel.
The purpose of the screen is to catch ice or snow during the cold season to prevent
clogging of the air cleaner element.
When the screen -1- becomes visible after removing the filter insert, do the
following:
- Remove bolt -2- .
- Remove screen -1- from guide and pull up.
- Brush screen and clean with compressed air.
- Insert screen, press down and secure with bolt.
Continuation (with or without screen):
- Clean air cleaner housing and install new filter element.
- Install upper air cleaner housing and secure with clamps -1- .
- If necessary install air intake hose and secure with hose clamp -2-.

119

- If applicable, install heat shield and secure with screws -arrows-.

- Install air intake hose -2-.

- If applicable, install cover -1-and secure in guides with either clamps or screws.

120

Automatic transmission, ATF level,

checking
Automatic transmission 01V ATF level,
checking
Transmission codes are listed on the vehicle
data sticker Page 19 .
Before checking ATF level, check ATF
temperature. There are two methods:
with V.A.G 1551 Scan tool

Page 121

or with
Vehicle Diagnosis, Testing and Information
System VAS 5051 Page 125 .
Check ATF level as follows:

121

ATF temperature of automatic transmission,

checking with V.A.G 1551 Scan Tool
Special tools and equipment
V.A.G 1551 Scan Tool

V.A.G 1551/3 A Adapter cable

122

V.A.G 1924 ATF Filling system

Checking requirements:
Transmission not in emergency running mode, ATF temperature not above
approx. 30 C (86 F)
Vehicle must be in level position.
Selector lever in "P"

- Attach ATF filling system V.A.G 1924 to vehicle.

- Connect V.A.G 1551 scan tool
- Start engine and let idle.

Page 15 .

123

On V.A.G 1551:
V.A.G. On Board Diagnostic

HELP

Indicated on display

1 - Rapid data transfer*

* Shown alternately

2 - Blink code output*

- Press button 1 for function"Rapid data transfer".

Rapid data transfer

HELP

Indicated on display

Input address word XX

- Press buttons 0 and 2 for "Transmission electronics".

Rapid data transfer

Indicated on display

02 Transmission electronics

- Press Q-button to confirm entry..

3B0927156S AG5 01V 1.85VT Rdw D63
Code 00003

WSC 00000

Control module does not answer! HELP

Indicated on display
Engine Control Module (ECM) identification, the code and dealer number are
shown on the V.A.G 1551 display.
Indicated on display
- By pressing the HELP-button a list of possible Diagnostic Trouble Codes (DTC)
can be printed out.
- After correcting DTCs, enter address word 02 again for transmission electronics
and confirm with Q-button.

124

3B0927156S AG5 01V 1.85VT Rdw D63

Code 00003

Indicated on display

WSC 00000

- Press

button.

- Raise vehicle.
- Place drip pan under transmission.
Rapid data transfer

HELP

Indicated on display

Select function XX

- Press buttons 0 and 8 to select "Read measured value block".

Rapid data transfer

Indicated on display

08 - Read measured value block

- Press Q-button to confirm entry..

Indicated on display

Read measured value block

Enter display group number XXX

- Press buttons 0; 0 and 4 to select "Display group number 004"

Read measured value block

Indicated on display

Enter display group number 004

- Press Q-button to confirm entry..

Read measured value block
300 C P 1000 0000

Indicated on display
The first display filed shows the ATF temperature.
- Bring ATF to checking temperature

Specified value: 35 to 45 C (95 to 113 F)

- Check ATF level

Page 129 .

125

Oil temperature of automatic transmission,

checking with Vehicle Diagnosis, Testing and
Information System VAS 5051
Special tools and equipment
VAS 5051 Vehicle Diagnosis, Testing and Information System
VAS 5051/3 Adapter cable

V.A.G 1924 ATF Filling system

126

Checking requirements
Transmission not in emergency running mode,
ATF temperature not above approx. 30 C (86
F)
Vehicle in level position
Selector lever in "P"
- Attach ATF filling system V.A.G 1924 to vehicle.
- Connect Vehicle Diagnosis, Testing and Information System VAS 5051
16 .
- Start engine and let idle.

Page

Indicated on display
Select function
- On display press button "On Board Diagnostics" -arrow-.

127

Note:
If no functions are shown on display:

Operating instructions for Vehicle Diagnosis,

Testing and Information System VAS 5051.
Indicated on display
Select vehicle system
- On display press on button "02 - Transmission electronics" -arrow-.

Indicated on display
The control module identification and code are shown -arrow-.
- Raise vehicle.
- Place drip pan under transmission.

128

Indicated on display
- On display press button "08 - Read measured value block" -arrow-.

Indicated on display
- On display press on display group number block -arrow- 004 (with 004 "Display
group number 004"is selected).
- On display group number block confirm entry by pressing Q-button.

129

Indicated on display
The display filed -1- shows the ATF temperature.
- Bring ATF to checking temperature
Specified value: 35 to 45 C (95 to 113 F)
Continue with test only when required temperature is reached.
- Check ATF level.
ATF level, checking
Special tools and equipment
V.A.G 1332 Torque wrench 40 - 200 Nm (30 to 148 ft lb)

130

Test temperature: 35 C to 45 C (95 to 113

F)
- Remove plug -arrow-to check ATF level in oil pan.

ATF in the over-flow tube 2- will run out.

If ATF drips from plug hole:
No ATF needs to be added.
- Install plug for ATF check with new seal and tighten plug to 80 Nm (59 ft lb). This
ends the ATF level check.
- End output at 1551 or 5051 and disconnect Data Link Connector (DLC).

131

If ATF runs out of plug hole from the overflow

pipe only:
Top up ATF
- Insert filler hose of 1924 into opening -arrow- of cap. Do not push cap up.

- With V.A.G 1924 -arrow- fill ATF until ATF drip from check hole.
Note:
Too much or too little ATF affects the function of the transmission.

132

- Install plug for ATF check with new seal and tighten to 80 Nm (59 ft lb).
- End output with 1551 or 5051 and disconnect Data Link Connector (DLC).

133

Power steering fluid level, checking

With fluid cold:
- With engine not running, move front wheels in
straight-ahead position.
- Remove reservoir cap -arrow- with dipstick.
- Clean dipstick with clean cloth.
- Screw cap on hand-tight and remove again.
Note:
Screw cap fully in to get an accurate fluid level reading.

- Fluid level must be in area of MIN mark (up to 2 mm above or below mark).
Notes:
If fluid level is above the mark, some fluid must be siphoned off.
If the fluid level is below the specified level, check the hydraulic system for leaks
(repair procedure). It is not sufficient just to add fluid.
If no leaks are detected, top up with hydraulic fluid G 002 000.

134

- Reinstall cap and tighten by hand.

Hydraulic fluid at operating temperature from
about 50 C (122 F):
- Start engine and move front wheels into straightahead position
- Remove reservoir cap -arrow- with dipstick.
- Clean dipstick with clean cloth.
- Screw cap on hand-tight and remove again.
Note:
Screw cap fully in to get an accurate fluid level reading.

- Check fluid level. I must be between MIN and MAX markings.

Notes:
If the fluid level is above the MAX mark, siphon fluid off.
If the fluid level is below the MIN mark, check the hydraulic system for leaks
(repair procedure). It is not sufficient to simply fill the system with hydraulic fluid.
If no leaks are found, top up with-hydraulic fluid G 002 000.

- Install reservoir cover and tighten by hand.

135

Brake fluid, changing

Notes:
When changing brake fluid use only brake filler
and bleeder unit VAS 5234.
Special tools and equipment
VAS 5234 brake filling and bleeding equipment (for all vehicles)
Only use new brake fluid conforming with US Standard FMVSS 116 DOT 4.

136

WARNING!
Do not let brake fluid come in contact with
fluids containing mineral oil (oil, gasoline,
cleaning fluid). Mineral oil will damage seals
in the brake system which may cause brake
failure.
Brake fluid is poisonous. Do not ingest brake
fluid. Wash thoroughly with soap and water if
brake fluid comes in contact with skin.
CAUTION!
Do not let brake fluid come in contact with
paint to prevent damage.
Brake fluid absorbs moisture from the
surrounding air and must always be stored in
air-tight containers.
Don't pollute. Follow local rules when
disposing of old brake fluid.

137

Vehicles up to m.y. 1999

Follow operator's instructions for VAS 5234.
- Remove cap -1- from brake fluid reservoir.

- Using suction hose -1- from VAS 5234 remove as much brake fluid from the
reservoir as possible.
Note:
Note that after extracting brake fluid, no brake fluid runs back through the screen.
The brake fluid level must be at the underside of the screen.

138

Vehicles from m.y. 2000

Follow operator's instructions for VAS 5234!
For vehicles with ABS/EDL/ASR/ESP please
observe the following:
CAUTION!
When changing brake fluid using VAS 5234
maintain a fill pressure of 2 bar
Be sure to maintain a minimum system
pressure of 2 bar
Set brake fluid pressure on VAS 5234 to 2 bar
and follow operating instructions.
- Remove cap -1- from brake fluid reservoir.

139

- Remove cap -arrow- of brake fluid reservoir by turning.

- Connect suction hose of VAS 5234 to tube -1- of brake fluid reservoir.
- With suction hose of VAS 5234, extract as much brake fluid as possible from
reservoir.
- Remove suction hose.
- Connect suction hose of VAS 5234 to tube -2- of brake fluid reservoir.
- With suction hose of VAS 5234, extract as much brake fluid as possible from
reservoir.
- Remove suction hose.
- Reinstall cap in brake fluid reservoir.

140

Continued for all vehicles:

CAUTION!
Don't pollute. Follow local rules when
disposing of old (used) brake fluid.
- Install adapter -1- on brake fluid reservoir.

- Connect filler hose -1- of VAS 5234 to adapter.

141

Vehicles with manual transmission:

- Remove cap off bleeder screw for clutch slave
cylinder.
- Attach bleeder hose -A- of bleeder bottle to bleeder screw of clutch slave
cylinder -arrow-. Open bleeder screw and let approx. 0,1 liter flow out. Close
bleeder screw and reinstall cap.
- Activate clutch pedal several times.
Continued for all vehicles:
- Remove caps for bleeder screws at all brake calipers.

- Starting with left rear, attach bleeder hose -1- of bleeder bottle to bleeder screw.
Open bleeder screw and let applicable amount of brake fluid flow out (see table
on next page). Close bleeder screw.
- Repeat procedure on other side at rear.

142

- At front right caliper, attach bleeder hose -1- of bleeder bottle. Open bleeder
screw and let applicable amount of brake fluid flow out (see following table).
Close bleeder screw.
- Repeat procedure on the other side at front.
Table: Sequence and brake fluid amount
Sequence:

Brake fluid that must flow from caliper

Brake caliper

right rear

left rear

right front

left front

Total amount1)

Up to m.y. 1999

From m.y. 2000

0.4 to 0.5 liter

0.2 liter

(0.4 to 0.5 qt)

(0.21 qt)

0.4 to 0.5 liter

0.2 liter

(0.4 to 0.5 qt)

(0.21 qt)

0.4 to 0.5 liter

0.2 liter

(0.4 to 0.5 qt)

(0.21 qt)

0.4 to 0.5 Liter

0.2 liter

(0.4 to 0.5 qt)

(0.21 qt)

2 liter

1 liter

(2.1 qt)
1)

(1.05 qt)

Including suctioned-off brake fluid from brake fluid reservoir and change quantity
from clutch slave cylinder.

143

- Re-install caps on bleeder screws on calipers.

- Set filling lever of VAS 5234 to position -B- (see
operators manual).
- Remove filling hose from adapter.
- Remove adapter from brake fluid reservoir.
- Check brake fluid level, correct if necessary.
- Install cap -1- of brake fluid reservoir.
- Remove brake pedal depressor.
- Check pedal pressure and free play.
Free play must not be more than 1/3 of brake pedal travel.

144

Brake fluid level (depending on brake

pad wear), checking
Only use new brake fluid conforming with US
Standard FMVSS 116 DOT 4.
WARNING!
Do not let brake fluid come in contact with
fluids containing mineral oil (oil, gasoline,
cleaning fluid). Mineral oil will damage seals
in the brake system which may cause brake
failure.
Brake fluid is poisonous. Do not ingest brake
fluid. Wash thoroughly with soap and water if
brake fluid comes in contact with skin.
CAUTION!
Do not let brake fluid come in contact with
paint to prevent damage.
Brake fluid absorbs moisture from the
surrounding air and must always be stored in
air-tight containers.

Don't pollute. Follow local rules when

disposing of old (used) brake fluid.

145

Pre-delivery inspection:
- For vehicles manufactured after 10.00, push battery cover to the left -arrowsand remove.

Through hole of battery cover and using flashlight, read brake fluid level in brake
fluid reservoir. At time of pre-delivery inspection, brake fluid level must be at MAX
mark.
Note:
To prevent the brake fluid from overflowing from the reservoir, the level must not
over the MAX mark.
Inspection Service:
Brake fluid level must always be evaluated depending on brake pad wear. During
operation of the vehicle, the brakes are automatically readjusted depending on
wear of the brake pads. Because of the adjustment, brake fluid level will be slightly
lower as a result.

146

With brake fluid at MIN mark or slightly above,

topping up brake fluid is not necessary when
wear limit of brake pads has been almost
reached.
When brake pads are new or if there is still
enough brake lining left, the brake fluid level
must be between MIN and MAX marks.
If brake fluid level is below MIN mark, check
brake system (repair procedure), before adding
brake fluid.

147

Battery connections, checking

Special tools and equipment
V.A.G 1331 Torque wrench 5 to 50 Nm (44 in. lb to 30 ft lbs)
Note:
Tight battery connections assure trouble-free battery function and long service life.

- Push battery cover to left -arrows- and lift cover off.

148

- By manually moving battery plus (B+) cable -1- and ground (GND) cable -2check whether battery connections -3- and -4- are tight.
WARNING!
If plus (B+) connection is loose: To prevent personal injury and battery
damage, disconnect ground (GND) cable first before attempting to remove or
tighten plus connection.
If battery plus (B+) connection is not tight:
Notes:
Before disconnecting battery, obtain radio anti-theft code.
When reconnecting battery, activate radio, adjust clock, activate power
windows, etc. (see repair manual or owner's manual).
- First disconnect ground (GND) cable connection -4- on battery.
- Tighten battery plus (B+) connection -3- with 5 Nm (44 in. lb).
- Reconnect ground connection -4- on battery and tighten to 5 Nm (44 in. lb).
If ground connection on battery is not tight:
- Tighten ground connection -4- on battery to 5 Nm (44 in. lb).

149

Battery, checking
Special tools and equipment
V.A.G 1331 Torque wrench 5 - 50 Nm (44 in. lb to 37 ft lb))

VAS 5033 Battery tester

or
VAS 5096 Battery tester
or
VAS 5097 Battery tester with printer

150

VAS 5045 battery filling bottle

Commercially available hydrometer

151

Pre-delivery inspection (battery with charge

indicator "magic eye")
Perform visual inspection Page 152 and
battery check using "magic eye" Page 153 .
Pre-delivery inspection (battery without
charge indicator"magic eye")
Perform visual inspection Page 152 and
battery load test
Page 154 .
Inspection Service (battery with charge
indicator"magic eye")
Perform visual inspection Page 152 and
battery load test with "magiceye" Page 153 .
Inspection Service (battery without charge
indicator"magic eye")
Perform visual inspection Page 152 and
electrolyte level check Page 157 . If distilled
water is added, also perform battery load test
Page 154 .

152

Visual check (all batteries)

- Check battery housing for damage.
If battery housing is damaged, electrolyte
(battery acid) can leak.
- Check battery pole (battery cable connections)
for damage.
If battery poles are damaged, the electrical
connection for the cable connections cannot be
assured. Such condition could cause cable burn
and damage to the electrical system.
- Check battery firm seating and attachment. Tighten bolt -arrow- at hold-down
bracket with 22 Nm (16 ft lb).
If battery is not firmly secured, the following danger exist:
Shortened service life of battery caused by vibration.
Damage to battery housing caused by hold-down bracket which may lead to
damage to the battery housing and electrolyte leaks resulting in extensive
damage.
Reduced crash safety.

153

Battery, checking (battery with charge

indicator"magic eye")
The "magic eye" provides information about the electrolyte level and state of the
battery charge.
- Before performing visual checks, carefully and slightly knock magic eye with
handle of a screwdriver.
Air bubbles that could affect the function of the magic eye are dispersed.
The color display of the magic eye will also be clearer.
Notes:
The "magic eye" can be at different locations on the battery.
Three color displays are possible:
Green:
Black

battery charge is OK.

no charge or too little charge (repair required)

No color or yellow
critical electrolyte level, distilled water needs to be added
Page 156 . After adding distilled water perform battery load test
Page
154 .

154

Note:
If the battery is older than 4 years and the magic
eye displays no color or yellow, the battery must
be replaced. Get customer OK first.
Battery load test
- Switch ignition off.
- Attach test lead tongs to battery poles.

Operator's guide of battery tester

The tongs must make good contact with battery
poles.
Load current depends on battery capacity and
must be adjusted on the tester.

Operating instructions for battery tester.

- Perform battery load test according to operating
instructions of battery tester and compare test

result with table.

155

Table:
Battery tester
display

Pre-delivery
inspection

Inspection
Service

battery very
good

battery OK

battery OK

battery good

recharge battery

battery OK

1)

battery poor

replace battery

replace
battery2)

battery faulty

replace battery

replace
battery2)

1)

After recharging the battery, again perform a

battery load test. If after recharging the battery
the result is again "battery good", replace
battery.
2)

Replace battery after getting OK from

customer.
Notes:
Regarding battery load test:
Because of the high load the battery is

subjected to during the load test, the battery

voltage is lowered.
If the battery is OK, the voltage only goes down
to the minimum voltage specification.
If the battery is faulty or not charged enough,
the battery voltage drops quickly below the
minimum voltage specification.
After the test, this low voltage remains steady
over a longer time before the voltage slowly
increases.

156

Filling with distilled water (battery with

charge indicator"magic eye")
To avoid contamination of the electrolyte - which
leads to accelerated self-discharging - use only
distilled water when the electrolyte level is too
low.
- Peel off foil over battery caps.
- Remove battery caps.
- Using battery filling bottle VAS 5045, fill with distilled water to max. marking.
Notes:
The design of the filler tube of battery filler bottle VAS 5045 prevents overfilling
of the battery cells. When the max. mark is reached, the flow of distilled water to
the cells is interrupted.
When the electrolyte level is too low (below the min. mark), the battery loses
capacity (loses performance) caused by drying of the cell plates. If the cell
plates are not covered by electrolyte, the plates and plate bridges start to
corrode causing the function of the battery to diminish. After a while the battery
does no longer function.
When the electrolyte level is too high (above the max. mark) the electrolyte may
leak out and cause damage to components in the engine compartment.
- Install battery caps.

157

Electrolyte level, checking (battery without

charge indicator "magic eye")
Markings -arrow- on battery housing
Note:
The correct electrolyte level is very important for long service life of the battery.

158

Electrolyte level too low

Notes:
When the electrolyte level is too low (below the
min. mark), the battery loses capacity (loses
performance) caused by drying of the cell
plates. If the cell plates are not covered by
electrolyte, the plates and plate bridges start to
corrode causing the function of the battery to
diminish. After a while the battery no longer
functions.
To avoid contamination of the electrolyte, use
only distilled water if it is necessary to increase
the level.
- Remove battery caps.
- With battery fill bottle VAS 5045 add distilled
water to bring level to the max. mark.
Note:
The design of the filler tube of battery filler bottle
VAS 5045 prevents overfilling of the battery cells.
When the max. mark is reached, the flow of
distilled water to the cells is interrupted.

- Install battery caps.

159

Electrolyte level too high

Note:
If the electrolyte level is too high (above the max.
mark),the electrolyte can leak out and cause
severe damage to components in the engine
compartment.
- Remove battery caps.
If the electrolyte level is too high (battery is
overfilled) and the electrolyte level is above the
inside electrolyte level mark (plastic bridge):
- Remove electrolyte with a hygrometer ( illustration) until level has reached
max. mark or plastic bridge.
Note:
Don't pollute! Dispose of electrolyte according to local regulations.
- Re-install battery caps.

160

Headlight adjustment, checking

Special tools and equipment
VAS 5107 Hella Universal Beamsetter IV Also,
see Instruction Manual for Hella Beamsetter
Series IV for additional instructions and
diagrams.)
Basically all procedures describing headlight
adjustments and checks apply for all countries,
however, check with local authorities for
adjustment requirements.
Requirements for checking and adjusting:
Tire pressure must be OK.
Headlight lenses must not be damaged or
dirty.
Reflectors and bulbs OK.
Vehicle must be properly loaded.

Vehicle must be loaded with one person on the

driver's seat, weighing 75 kg (165 lb), otherwise

vehicle must be empty (curb weight)
The curb weight is the weight of the vehicle
ready to be operated with filled fuel tank (at least
90 % filled), including the weight of all
equipment usually carried in the car such as
spare wheel, tools, car jack, fire extinguisher,
etc.

161

If the fuel tank is not at least 90% full, adjust the

weight as follows:
- Read fuel level from fuel gauge. Calculate
additionally needed weight using table. Place
extra weight in luggage compartment.
Tank filling table
Fuel level according to fuel Additional weight
gauge
in luggage
compartment
1/4

45 kg (99 lb)

1/2

30 kg (66 lb)

3/4

15 kg (33 lb)

full

Example:
If the fuel tank is half full, place a weight of 30 kg
(66 lb) in the luggage compartment.
Note:
For additional weight use containers filled with
water. A container filled with 5 liters(1.3 gal) of

water weighs approx. 5kg (11 lb).

- Move vehicle back and forth for 1 meter (3 to 4
feet) or bounce front and rear of vehicle several
times up and down to settle suspension.

162

- Position vehicle on a flat floor surface that meets following (ISO 10640)
specifications:
0.5 mm or less slant from front wheel to back wheel of Beamsetter -A-.
1 mm or less slant per meter for length of vehicle -B-.
- Clean headlight lenses.
- Adjust vehicle tire pressure to specifications.

163

Driver's side headlight, setting low beam

alignment
- Move Beamsetter into position in front of vehicle
so it is aligned with vehicle and Beamsetter box
is 30 to 70 cm (12 to 28 in.) from driver's side
headlight.
- Switch headlights ON in low beam position.
- Align Beamsetter box so it is centered on
headlight (align vertically then horizontally).
Notes:
Use arrows on Beamsetter box as a guide.
You may want to use a straight edge or tape
measure, because alignment must be within 3
cm (1.2 in.) of headlight center.
- Without moving Beamsetter, slide Broad-band
sight toward center of vehicle (Broad-band sight
can also be moved up and down for a better
position).

Use Broad-band sight to make final alignment of

Beamsetter box to vehicle by:
- Loosening hand-wheel that locks column in
place.
- Sighting down through slit in Broad-band sight
and rotating Beamsetter box and column until
two similar points on vehicle are aligned.

164

Note:
Try using corners of headlight housings or two
screws that are the same height and as far apart
as possible on the vehicle.
- Carefully tighten hand wheel without changing
Beamsetter position.
- Find correct State or Province Inclination %
specification for low beam adjustment (if there is
no local specification, use 0.7%).
Note:
DO NOT use inclination % molded into plastic of
headlight housing near headlight adjustment
screws; it is for Europe only!
Page 165 and
page
Page 167 for location of headlight
adjuster screws).
- Set Beamsetter "Scaled wheel" to proper low
beam inclination %.
- Adjust height (vertical) alignment first. Turn
headlight height adjuster screw to align upper
edge of flat portion of beam with center
horizontal line of grid on Beamsetter pattern

screen.

165

Headlights, adjusting (vehicles up to

production date 09.00)
Headlights, adjusting (vehicles from production
date10.00) Page 167
Note:
When adjusting the low beams, the high beams
are also automatically adjusted.
Headlight, (left):
1 - Side adjustment
2 - Height adjustment
The adjustment screws for the right headlight are in reversed position.
- Guide Phillips screwdriver or socket head wrench through hole in lock carrier.
- Turn adjustment screw -1- for side adjustment and screw -2- for height
adjustment until proper adjustment is made.
Notes:
Also check whether both headlights work properly when the dynamic headlight
adjustment is activated.
The adjustment of the fog lights is automatically done with the adjustment of the
headlights.

Auxiliary driving lights:

Service-installed driving lights must be adjusted according to the applicable
regulations.

166

Note:
VOL is correct beam pattern for both right and
left headlights.
- Adjust lateral (horizontal) alignment of driver's side headlight (if possible) so that
peak (highest point) of headlight beam pattern aligns with right edge of target
box of grid on pattern screen (it should match VOL pattern shown on Beamsetter
box).
Note:
If height alignment changed, readjust.

167

Headlights, adjusting (Vehicles from

production date 10.00)
Note:
When adjusting the low beams, the high beams
are automatically adjusted.
Headlight, left:
1 - Side adjustment
2 - Height adjustment
The adjustment screws for the right headlight are positioned in mirror image.
- Guide Phillips screwdriver or socket with extension through hole in lock carrier.
- Turn adjustment screw for side adjustment -1- and height adjustment -2- until
adjustment is attained.
Note:
VOL is correct beam pattern for both right and left headlights.
- Adjust lateral (horizontal) alignment of driver's side headlight (if possible) so that
peak (highest point) of headlight beam pattern aligns with right edge of target
box of grid on pattern screen (it should match VOL pattern shown on Beamsetter
box).

Note:
If height alignment changed, readjust.

168

Fog light (right):

- To adjust fog lights, unclip cover -arrow- in lower part of bumper.

- To reduce the beam distance, turn adjustment screw -arrow- clockwise. There is
no provision for side adjustment.
The adjustment of the left fog light is the reverse of the right.
Auxiliary driving lights:
Service-installed driving lights must be adjusted according to the applicable local
regulations.

169

Driver's side headlight high beam

alignment, checking
- Switch headlights ON in high beam position.
- Realign Beamsetter box with high beam headlight if necessary.
- Set Beamsetter "Scaled wheel" to 0%.
- Cover low beam lamp (use hand or small piece of cardboard) and check high
beam pattern "hot spot" is centered on square target box of pattern screen.
Notes:
High beam pattern is built into reflector design and cannot be adjusted
separately.
If high beam pattern is way out of adjustment:
- Inspect for reflector damage.
- Replace reflector if needed.
Note:
Always align headlight in low beam position.

170

Fog lamp, alignment

- Switch fog lamps ON.
- Align Beamsetter box with fog lamp (make sure it is between 30 and 70 cm (12
to 28 in.) from fog lamp lens).
- Set Beamsetter scaled wheel to 1.4%.
- Adjust fog lamp so top of beam pattern aligns with center line of target grid on
beam pattern screen.
Passenger's side headlight, alignment
- Move Beamsetter to passenger side of vehicle and follow same procedures to
align Beamsetter box to head lamp.
- Align headlight low beam, check high beam and align fog lamp.
Note:
Make sure to reset Beamsetter "Scaled wheel" to proper setting each time you
change from low beam to high beam or to fog lamp.
- Ensure headlights and vehicle body are clean and free of fingerprints.

171

Road test
The following checks depend on the vehicle
equipment level and the available testing
possibilities (city or urban streets).
During the road test, check the following:
- Engine: Performance, stalling, idle,
acceleration
- Clutch: Driving off, pedal force, smell
- Gearshift: Easy movement, gearshift lever
position
- Automatic transmission: Selector lever position,
shiftlock / ignition key interlock, shift behavior,
display in instrument cluster

172

- Foot and parking brake: Function, free-play and

action, one-sided pull, chatter, squealing.
- ABS-Function: When braking with activated
ABS, the brake pedal must pulse noticeably.
- Steering: Function, steering free-play, steering
wheel center position when driving straight
ahead.
- Power roof: Function
- Radio / radio navigation system: Function,
reception, GALA, objectionable noise
- Multi-function display (MFA): Functions
- Air conditioning: Function
- Vehicle: Pulling to one side while driving straight
ahead (level road)
- Imbalance: Wheels, axle joints

- Wheel bearings: Noise

- Engine: Hot-start function

173

RAPGARD , inspection, removal and

disposal
From my 2002
Service
Within 48 Hours after arrival at Dealer:
Inspection
- Inspect RAPGARD
If RAPGARD
etc.):

for damage or peeling.

is disturbed (dented, scratched,

- You must note the damage on the Carrier

Delivery Receipt, including damage type, extent
and location. Failure to note damage on the
Carrier Delivery Receipt will result in nonpayment of the repair.
Within 72 Hours prior to delivery to the
Customer:
Remove RAPGARD

from vehicle.

Wash vehicle exterior.

Inspect paint surfaces, moldings and glass.
Protect the paint surface of all new vehicles
by applying 3M Perfect-It Paste Wax (3M
Part No. 39526) or equivalent.

174

Removal
Vehicle must be at room temperature.
The ideal body surface temperature for
RAPGARD removal is 60 F (15.5 C) to 80
F (26.6 C).
If body surface temperatures are below 60 F
(15.5 C) or above 80 F (26.6 C) then:
Removal procedure should be performed
indoors after surface temperatures have
been allowed to stabilize within the given
range.
- Rinse vehicle thoroughly with water to remove
surface dirt or dust and to help stabilize body
surface temperatures.
- Starting at the corners of each panel, carefully
remove RAPGARD from vehicle.
RAPGARD , paint inspection after removal
-

Inspect painted surfaces under one of the

following lighting conditions:

Indoors under fluorescent lighting.
Outdoors under bright sunlight.

175

Important!:
If any defects on the exterior have been identified
(scratches, dings, dents and other types of body
damage):
- Contact your Service Manager and arrange to
repair defects immediately.
Note:
After removal of RAPGARD , some vehicles
may exhibit temporary paint discoloration or paint
swelling (caused by trapped moisture under the
RAPGARD ).
This temporary swelling is caused by the paint
finish absorbing moisture trapped under the
RAPGARD film.
This swelling will disappear with exposure to
the sun or heat lamps within 2 - 3 hours. Severe
Paint swelling may require 2 - 3 days to
recover.
DO NOT buff or refinish paint for this condition!
Adhesive residue removal

CAUTION!
Always read and follow manufacturer
Cautions and Warnings regarding use of
product.

176

If RAPGARD adhesive residue remains on

paint finish, remove with a non-abrasive polishing
product such as, (3M Part No. 5995) light colors
or (3M Part No. 5996) dark colors.
Thick lines of adhesive residue can be removed
with general purpose adhesive cleaner (3M Part
No. 08987-aerosol, or Part No, 08984-qt. can) or
equivalent.
Note:
Paint discoloration (looks like shaded or dark
magic marker lines) can be removed with a heat
gun using the following procedure:
- Hold heat gun approximately 3 in. away from
affected paint surfaces and apply heat using
slow oscillating motions until discoloration is
gone.
- If discoloration remains, wipe the heated area
with Isopropyl alcohol and repeat procedure to
increase surface drying.
Important!
After inspecting and removing RAPGARD ,
washing vehicle, inspecting and repairing any

defects in paint surfaces, moldings and glass:

- Protect the vehicle paint surface by applying 3M
Perfect-It Paste Wax (3M Part No. 39526) or
equivalent.
RAPGARD

Disposal

RAPGARD can be disposed as normal paper

waste. If unsure about proper disposal
procedures in your area, check local regulations.

177

Transportation wiper blades, removing

at vehicle delivery
Service
For all Models arriving at your dealership with
transportation wiper blades:
Transportation wiper blades are shorter than
original equipment wiper blades and colored blue
or yellow.
Original equipment blades are temporarily
installed during the Pre-Delivery Inspection to
check wiper blade park position.
To ensure customer satisfaction, leave
transportation wiper blades on vehicle until time
of retail vehicle delivery.
Transportation wiper blades, removing
Transportation blades can easily be removed as
follows:
- Grasp blade as shown and rotate in direction of arrow (toward windshield).

178

- Rotate blade in opposite direction (black arrow) then, carefully slide blade off
wiper arm.
Note:
Wiper arm/blade alignment has been preset at the factory, then checked and
adjusted (if necessary) during the PDI.
DO NOT twist or bend the wiper arm. If wiper arm/blade alignment is incorrect,
chattering and/or streaking will occur.
If arm has been bent:
Repair Manual, Electrical Equipment, Repair Group 92
- Install original equipment wiper blades (located in trunk) at the time of retail
vehicle delivery.
Note:
Wiper blade with air deflector (arrow) must be installed on driver's side with
deflector on bottom of wiper blade.

179

Passenger's side wiper blade may be curved, install with curved ends of blade
pointing up.