Service Manual for Volkswagen Jetta, Golf, GTI

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Bentley Publishers is proud to announce the publication of the Volkswagen Jetta, Golf, GTI Service Manual: 1999-2005. This repair manual covers the late 1999 through 2005 model year Jetta, Golf, and GTI built on the Volkswagen “A4″ platform. New coverage of the 1.9- Liter TDI Engine with Pump Injection (Pumpe Düse) has been added to this edition along with 114 pages of new wiring diagrams and extensive revisions throughout the manual. Bentley repair manuals provide the highest level of clarity and comprehensiveness for all service and repair procedures. If you’re looking for better understanding of your Volkswagen, look no further than Bentley.Engines covered:

* 1.8L turbo gasoline
(engine codes: AWD, AWW, AWP)
* 1.9L TDI diesel
(engine code: ALH)
* 1.9L Turbo diesel Pumpe Düse (PD)
(engine code: BEW)
* 2.0L gasoline
(engine codes: AEG, AVH, AZG, BBW, BEV)
* 2.8L gasoline
(engine code: AFP, BDF) Transmissions covered (remove, install, external service):

2005-2010 Volkswagen Jetta (A5) Service Manual

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The Volkswagen Jetta (A5) Service Manual: 2005-2010 is a definitive reference source of technical automotive repair and maintenance information for Volkswagen Jetta models built on the “A5″ platform.

Service to Volkswagen owners is of top priority to Volkswagen and has always included the continuing development and introduction of new and expanded services. Whether you’re a professional or a do-it-yourself Volkswagen owner, this manual will help you understand, care for and repair your Volkswagen. The do-it-yourself Volkswagen owner will find this manual indispensable as a source of detailed maintenance and repair information. Even if you have no intention of working on your vehicle, you will find that reading and owning this manual makes it possible to discuss repairs more intelligently with a professional technician.

Engines:

* 1.9L TDI PD diesel (engine code: BRM)
* 2.0L TDI common rail (engine code: CBEA, CJAA)
* 2.0L FSI turbo gasoline (engine code: BPY)
* 2.0L TSI turbo gasoline (engine code: CBFA, CCTA)
* 2.5L gasoline (engine code: BGP, BGQ, CBTA, CBUA)

Transmissions

* 0A4 5-speed manual
* 02Q 6-speed manual
* 09G 6-speed automatic
* 02E 6-speed DSG

volkswagen manual for passat b6 manual

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Description: Vehicle VW Passat (N) Production VW Passet N General Rating Vehicle Date July 1 Soak City 1 City 2 City 3 City 4 30Breath Comfortable. Warm. Comfort Rating. VW Passat (N) Production

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Volkswagen 1.9 Liter 4-Cyl. 2V TDI Fuel Injection & Glow Plug, Engine Code(s) ALH

Short Description
The MAF sensor -G70- signal is used by the ECM to calculate the quantity injected and to control the required exhaust gas recirculation. The smaller the signal from MAF sensor -G70- the smaller the quantity of fuel injected.

Website: pics.tdiclub.com | Filesize: 215kb
No of Page(s): 6

Content
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Special tools and equipment
- VAG 1551/1552 Scan tool with adapter cable VAG 1551/3
- Test box VAG 1598/31
- Hand multimeter VAG 1526 or multimeter VAG 1715
- Adapter set VAG 1594
- Wiring diagram
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Check exhaust gas recirculation:
=> Repair Manual, 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH, Repair Group 26
If the specification is obtained:
- Road test vehicle with a 2nd technician to observe display.
Observe valid safety precautions when road testing => page 23-2.
- Accelerate vehicle in 3rd gear (vehicles with manual transmission) or 2nd gear (vehicles with automatic transmission) from about 1500 rpm using wide open throttle.
- Press PRINT button on VAG 1551 at approx. 3000 rpm. The accelerator pedal must be fully depressed at this moment in time.
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Volkswagen Passat B6 - Wheel bearings, assembly overview

Short Description
Wheel bearings, assembly overview
- Multi-point socket head bolt
- Tip of bolt must point in direction of travel
- Left Front ABS Wheel Speed Sensor G47 / Right Front ABS Wheel Speed Sensor G45
- Can be checked in Guided Fault Finding using Vehicle Diagnosis, Testing and Information System VAS 5051

Website: volkswagen.msk.ru | Filesize: 271kb
No of Page(s): 9

Content
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- Remove brake disc.
- Remove shield from wheel bearing housing.
- Loosen tie rod end nut, do not remove.
To protect threads, leave nut on stud a few turns.
…
- Press off tie rod end from wheel bearing housing using ball joint puller 3287A , and then remove nut.
- Press drive axle out of hub as far as possible (in direction of transmission).
…

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Technical Bulletin, New VW ATF / 01M transmission, checking ATF level, changing ATF

Short Description
A new Volkswagen ATF (Automatic Transmission Fluid) is available. Only the new VW ATF must be used in all Volkswagen Phase II automatic transmissions (types 01M and 01P). These transmissions have been installed in production beginning in January 1995. VW ATF is a yellowish-colored fluid unlike the red Dexron II fluid used previously. Use Dexron II transmission fluid only for automatic transmissions in vehicles produced up to and including December 1994. VW ATF can also be used in these transmissions.

Website: www.diakom.ru | Filesize: 110kb
No of Page(s): 6

Content
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ATF, changing
– Remove ATF level plug from oil pan (arrow).
– Remove overflow tube through the plug hole.
– Drain ATF.
– Install overflow tube.
– Screw level plug in hand-tight.
– Fill with 3 Liters of ATF through filler pipe.
– Start engine and shift through all selector lever positions with vehicle stationary.
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VW/Audi V-Checker Service Manual

Short Description
This manual describes common test procedures used by experienced service technicians. Many test procedures require precautions to avoid accidents that can result in personal injury, and/or damage to your vehicle or test equipment. Always read your vehicle’s service manual and follow its safety precautions before and during any test or service procedure.

Website: www.acb.no | Filesize: 173kb
No of Page(s): 19

Content
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V-CHECKER is a powerful, affordable handy scanner designed for all VW, AUDI, SKODA, and SEAT vehicles. It is small in size, robust in design, competitive in price and easy to use. With only 10% of the cost of a large special tool, it can nearly do the same work as that of a VAG1551/1552. This is a stand alone unit; it does not need a laptop computer to operate.
Available Functions
- Control Unit Information
- Read Fault Codes
- Measuring Blocks
- Clear Fault Codes
- Basic Setting
- Adaptation
- Independent Channel Value
- Output Tests
- Coding Control Unit
- Login
- Service Oil Reset
- Code Modes
- Dealership Code Set
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Preparation for Testing
The V-CHECKER aids in monitoring electronic and emissions-related faults in your vehicle and retrieving fault codes related to malfunctions in these systems. Mechanical problems such as low oil level or damaged hoses, wiring or electrical connectors can cause poor engine performance and may also cause a “false” fault code. Fix any known mechanical problems before performing any test. See your vehicle’s service manual or a mechanic for more information.
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VAG (Audi, VW, Seat, Skoda) Airbag Reseter

Short Description
After car crash and airbag deployment, VW-Audi airbag sensor can by locked (Control unit faulty or deployed) and must be replaced. Even after small accident Airbag sensor will write in internal memory special error message “crash data stored” or “computer fault” and after you need o exchange very expensive sensor to new one. With our VAG Airbag Reset Tool you can reset and repair airbag computer in your office in 1 minute. No need to remove airbag sensor from the car.

Website: www.cardecode.co.yu | Filesize: 683kb
No of Page(s): 12

Content
How VW-Audi Airbag Reseter works:
Very simple user instruction: connect this tool to VW-Audi OBD II connector (for cars from year 1996-2002). RED button is for airbag “crash data” erase. Push this button once and wait: yellow light start to flash and after 15 second green light inform you that “crash data” is erased. Red light set ON if erasing is not successful. YELLOW button is for erase airbag “fault memory” or “errors”. If airbag warning lamp go OFF and immediately ON - evaluate airbag “error memory” using any VAG K-line scanner or VAS5051 or similar dealer equipment and repair according error code.
When we apply the +12V power supply to VAG airbag reseter ,the yellow light will flash 10 times,this indicates the system checking .After this we can do the normal operation. VAG Airbag Reset Tool has incorporated fully automatic airbag sensor type recognition. Opel Airbag Reset Tool works without additional computer and thought car OBD II connector can erase airbag sensor “crash data” or only fault memory.
Works with these cars: Older VW-Audi cars. In some cases use OBD to VAG old type converter (VAS-5051-2 not included in package). Sensors with white or orange 30-pin connector.
- AUDI A4, A6, A8 1994-1997: Airbag V BOSCH: 8A0 959 655 C (Bosch 0 285 001 038), 8A0 959 655 K (Bosch 0 285 001 155), 8A0 959 655 K (Bosch 0 285 001 151) - Crash data erase, Fault erase; - VW - Golf III, Passat B4, Sharan: 1J0 909 603 SIEMENS - Crash data erase, Fault erase;
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Electrical installation kit (VW Golf A5 Variant RHD, 13-pin, VW Jetta A5 Limousine RHD, 13-pin)

Short Description
Before starting work read the installation instructions. The electrical installation kit may only be fitted by qualified specialists. Follow guidance in the current repair manual when carrying out installation work on the vehicle. The ABS control unit must be recoded for activation of the trailer stabilisation system.

Website: www.westfalia-automotive.de | Filesize: 274kb
No of Page(s): 9

Content
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When fitting, pay particular attention to the following points:
- Wiring must not be pinched or damaged.
- All seals must be properly seated.
- The seal for the socket must be positioned on the insulating sleeve and not on the individual wires.
- Route wiring so that it does not chaff against the vehicle or break off.
- Do not route wiring immediately next to the exhaust system.
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Volkswagen L-Jetronic Fuel Injection Workshop Manual PDF

Short Description
This manual is designed to assist the technician unfamiliar with Rober Bosch fuel injection systems in locating faults in the L-Jetronic system, isolating the component involved and testing the component for correct function. You will need a volt-ohmmeter and a pressure gauge as described in the Tool List. Electrical measurements are made at the terminals of the large plug at the end of the wiring harness after it is removed from the control unit, or at the terminals of the individual components themselves. Most components of this system cannot be repaired and will have to be replaced once you have determined them defective.

Website: www.vaglinks.com | Filesize: 3459kb
No of Page(s): 25

Content
If you are already familiar with Bosch EFI systems and can identify and locate all the components in the vehicle, go directly to the Trouble-Shooting Chart to track down the faulty component according to the engine sympthom given. Then go to the Component Test Instructions for directions on testing the suspected component. Technicians who are experienced in the various tests on this vehicle model can go directly to the Test Chart where the individual test steps and values are given.
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Volkswagen Owner's Manual 1969 Models - Introduction Manual

Short Description
It is advisable to read this Owner’s Manual carefully. You will then get to know your new car quickly and will be able to start off on your trip with complete confidence. You will notice, your Volkswagen has many features designed with your safety in mind.

Website: www.vwtype3.org | Filesize: 321kb
No of Page(s): 21

Content
The first part of this manual deals with the operation of your Volkswagen. Everything about winter driving, tips on care of the vehicle and numerous points on carrying out small repairs and adjustments are given in the second half. It further contains information on lubrication and maintenance and some interesting technical data. Additionally, this book contains the warranty voucher and the terms of warranty as well as a punchcard for the free-of-charge maintenance service and a maintenance schedule. An easy-touse maintenance record provides a stamping field. so you can tell at a glance when a maintenance service is due. The stamps in the squares show that the oil changes and maintenance services have been carried out regularly.

Sit down and make yourself comfortable
When driving, you must be comfortable. That is why the Volkswagen has separate front seats which are built so that you can alter seat position and backrest rake to suit your requirements. This is quite simple-just lift the lever-A-on the side of the seat and slide the seat forward or backward. After adjusting, be sure the seat is securely locked in position.
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Volkswagen Repair Manual – Hazard Switch Wiring

Beetle Late 68-69, From Vin 1×8 381 367, using 111-953-235 D, 211-953-235 A Switch, Chassis Ground Note: This terminal is not present on original switch. Add a Brown Wire when using replacement switch or if this terminal is present. Standard Beetle 70-71 With 10 Pole Fuse Box using 211-953-235 A Switch, Standard Beetle Late 71 & 72-73 With 12 Pole Fuse Box using 211-953-235 A Switch.

Headlights Wiring Diagram VW Passat 1.L 2001

Look inside behind the fuse panel. You’ll see the relay panel and relay 173. A closer look at relay 173 installed. Pull relay 173 out to disable the daytime running, Second method: Modifying the light switch The pin connectors at the back of the light switch lights. The object here is to stop electrical current from traveling through these pins.

For MY 1998-2001 Passats (B5) tape over, bend, or break pin TFL to disable the DRL when the light switch is in the OFF position. For MY 2001.5-2003 Passats (B5.5) tape over, bend, or break pin B to disable the DRL when the light switch is in the OFF position.

Owners Guide – Glove Compartment Lock Modification Volkswagen Beetle.pdf

This is achieved simply by cutting away the bottom collar using a sharp scalpel. When the lock and rubber grip part are inserted into the lock cylinder, the protrusion should be less than 1 cm, as can be seen here in the diagram. Modifying the glove compartment lock was a defiant move on my part to show the Vehicle Inspectorate that this Beetle owner will not be intimidated.

Technical Bulletin, New VW ATF / 01M transmission, checking ATF level, changing ATF

Short Description
A new Volkswagen ATF (Automatic Transmission Fluid) is available. Only the new VW ATF must be used in all Volkswagen Phase II automatic transmissions (types 01M and 01P). These transmissions have been installed in production beginning in January 1995. VW ATF is a yellowish-colored fluid unlike the red Dexron II fluid used previously. Use Dexron II transmission fluid only for automatic transmissions in vehicles produced up to and including December 1994. VW ATF can also be used in these transmissions.

Website: www.diakom.ru | Filesize: 110kb
No of Page(s): 6

Content
…
ATF, changing
– Remove ATF level plug from oil pan (arrow).
– Remove overflow tube through the plug hole.
– Drain ATF.
– Install overflow tube.
– Screw level plug in hand-tight.
– Fill with 3 Liters of ATF through filler pipe.
– Start engine and shift through all selector lever positions with vehicle stationary.
…

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Volkswagen Passat B6 - Wheel bearings, assembly overview

Short Description
Wheel bearings, assembly overview
- Multi-point socket head bolt
- Tip of bolt must point in direction of travel
- Left Front ABS Wheel Speed Sensor G47 / Right Front ABS Wheel Speed Sensor G45
- Can be checked in Guided Fault Finding using Vehicle Diagnosis, Testing and Information System VAS 5051

Website: volkswagen.msk.ru | Filesize: 271kb
No of Page(s): 9

Content
…
- Remove brake disc.
- Remove shield from wheel bearing housing.
- Loosen tie rod end nut, do not remove.
To protect threads, leave nut on stud a few turns.
…
- Press off tie rod end from wheel bearing housing using ball joint puller 3287A , and then remove nut.
- Press drive axle out of hub as far as possible (in direction of transmission).
…

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Modification and Integration Fuel Gauge Volkswagen Golf TDI

Step by step instructions : Always disconnect the battery before doing any electrical work on the car. Instructions: 1. Run the control wire: You will need to cut into your wiring for the Greasecar electrical system. Locate the wire that you ran from the main fuel selector switch to the 6-port valve. These wires. will default to the diesel fuel sender gauge, in the unlikely event of electrical problems. Now put 2 pieces of electrical tape on this wire close together, and cut the wire in between them.

Strip both ends of the wire that you just cut and insert one side into a butt splice. Crimp on the butt splice on one side. On top of the tank, you will notice both the fuel supply and return lines from the engine.

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Injector Nozzles Installation Manual for 1997 – 2003 Volkswagen 1.9L TDI.pdf

Remove the engine cover to reveal the engine. 2. Remove the fuel lines using a flat head screwdriveranda17mm wrench. When removing the fuel lines place a paper towel under the line opening stosoakup any fuel leakage. Note that the instructions will refer to the injectors from left right as if facing the engine.