Volkswagen Jetta, Golf, GTI Service Manual: 1999-2005

Volkswagen repair manual index:

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A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

A

ABS
see Anti-lock brakes (ABS)
ABS/EDL/ASR/ESP coding tables ST-29
Air conditioning (A/C)
A/C, heating and ventilation controls 87-23
A/C clutch 87-38
A/C components, underhood 87-32
A/C compressor 87-34
A/C passenger compartment components (climatronic) 87-24
A/C pressure switches, checking 87-9
A/C refrigerant circuit, 87-2
A/C refrigerant system 87-5
A/C refrigerant system, replacing components 87-12
A/C refrigerant system servicing 87-16
A/C refrigerant system, discharging and charging 87-21
A/C refrigerant system, flushing 87-22
A/C system, troubleshooting 87-18
A/C system odor, checking 87-16
air flap motors (climatronic) 87-28
condenser assembly, overview 87-14
control module for fresh air blower, removing 87-26
evaporator/heater assembly, overview 87-15
evaporator water drain valve 87-33
footwell air outlet temperature sensor, removing and installing 87-26
footwell/defrost flap motor (V85), removing and installing 87-31
fresh air blower, removing 87-27
high pressure service valve assembly 87-10
low pressure service valve assembly 87-10
pressure relief valve 87-10
refrigerant oil, pag 87-12
refrigerant lines and hoses 87-12
sunlight photo sensor, removing 87-26
temperature flap motor (V68) 87-30
Air filter
see Maintenance
Airbag system coding tables ST-32
Airbags
see Seatbelts, airbags
control module coding
see Scan Tool
Alarm system
see Front doors, comfort system
Alternator
see Engine Electrical, generator
Antenna
see Radio
Anti-freeze
see Engine?cooling system
Anti-lock brakes (ABS)
ABS components 45-4
ABS control module 45-21
ABS control module coding
see Scan Tool
brake light switch, removing and installing 45-10
brake system warning lights 45-8
electrical components 45-5
front ABS rotor, checking 45-23
hydraulic/mechanical ABS components 45-13
hydraulic unit, distinguishing features 45-6
hydraulic unit, removing/installing 45-16
special precautions for ABS or
ABS/EDL equipped vehicles 45-2
wheel speed sensors 45-22
Anti-theft Immobilizer 96-8
Automatic transmission
ATF cooler 37-58
automatic transmission electronic and electrical components 37-11
basic settings 37-19
selector lever cable, checking and adjusting (01M) 37-27
selector lever cable, checking and adjusting (09A) 37-28
shift lock 37-29
shift lock operation checking 37-36
shift mechanism, assembly 37-21
transmission, removing and installing (01M) 37-37
transmission, removing and installing (09A) 37-48
transmission code location 37-2
transmission range switch, removing, installing, adjusting 37-17

B

Battery
see Engine electrical
remote control batteries, changing
see Front doors
Belts
ribbed v-belt, see Maintenance
toothed belt, see Timing belt
Bleeding brakes
see Brakes?hydraulic system
Body?exterior equipment
exterior moldings 66-7
front grille 66-10
?GTI 337 edition? special trim 66-11
mirror housing 66-1
roof moldings, overview 66-7
roof rack rail (Jetta wagon) 66-9
rear spoiler 66-13
rear spoiler stoplight 66-14
side moldings, overview 66-8
side-view mirror 66-1
side-view mirror assembly 66-3
sill panel extension 66-12
wheel housing liners 66-5
Body?front
front body components 50-1
fender dimensions, Golf/GTI 50-3
fender dimensions, Jetta 50-3
front fender assembly 50-2
lock carrier 50-4
front noise insulation 50-5
Boost pressure
Turbocharger and intercooler
Brake fluid
see Brakes?hydraulic system
see also Maintenance
Brake light switch
removing and installing 45-10
Brakes?hydraulic system
brake booster 47-22
brake booster pressure sensor 47-19
brake pressure regulator 47-11
brake fluid 47-13
bleeding 47-14
replacing 47-15
brake master cylinder 47-21
brake service precautions 47-1
electric vacuum pump 47-20
front brake caliper 47-2
front brake caliper (FS III) 47-3
front brake caliper (FN 3) 47-4
front caliper piston, removing and installing (FS III and FN 3) 47-5
master cylinder/brake booster 47-17
rear brakes 47-7
rear caliper piston 47-8
rear caliper, pre-bleeding 47-10
vacuum check valve 47-19
vacuum pump for brake booster
(TDI engine) 47-19
Brakes?mechanical components
front brakes 46-2
front brake assembly
FS III caliper 46-3
FN3 caliper 46-6
front brake pads, removing and installing
FS III caliper 46-4
FN 3 caliper 46-7
parking brake, adjusting 46-13
parking brake cables, removing and installing 46-14
parking brake lever assembly 46-16
rear brakes 46-9
rear brake pads, removing and installing 46-10
Bumpers
bumpers, servicing 63-1
front bumper assembly 63-2
front bumper beam assembly 63-3
hood release lever, removing 63-1
rear bumper assembly 63-4
rear bumper beam assembly 63-5
trailer hitch, assembly 63-6

C

Caliper
see Brakes?hydraulic system
Catalytic converter
see Exhaust system and emission controls
CD changer/player
see Radio
Central locking
Front doors
Clutch
clutch assembly 30-18
clutch hydraulic system 30-6
clutch hydraulic system bleeding
(02J and 02M) 30-14
clutch master cylinder, removing and installing (02J and 02M) 30-10
clutch pedal (02J and 02M) 30-2
clutch pedal, removing and installing 30-6
clutch release mechanism 30-15
clutch servicing (02J and 02M) 30-18
over-center spring, removing and installing 30-4
Comfort system
see Front doors
control module coding
see Scan Tool
Component locations (electrical) 97-7
Compression test
see Cylinder head and valvetrain
Control module coding
see Scan Tool
Console, center
see Trim?interior
Convenience system coding tables ST-37
Coolant pump
see Engine?cooling system
Crankshaft/cylinder block (4-cylinder)
crankshaft 13a-18
crankshaft assembly (gasoline engines) 13a-20
crankshaft assembly (diesel engine) 13a-21
cylinder bore dimensions 13a-16
cylinder block 13a-2
cylinder block internal components 13a-10
driveplate clearance, adjusting (cars with automatic transmission) 13a-9
flywheel/driveplate 13a-8
oil seals 13a-4
piston projection at TDC
(diesel engine) 13a-17
piston rings 13a-14
pistons and connecting rods 13a-10
Crankshaft/cylinder block (6-cylinder)
cylinder block components 13b-2
cylinder block internal components 13b-9
cylinder bore dimensions 13b-12
crankshaft 13b-13
driveplate clearance, adjusting (cars with automatic transmission) 13b-8
flywheel/driveplate 13b-7
oil seals 13b-5
pistons and connecting rods 13b-9
vibration damper, removing and installing 13b-4
Cruise control 27-21
CV joint
see Front suspension and drive axle
Cylinder head and valvetrain (1.8L engine)
cylinder head components 15a-30
cylinder head, removing and installing 15a-24
cylinder head service 15a-3
camshaft oil seal, replacing 15a-7
camshafts, removing and installing 15a-11
cylinder head (valve) cover, removing and installing 15a-6
external cylinder head assembly 15a-5
hydraulic cam followers, checking 15a-14
internal cylinder head assembly 15a-4
valve stem oil seals 15a-15
diagnostic testing 15a-2
compression test 15a-2
cylinder leakdown test 15a-3
timing belt - camshaft drive 15a-18
valves 15a-31
Cylinder head and valvetrain (1.9L engine)
cylinder head components 15b-28
cylinder head, removing and installing 15b-22
cylinder head service 15b-3
camshaft oil seal, replacing 15b-6
camshaft, removing and installing 15b-9
cylinder head (valve) cover, removing and installing 15b-6
external cylinder head assembly 15b-5
hydraulic cam followers, checking 15b-11
internal cylinder head assembly 15b-4
valve stem oil seals 15b-12
diagnostic testing 15b-2
compression test 15b-2
cylinder leakdown test 15b-3
timing belt ? camshaft drive 15b-14
valves 15b-29
Cylinder head and valvetrain (1.9L PD engine)
cylinder head components 15c-25
cylinder head, removing and installing 15e-22
cylinder head service 15e-3
camshaft oil seal, replacing 15e-8
camshaft, removing and installing 15e-9
cylinder head (valve) cover, removing and installing 15e-7
external cylinder head assembly 15e-5
internal cylinder head assembly 15e-4
valve stem oil seals 15e-12
diagnostic testing 15e-2
compression test 15e-2
cylinder leakdown test 15e-3
timing belt - camshaft drive 15e-15
valves 15e-26
Cylinder head and valvetrain (2.0L engine)
cylinder head components 15c-35
cylinder head, removing and installing 15c-28
cylinder head service 15c-3
camshaft oil seal, replacing 15c-10
camshaft, removing and installing 15c-11
cylinder head (valve) cover, removing and installing 15c-9
external cylinder head assembly 15c-6
hydraulic cam followers 15c-13
internal cylinder head assembly 15c-4
valve stem oil seals 15c-14
diagnostic testing 15c-2
compression test 15c-2
cylinder leakdown test 15c-3
timing belt - camshaft drive 15c-13
valves 15c-37
Cylinder head and valvetrain (2.8L engine)
camshaft drive chains (AFP engine) 15d-17
valve timing, checking 15d-18
camshaft drive chains (BDF engine) 15d-50
valve timing, checking 15d-51
cylinder head components
(AFP engine) 15d-31
camshafts and cam followers 15d-32
valves 15d-33
cylinder head components
(BDF engine) 15d-66
camshafts and cam followers 15d-67
valves 15d-68
cylinder head, removing and installing (AFP engine) 15d-25
cylinder head, removing and installing (BDF engine) 15d-58
cylinder head service (AFP engine) 15d-5
camshafts, removing 15d-10
cylinder head (valve) cover, removing and installing 15d-7
hydraulic cam followers 15d-14
internal cylinder head assembly 15d-6
valve stem oil seals, replacing 15d-15
cylinder head service (BDF engine) 15d-35
camshafts, removing 15d-43
camshaft sprocket cover assembly 15d-37
cylinder head (valve) cover, removing and installing 15d-40
external cylinder head assembly 15d-36
valve stem oil seals, replacing 15d-48
diagnostic testing 15d-2
compression test 15d-2
cylinder leakdown test 15d-4

D

Dashboard
see Instrument panel 70-32
Diagnostic trouble codes
see Scan Tool
Diesel fuel injection
see Fuel injection?diesel
Differential and final drive
automatic transmission 39-9
differential and final drive assembly 39-10, 39-11
drive flange oil seals, replacing (01M) 39-12
drive flange oil seals, replacing (09A) 39-16
manual transmission 39-1
differential and final drive assembly 39-2, 39-3
drive flange oil seals, replacing (02J) 39-4
drive flange oil seals, replacing (02M) 39-6
rear final drive, identification
(R32 models)
R32 supplement
Disc brakes
see Brakes?mechanical components
see also Brakes?hydraulic components
Door panel
see Trim?interior
Doors
see Front doors
see also Rear doors
Drive axles
see Front suspension and drive axles
Drive belt
see Cylinder head and valvetrain, camshaft drive belt
see also Maintenance: ribbed V-belts
Driveplate
Crankshaft/cylinder block
DTC table ST-2
Dust and pollen filter
see Heating and ventilation

E

Engine Control Module (ECM) coding tables ST-25
EGR
see Exhaust system and emission controls
Electrical system?general
continuity, checking 9-6
electrical test equipment 9-2
electrical troubleshooting 9-3
safety precautions 9-1
short circuit test with voltmeter 9-7
short circuits, checking 9-6
voltage, measuring 9-5
voltage and ground, checking 9-4
voltage and polarity 9-1
voltage drop, testing 9-5
wiring diagrams, fuses and relays 9-3
Electronic Power Control (EPC) System
EPC pedal components 20-17
malfunction light for accelerator activation 20-16
Engine?cooling system
after-run coolant pump, checking 19-10
auxiliary radiator (2.8L engine)19-34
coolant/anti-freeze concentration 19-6
coolant, pump and thermostat 19-2
coolant pump, replacing
(1.8L engine) 19-15
(1.9L engine) 19-17
(1.9L PD engine) 19-19
(2.0L engine) 19-23
(2.8L AFP engine) 19-25
(2.8L BDF engine) 19-27
coolant temperature/level warning lights 19-4
cooling fans and thermo-switch 19-7
cooling system, components 19-14
cooling system, draining and filling 19-11
cooling system, pressure testing 19-6
radiator and cooling fans 19-29
thermostat, replacing (4-cylinder) 19-35
thermostat assembly (2.8L engine) 19-37
troubleshooting 19-4
warnings and cautions 19-2
Engine electrical
battery charging 27-6
battery, removing and installing 27-7
battery service 27-3
charging system 27-11
cruise control 27-21
electrolyte level, checking 27-3
generator, overview 27-13
generator, removing and
installing 27-12
load voltage testing 27-5
open circuit voltage test 27-4
procedure following interruption of voltage supply 27-10
regulator brushes, checking 27-16
specific gravity, checking 27-5
static current draw, checking 27-4
starter bushing 27-21
starter, removing and installing 27-19
starter service 27-17
Engine?general
1.8L engine 1-2
1.9L engine 1-3
1.9L engine (PD diesel) 1-6
2.0L engine 1-4
2.8L engine 1-5
Engine?lubrication system
lubrication system, components 17-5
oil cooler 17-20
oil filter flange assembly
(1.8L engine) 17-10
(1.9L engine) 17-11
(2.0L engine) 17-12
(2.8L AFP engine) 17-13
(2.8L BDF engine) 17-14
oil pan 17-14
oil pressure and oil pressure switch, testing 17-3
oil pressure warning system 17-3
oil pump 17-18
oil spray nozzles 17-20
oil supply to turbocharger (1.9L PD diesel engine) 17-21
Engine?removing/installing
1.8L 10-2
1.9L 10-13
2.0L 10-23
2.8L 10-33
Exhaust system and emission controls
catalytic converter 26-5
combi-valve, checking (2.8L engine) 26-32
emission controls (diesel engine) 26-33
emission controls (gas engines) 26-23
exhaust gas recirculation (EGR) 26-33
EGR cooler 26-38
EGR valve, checking 26-36
exhaust system
(1.8L engine) 26-7
(1.9L engine) 26-10
(2.0L engine) 26-13
(2.8L engine) 26-20
exhaust system, installation details 26-4
oxygen sensor, removing and installing 26-6
positive crankcase ventilation (PCV)
gas engines 26-23
diesel engines 26-33
secondary air injection system 26-23
secondary air injection system, components
(1.8L engine) 26-27
(2.0L engine) 26-28
(2.8L engine) 26-30
service precautions 26-2
vacuum hose connections
1.9L TDI engine 26-35
1.9L PD TDI engine 26-37

F

Fender
see Body?front
Flywheel
see Crankshaft/cylinder block
Fog light
see Lights, accessories?exterior
Front doors
central locking 57-2
comfort system and central locking, component overview 57-19
connector station in a-pillar 57-20
door, adjusting 57-4
door assembly 57-3
door handle and lock assembly 57-5
door handle, removing and installing 57-7
door, removing and installing 57-4
door seals 57-17
door window assembly 57-14
door window glass 57-15
keys and remote control 57-20
lock button, removing and installing 57-12
lock cylinder housing, removing and installing 57-6
power windows 57-1
remote control batteries, changing 57-21
Front seats
see Seats
Front suspension and drive axles
ball joint, removing and installing 40-6
coil spring, removing, installing, identifying 40-17
cv joints, servicing 40-39
drive axles 40-18
drive axle, removing and installing 40-44
front suspension strut assembly 40-13
front suspension struts, removing and installing 40-14
inner cv joint and boot 40-41
outer cv joint and boot 40-39
subframe, stabilizer bar, control arm assembly 40-3
suspension struts 40-13
triple roller joint, 40-27
wheel bearings 40-8
Fuel, ignition, and exhaust systems?general
diesel turbo direct injection (TDI) 2-3
electronic power control (EPC) 2-8
emission controls 2-8
fuel injection 2-1
fuel supply 2-1
ignition system 2-8
motronic 5.9.2 engine management 2-2
motronic ME 7 engine management 2-5
Fuel filter
see Maintenance
Fuel injection?motronic (1.8L engine)
adaptation 24a-4
air cleaner assembly 24a-11
engine control module (ECM) 24a-13
engine coolant temperature (ECT) sensor, measuring resistance 24a-7
engine speed (RPM) sensor 24a-13
fuel injection system component locations, overview 24a-6
fuel injection system components, removing and installing 24a-8
fuel rail and injector assembly 24a-12
intake air temperature (IAT) sensor, measuring resistance 24a-10
on board diagnostics 24a-3
readiness codes 24a-4
safety precautions 24a-2
Fuel injection?diesel (1.9L engine)
diesel injection system (1.9L TDI diesel) 23-2
basic fuel delivery, checking 23-9
diagnostic quick checks 23-7
engine control module 23-23
fuel injectors 23-27
fuel shut-off valve, checking 23-8
injection pump 23-12
injection pump dynamic timing, checking and adjusting 23-20
intake manifold change-over valve 23-26
readiness codes, setting 23-25
throttle position sensor 23-10
timing belt - camshaft drive 23-11
troubleshooting 23-5
diesel injection system (1.9L PD TDI diesel) 23-30
engine control module 23-33
pump injector 23-35
throttle position sensor 23-31
timing belt - camshaft drive 23-31
variable intake manifold 23-34
Fuel injection?motronic (2.0L engine)
motronic engine management components 24b-5
air cleaner assembly 24b-14
engine control module (ECM) 24b-16
engine coolant temperature (ECT) sensor, measuring resistance 24b-10
engine speed (RPM) sensor 24b-16
intake air temperature (IAT) sensor, measuring resistance 24b-15
lower intake manifold section, assembly 24b-12
upper intake manifold assembly 24b-11
on board diagnostics 24b-3
adaptation 24b-4
engine control module coding 24b-5
readiness codes 24b-4
Fuel injection?motronic (2.8L engine)
fuel injection components testing 24c-21
engine control module (ECM) 24c-23
engine coolant temperature sensor (ECT) 24c-22
engine speed (RPM) sensor 24c-23
intake air temperature (IAT) sensor 24c-21
throttle valve (TV) control module 24c-24
motronic engine management components (AFP engine) 24c-5
air cleaner assembly 24c-12
intake manifold, upper section,
assembly 24c-10
intake manifold, lower section and fuel rail, assembly 24c-11
motronic engine management components (BDF engine) 24c-13
air cleaner assembly 24c-20
fuel rail assembly 24c-19
intake manifold assembly 24c-18
throttle valve control module, measuring resistance 24c-24
on board diagnostics 24c-3
adaptation 24c-4
engine control module coding 24c-5
readiness codes 24c-4
Fuel storage and supply
change-over valve, checking 20-21
electronic power control (EPC) system 20-30
EPC pedal components 20-31
evaporative emissions 20-32
EVAP system overviews 20-35
LDP system overviews
fuel cooler (1.9L) 20-25
fuel filter assembly (1.9L PD) 20-26
fuel gauge sensor, removing and installing 20-11
fuel pump (fuel delivery unit) 20-13
fuel pump troubleshooting 20-3
fuel tank and lines 20-19
tandem pump (1.9L PD) 20-27
throttle mechanism (AEG engine)20-26
Fuel tank
see Fuel storage and supply
Fuses
see Wiring diagrams, fuses and relays

G

Generator
see Engine electrical system
Glow plugs
see Ignition system?diesel

H

Haldex clutch
see R32 supplement
Hand brake
see Parking brake 46-13
Headlight
see Lights, accessories?exterior
Headliner
see Trim?Interior
Heating and ventilation
air outlets, removing 80-3
blower fan, removing and installing 80-13
central flap cable 80-10
central flap lever 80-13
connecting duct 80-5
defroster duct 80-5
dust and pollen filter 80-11
footwell/defrost flap cable 80-10
heater assembly, overview 80-12
heater core bulkhead seal 80-13
heating and ventilation components 80-11
heating and ventilation controls 80-2
instrument panel crossmember, loosening and tightening 80-5
passenger compartment components, overview 80-2
recirculation flap servo 80-14
side window fixed air vents 80-3
temperature flap cable 80-10
ventillation system, checking 80-15
Hood and lids
front hood 55-2
hood assembly 55-2
hood lock assembly 55-5
hood lock support, removing 55-6
hood lock, removing 55-6
hood release cable assembly 55-3
release lever, removing and installing 55-4
rear lids 55-7
gas-filled strut, removing 55-9
lock cylinder housing assembly (Golf) 55-11
rear hatch assembly (Golf) 55-8
rear hatch lock assembly (Golf) 55-10
rear hatch/lid, adjusting 55-7
rear hatch/tailgate assembly (Jetta wagon) 55-16
rear lid assembly (Jetta) 55-12
rear lid lock assembly (Jetta) 55-13
tailgate/trunk lock assembly (Jetta wagon) 55-17
tank flap unit assembly (Golf) 55-18
tank flap unit assembly (Jetta and wagon) 55-19

I

Ignition system?diesel
coolant glow plugs/auxiliary heater 28b-5
diesel glow plug system 28b-2
Ignition system?gasoline
disabling ignition system 28a-2
ignition system troubleshooting 28a-4
quick check of ignition system 28a-5
spark plug wires/connectors, checking 28a-6
ignition system
(1.8L engine) 28a-7
(2.0L engine) 28a-10
(2.8L engine) 28a-16
knock sensors, checking resistance (2.8L BDF engine) 28a-19
Immobilizer
see Anti-theft immobilizer
Instrument cluster
see Instruments
Instruments
instrument cluster 90-1
instrument cluster, removing and installing 90-3
malfunction recognition and
display 90-2
multi-pin connector terminal assignment 90-4
service interval display, resetting 90-7
Intercooler
see Turbocharger and intercooler
Interior lights
see Lights, accessories?interior

J

Jacking vehicle
see Maintenance, lifting

K

Keys
see Front doors, comfort system
Kick-down point, adapting ST-48

L

License plate light
see Lights, accessories?exterior
Lid
see Hood and lids
Lifting vehicle
see Maintenance
Lights, accessories?exterior
Golf/GTI exterior lights 94-2
headlight 94-3
high-mount brake light 94-9
taillight 94-7
Golf/GTI/Jetta exterior lights 94-17
headlight upper securing lugs 94-17
side mounted turn signals 94-17
license plate light 94-18
Jetta exterior lights 94-10
headlight 94-10
high-mount brake light 94-14
taillight 94-15
Lights, accessories?interior
anti-theft immobilizer 96-8
door panel switches 96-3
door warning light 96-6
glovebox light 96-6
headlight switch 96-2
instrument panel light dimmer switch 96-2
instrument panel switches 96-4
interior light and sunroof switch 96-5
luggage compartment light 96-6
mirror adjustment switch 96-3
rear lid handle release button (Jetta) 96-8
rear reading light 96-5
remote fuel tank door/rear lid unlock switch 96-7

M

Maintenance
air filter element, replacing 0-38
airbag unit, visual inspection 0-48
ATF, replacing 0-45
battery service 0-29
body and interior maintenance 0-47
brake fluid 0-25
brake system, visual inspection 0-39
brake pads (front and rear) 0-39
coolant, checking 0-23
door check straps and hinges, lubrication 0-48
drive axles, checking boots 0-40
dust and pollen filter, replacing 0-47
emergency towing with commercial equipment 0-9
engine identification 0-6
engine oil, changing 0-19
engine oil filter, replacing 0-22
engine oil level, checking 0-18
exhaust system, checking 0-46
exterior lights, checking 0-47
final drive oil level, checking 0-41
fluid leaks 0-27
front suspension components, checking 0-41
fuel filter, replacing
(gasoline engines) 0-27
fuel filter, draining
(diesel engine) 0-28
fuel filter, replacing
(diesel engine) 0-29
how to use this manual 0-2
identification plates and labels 0-4
interior lights, checking 0-47
lifting vehicle 0-12
maintenance schedules 0-50
on board diagnostics (OBD),
checking 0-49
parking brake, adjusting 0-40
power steering fluid level 0-26
ribbed v-belt 0-31
road test 0-50
sound absorber panels 0-16
spark plugs, replacing 0-36
timing belt, checking 0-35
tire service 0-40
transmission, checking for
leaks 0-41
transmission fluid (ATF) level 0-43
transmission identification 0-7
transmission oil level, checking (manual transmission) 0-42
towing 0-9
towing eyes 0-12
underbody sealant, checking 0-46
under car maintenance 0-38
vehicle hook-up, front 0-11
vehicle hook-up, rear 0-11
vehicle identification number (VIN) 0-4
warnings, cautions and notes 0-3
windshield wipers and washers 0-49
work safety 0-4
working under the vehicle 0-13
Manual transmission
02J specifications 34-4
02M specifications 34-8
gear selector mechanism, 02J (through 05/99) 34-15
gear selector mechanism, 02J
(from 05/99) 34-27
gear selector mechanism, 02M 34-38
transmission, 02J, removing and installing 34-49
transmission, 02M, removing and installing 34-62
transmission code location 34-3
Master cylinder
see Brakes?hydraulic system
see also Clutch
Mirrors
see Body?exterior equipment
see also Trim?interior
Moonroof
see Sunroof

O

Oil
changing 0-19
filter 0-22
see also Engine?lubrication system

P

Parking brake
see Brakes?mechanical components
Piston
see Crankshaft/cylinder block
Pollen filter
see Heating and ventillation, dust and pollen filter
Power windows
see Front doors
see also Rear doors
Product familiarization
body exterior 00-14
body interior 00-16
electrical system 00-20
engine and transaxle 00-7
heating and air conditioning 00-19
product overview (1999 model introduction) 00-2
golf dimensions 00-6
jetta dimensions 00-7
suspension and brakes 00-10
technical specifications 00-22

R

R32 supplement
body components R32-43
front bumper cover R32-43
rear bumper cover R32-45
sill panel extension R32-48
spoilers R32-47
engine R32-12
chain drive R32-14
cooling system R32-18
cylinder block R32-13
cylinder head R32-15
engine number R32-12
lubrication R32-16
oil filter R32-17
oil pressure R32-16
fuel supply, injection, ignition and exhaust R32-20
exhaust system R32-25
fuel injection R32-22
fuel supply R32-21
ignition system R32-27
general R32-1
maintenance R32-5
2004 m.y. maintenance R32-11
ball joints, checking R32-5
brake pads, checking R32-6
ribbed v-belt R32-7
sound absorber panels, removal R32-8
spark plugs, replacing R32-9
suspension and brakes R32-34
front brakes R32-38
front suspension R32-34
rear brakes R32-42
rear suspension R32-36
transmission R32-28
02Y transmission specifications R32-29
all wheel drive control module R32-31
electrical components R32-30
haldex clutch oil and filter R32-32
rear final drive R32-32
Radio and communication
cd player/changer 91-14
cd player, terminal
assignment 91-15
interference suppression 91-3
multi-function steering wheel 91-18
radio reception 91-1
radio system 91-3
amplifier (monsoon) 91-6
antenna 91-11
radio anti-theft system 91-8
radio head unit 91-4
radio head unit terminal
assignment 91-12
speakers, removing and
installing 91-8
telematics 91-21
Radio and sound system coding tables ST-40
Rear hatch
see Hood and lids
Rear doors
door, adjusting 58-3
door, removing and installing 58-3
door handle and lock assembly 58-4
door handle, removing and
installing 58-5
door lock, removing 58-11
door lock, installing 58-13
rear door assembly 58-2
rear door seals 58-14
rear door windows 58-6
Rear seats
see Seats
Rear suspension
bushings 42-5
rear coil springs 42-11
rear shock absorber assembly 42-10
rear shock absorbers, removing and installing 42-12
rear suspension assembly 42-3
rear wheel bearings 42-14
Relays
see Wiring diagrams, fuses and relays
Remote control (locking)
see Front doors

S

Scan tool (ST)
basic settings ST-42
kick-down point, adapting ST-48
throttle valve control module, adapting ST-42
transmission control module, adapting ST-47
control module coding ST-25
diagnostic scan tool suppliers ST-24
on-board diagnostics II ST-1
VAG 1551/1552 operating overview flow chart ST-50
Seatbelts, airbags
airbag control module 69-16
airbag slip ring, removing and installing 69-20
airbag system, overview 69-15
airbag unit, front passenger, assembly (with seams in dash for airbag) 69-24
airbag unit, front passenger, assembly (without seams in dash for airbag) 69-25
airbag unit in 4-spoke steering wheel, distinguishing features 69-16
3-spoke steering wheel and
airbag 69-18
4-spoke steering wheel and
airbag 69-17
airbag unit in steering wheel, removing and installing 69-19
airbags 69-13
impact sensor, side airbag,
overview 69-23
side airbag unit safety
harness 69-22
special precautions for airbag equipped vehicles 69-13
seatbelts 69-2
child restraint latch guidance fixture, installing 69-11
front seatbelt assembly 69-7
rear center belt reel, removing 69-10
rear seatbelt assembly 69-8
rear top latch tether
(Jetta sedan) 69-12
seatbelts, inspecting 69-4
special precautions for pyrotechnic seatbelt equipped vehicles 69-2
Seats
front seats 72-1
electrically adjustable front
seats 72-10
front seat, removing and installing 72-2
front seat assembly 72-4
front seat backrest cover and padding 72-8
head restraint guides 72-5
locking backrest assembly
(2-door) 72-6
seat height adjuster 72-7
rear seats 72-13
backrest lock 72-16
rear backrest padding and armrest 72-14
rear seat backrest 72-14
rear seat bottom 72-13
Secondary air injection system
see Exhaust system and emission controls
Service interval display, resetting
see Instruments
Shift-lock
see Automatic transmission
Slave cylinder
see Clutch hydraulic system assembly
Sound system
see Radio and communication
Spark plugs
see Maintenance
Starter
see Engine electrical system
Steering
ESP steering angle sensor 48-9
ignition lock cylinder and switch, removing and installing 48-17
power steering fluid reservoir 48-22
power steering gear 48-19
power steering gear, adjusting 48-20
power steering hydraulic hoses 48-21
pressure hose, mounting to manual transmission 48-25
pressure hose, mounting to automatic transmission 48-26
power steering pump 48-27
power steering rack, determining center position 48-20
power steering return line 48-20
special precautions for airbag equipped vehicles 48-2
steering column 48-7
steering column switches and lock housing 48-13
steering wheel, inner assembly 48-4
steering wheel and steering column, installed position 48-5
steering wheel 48-3
tie rod, removing 48-20
Steering wheel, multifunction 91-18
Sunroof
distinguishing features 60-1
drain hoses 60-14
drive motor 60-8
glass panel 60-3
parallel movement 60-11
rockwell/meritor sunroof 60-12
sliding headliner 60-7
sunroof switch 60-9
webasto sunroof 60-10
Suspension, front
see Front suspension and drive axles
Suspension, rear
see Rear suspension

T

Taillight
see Lights, accessories?exterior
TCM coding ST-28
Telematics
see Radio and communication
Throttle valve control module, adapting ST-42
Timing belt (toothed belt)
checking 0-35
removing and installing
1.8L engine 15a-19
1.9L engine 15b-16
2.0L engine 15c-18
Timing chain (Camshaft drive chain)
AFP engine 15d-17
BDF engine 15d-52
Tires
see Wheels?tires, wheel alignment
Torque converter
torque converter, draining 32-8
torque converter
identification (01M) 32-2
torque converter
identification (09A) 32-3
torque converter installing (09A) 32-7
torque converter oil seal replacement (01M) 32-4
torque converter oil seal replacement (09A) 32-5
turbine shaft sleeve bearing removal (01M) 32-6
Trailer hitch
see Bumpers
Transmission, automatic
see Automatic transmission
Transmission, manual
see Manual transmission
Transmission control module, adapting ST-47
Trim?Interior
center console 70-2
center console assembly 70-2
center console extension 70-3
front ashtray, removing 70-5
front center armrest, removing 70-4
rear ashtray, removing 70-5
rear cupholder, removing and installing 70-6
headliner, removing and installing 70-40
instrument panel 70-33
interior equipment 70-6
automatic dimming mirror 70-8
front cup holder, removing 70-6
glovebox, removing 70-7
interior mirror 70-8
roof handle, removing 70-10
sun visors, removing 70-11
luggage compartment trim 70-26
rear lid trim 70-27
rear lock carrier trim 70-29
right-side luggage compartment trim 70-31
passenger compartment trim 70-11
a-pillar trim 70-11
b-pillar trim 70-13
c-pillar trim 70-15
d-pillar trim 70-19
driver's door panel 70-19
front door window triangular trim (with speaker), removing 70-22
inner wheel housing trim 70-22
parcel shelf trim (Jetta) 70-23
passenger door panel, removing and installing 70-21
rear door panel 70-23
rear side trim (2-door Golf) 70-24
sill panel trim 70-25
steering column lower trim 70-24
Turbocharger and intercooler
intercooler 21-13
recirculating valve, checking
(1.8L engine) 21-5
turbo boost pressure, checking 21-3
turbocharger assembly (1.8L engine) 21-6
turbocharger assembly (1.9L engine) 21-11
turbocharger diagnostics 21-2
turbocharger hose connections
(1.8L engine) 21-8
turbocharger hose connections
(1.9L engine) 21-13
wastegate by-pass regulator valve, checking 21-4

V

Vehicle Identification Number (VIN)
see Maintenance
see also Foreword
Ventilation
see Heating and ventilation
Voltage, interruption of
see Engine electrical system

W

Water pump
see Engine?cooling system, coolant pump
Wheel alignment
see Wheels?tires, wheel alignment
Wheel bearing
see Front suspension and drive axles
see also Rear suspension
Wheels?tires, Wheel Alignment
alignment requirements 44-5
alloy wheel trim (GTI) 44-3
front axle camber, adjusting 44-8
front axle toe, adjusting 44-9
rear axle toe, adjusting 44-9
suspension type 44-7
thrust angle, calculating 44-8
wheel alignment 44-3
wheel lock, left and right,
checking 44-10
wheel seat protection 44-2
wheels and tires 44-1
Windows
see Front doors
see also Rear doors
Wipers and washers
?aero-wiper? blades, removing and installing 92-2
rear wiper assembly 92-6
rubber wiper inserts, replacing 92-2
windshield washer system 92-7
windshield washer jets 92-7
windshield washer reservoir 92-9
wiper arm, front, removing and installing 92-3
wiper motor, front, removing and installing 92-4
Wiring Diagrams, Fuses and Relays
component locations 97-7
fuses and relays 97-2
fuse panel, removing/installing 97-4
ground locations 97-6
how to read wiring diagrams 97-12
indexes (by model year)
1999 97-16
2000 97-22
2001-2002 97-30
2003-2005 97-30
relay panel, removing/installing 97-5
relay positions 97-3
symbols used in wiring diagrams 97-14
using wiring diagrams 97-9
wiring diagram layout 97-11