INSTANT DOWNLOAD: VW Volkswagen Service Repair Manual Models MK4: Jetta, GTI, Golf 1999-2005

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Important Safety Notice Foreword and Disclaimer Vehicle Identification and VIN Decoder Warnings and Cautions R32 Supplement Index 00 Golf, GTI and Jetta Product Familiarization Maintenance

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ii v vi vii back of book end of book

Overview, Maintenance

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Engine

General Information Engine-Removing and Installing Crankshaft/Cylinder Block (4-Cylinder) Crankshaft/Cylinder Block (6-Cylinder) I, CYin der H d and VaI t ' .ea ve rain (1.8L Engine) 15b Cylinder Head and Valvetrain (1.9L Engine) 2 20 21 23 24a 24b Generallnformation Fuel Storage and Supply Turbocharger and Intercooler Fuel Injection-Diesel (1.9L Engine) Fuellnjection-Motronic (1.8L Engine) Fuellnjection-Motronic (2.0L Engine)

15c Cylinder Head and Valvetrain (2.0L Engine) 15d Cylinder ~ead and Valvetrain (2.8L Engine) 15e Cylinder Head and Valvetrain (1.9L PO Engine) .. , 17 Enqine-Lubricatlon System 19 Engine-Cooling System 24c 26 27 28a 28b Fuellnjection-Motronic (2.8L Engine) Exhaust System andEmission Controls Engine Electrical Ignition System-Gasoline Ignition System-Diesel

Engine Management, Exhaust, and Engine Electrical Clutch, Transmission, and Final Drive Suspension, Brakes, and Steering BodyAssembly BodyComponents and Accessories BodyInterior Trim

30 32 34

Clutch Torque Converter Manual Transmission

37 39

Automatic Transmission Differential and Final Drive

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5 6 7 8 9

40 42 44 45

Front Suspension and Drive Axles Rear Suspension Wheels-Tires, Wheel Alignment Anti-Lock Brakes (ABS)

46 47 48

Brakes-Mechanical Components Brakes-Hydraulic System Steering

50 55

Body-Front Hood and Lids

57 58

Front Doors Rear Doors

60 63

Sunroof Bumpers

66 69

Body-Exterior Equipment Seatbelts, Airbags

70 72

Trim-Interior Seats

Heating and Air Conditioning

80 87

Heating and Ventilation Air Conditioning

Electrical System

9 90 91 92

General Information Instruments Radio and Communication Wipers and Washers

94 96 97 ST

Lights, Accessories-Exterior Lights, Accessories-Interior Wiring Diagrams, Fuses and Relays Scan Tool

Foreword and Disclaimer
Service to Volkswagen owners is a top priority of the Volkswagen organization and has always included the continuing development and introduction of new and expanded services. In line with this purpose, Robert Bentley, Inc., in cooperation with Volkswagen of America, Inc., has introduced this Volkswagen Jetta, Golf, GTI Service Manual. This manual covers Volkswagen Jettas, Golfs, and GTls for the model years 1999 through mid2005 based on Volkswagen's A4 platform. Please see the Vehicle Identification & VIN decoder remarks on the following page for more information. This manual was created specifically to cover only those models built for sale in the United States and Canada. For the Volkswagen owner with basic mechanical skills and for independent auto service professionals, this manual includes the specifications and procedures that were available in an authorized Volkswagen dealer service department as this manual went to press. The Volkswagen owner with no intention of working on his or her car will find
that owning and referring to this manual will make it possible to be better informed and to more knowledgeably discuss repairs with a professional automotive technician. The Volkswagen owner intending to do maintenance and repair should have screwdrivers, a set of metric wrenches and sockets, and metric hex wrenches, since these basic hand tools are needed for most of the work described in this manual. Most procedures will also require a torque wrench to ensure that fasteners are tightened properly and in accordance with specifications. In some cases, the text refers to special tools that are recommended or required to accomplish adjustments or repairs. These tools are usually identified by their Volkswagen special tool number and illustrated.

Disclaimer
We have endeavored to insure the accuracy of the information in this manual. When the vast array of data presented in the manual is taken into account, however, no claim to infallibility can be made. We therefore cannot be responsible for the result of any errors that may have crept into the text. Please also read the Important Safety Notice on the copyright page at the beginning of this book. A thorough pre-reading of each procedure, and the WARNINGS and CAUTIONS at the front of the book and those that accompany the procedure is essential. Reading a procedure before beginning work will help you determine in advance the need for specific skills, identify hazards, prepare for appropriate capture and handling of hazardous materials, and the need for particular tools and replacement parts such as gaskets. Bentley Publishers encourages comments from the readers of this manual with regard to errors, and/or suggestions for improvement of our product. These communications have been and will be carefully considered
job for you. Bentley Publishers

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Vehicle Identification & VIN Decoder
Some of the information in this manual applies only to cars of a particular model year or range of years. For example, "1999 m.y." refers to the 1999 model year. The model year does not necessarily match the calendar year in which the car was manufactured or sold. To be sure of the model year of a particular car, check the vehicle identification number (VIN) on the car. Technical changes made in production within a model year are identified in this manual by listing the VIN for the first car produced with this change. The VIN is a unique sequence of 17 characters assigned by Volkswagen to identify each individual car. WVWDE21 JXYW671801 is an example. Each of the 17 letters and numbers indicates certain facts about the car and its manufacture. VINs used to distinguish information in this manual may refer only to the last eleven digits-the characters 1JXYW671801 in the example above. Your Volkswagen's VIN can be found on a plate mounted on the top of the instrument panel, on the driver's side where the number
can be seen through the windshield. The 10th character is the model year code. The letters "I", "0", "Q" and "U" are not used for model year designation, for example, "X" for 1999 m.y., "Y" for 2000 m.y., "1" for 2001, "2" for 2002 m.y., etc. This manual covers Volkswagen Jettas, Golfs, and GTls for the model years 1999 through mid-2005. The table below explains some of the various codes in the VIN numbers of models covered by this manual.

position

1 2 3 4 5 6 7 8 9 1a 11 12 13 14 15 16 17

1 2 3 4 5 6 7 8 9 1a 11 12 13 14 15 16 17

Jetta: Golf:

DDDDDD~~DDD@]@]@]@]@]~
DDDDDD~QJDDD@]@]@]@]@]~
Description
Country of origin

to to

DDDDDD~~DDD@J@J@J@J@J@J
DDDDDD~QJDDD@J@J@J@J@J@J

Position
1

Decoding Information

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W 9

Mexico Germany Brazil Volkswagen Passenger Car Varies with model year See BentleyPublishers.com for more information

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Manufacturer Vehicle Type Series Engine Restraint system Model Check Digit Model Year

V W

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9M Jetta sedan 1J Golf, GTI, Jetta Wagon, R32 0-9 or X, calculated by NHTSA X Y 1 2 3 4 5 4 H 1999 2000 2001 2002 2003 2004 2005 Curitiba, Brazil Hannover, Germany Dresden, Germany Puebla, Mexico Bratislava, Slovakia Mosel, Germany Emden, Germany Wolfsburg, Germany Sequential production number of the specific vehicle

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Assembly Plant

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M D P E W 12-17 Serial Number

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