Target Audience:
Do-it-yourself enthusiasts, independent repair shops, professional mechanics
Comparison To Dealer Manuals:
This manual provides the same depth of information and diagnostic procedures used by authorized Volkswagen dealerships.
Illustrations:
Hundreds of detailed illustrations and diagrams to aid in understanding procedures
Completeness:
100% complete and intact, no missing or corrupt pages/sections
Usability:
Step-by-step instructions, printable pages for workshop use
Engine Mechanical:
Complete engine overhaul, timing belt/chain, cylinder head, pistons, crankshaft, lubrication system
Engine Electrical:
Ignition system, fuel injection, sensors, ECU, starting and charging systems, wiring diagrams
Transmission:
Manual and automatic transmission overhaul, clutch, gear selection mechanisms, torque converter
Drivetrain:
Front-wheel drive system, CV joints, drive axles, differential components
Suspension:
Front and rear suspension components, shock absorbers, struts, bushings, alignment procedures
Brakes:
Disc brake systems (front and rear), ABS, hydraulic lines, brake fluid replacement, caliper and rotor service
Steering:
Power steering system, steering rack, tie rods, wheel alignment
Electrical And Electronics:
Lighting, power windows, central locking, climate control, instrument cluster, SRS (airbag) system, body control modules
HVAC:
Air conditioning system, heater core, blower motor, refrigerant servicing, cabin air filter replacement
Body And Chassis:
Body panel removal and installation, doors, bumpers, interior trim, chassis diagnostics
Exhaust System:
Exhaust manifold, catalytic converter, muffler, pipes, exhaust hangers
Fuel System:
Fuel pump, fuel injectors, fuel filter, fuel lines, EVAP system
Cooling System:
Radiator, coolant hoses, thermostat, water pump, cooling fan, coolant specifications
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, common fault codes and remedies
Repair:
Step-by-step repair instructions for all major mechanical and electrical components
Overhaul:
Complete disassembly, inspection, and reassembly procedures for engines and transmissions
Replacement:
Component replacement instructions (e.g., alternator, starter, brake pads, clutch kit)
Diagnostics:
On-board diagnostics (OBD-II), sensor testing, electrical system testing
Installation:
Installation procedures for accessories and replacement parts
Alignment And Balancing:
Wheel alignment specifications and procedures, wheel balancing
Depth:
Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, including in-depth electrical diagnostics and wiring diagrams.
1.8L Turbocharged (Agu, Aum, Auq, AWD, App, Apx, Aqa, Amb Engines):
20 valves, DOHC, intercooled turbocharger, Electronic Fuel Injection (EFI). Power output typically ranges from 150-180 HP depending on engine code and market. Torque around 160-180 lb-ft.
1.9L Tdi (Alh, Ahu, Ahf, Asv, Ajm, Auy Engines):
8 or 16 valves, SOHC or DOHC, Turbocharged Direct Injection (TDI) diesel. Power typically 90-110 HP. Torque around 145-165 lb-ft. PD (Pumpe Düse) variants also covered.
2.0L Gasoline (Aba, Aeg, Apk, Aqy, Avh, Azg, Azj Engines):
8 or 16 valves, SOHC or DOHC, Multi-Point Fuel Injection (MPI). Power typically 115-130 HP. Torque around 122-125 lb-ft.
2.8L Vr6 (Aaa, Afp, Aqp, Aww, Aue Engines):
12 valves (early VR6) or 24 valves (later VR6), SOHC or DOHC, natural aspiration. Power typically 174-204 HP. Torque around 180-200 lb-ft. Known for its unique narrow-angle V-configuration.
Acceleration 0 60 Mph:
Varies by engine and transmission, but generally between 6.5 seconds (1.8T GTI) and 10.5 seconds (2.0L Golf).
Fuel Type Gasoline:
Unleaded gasoline (Octane rating typically 91 or higher recommended for turbo models)
Fuel Type Diesel:
Diesel fuel
Induction System:
Naturally Aspirated (2.0L, early 2.8L VR6) and Turbocharged (1.8T, 1.9L TDI)
Standard Transmission:
5-speed Manual Transmission
Optional Transmission:
4-speed Automatic Transmission (e.g., 01M for most gasoline engines), 5-speed Tiptronic Automatic Transmission (later models, some VR6/1.8T)
Clutch Type:
Dry single-plate clutch (Manual)
Gear Ratios:
Detailed gear ratios for all applicable manual and automatic transmissions are provided in the manual.
Transmission Fluid Type:
Specific ATF or manual transmission fluid types and capacities for each transmission variant are detailed (e.g., G 052 162 A2 for manual, G 052 990 A2 for certain automatics).
Oil Change Interval:
Typically every 7,500 to 10,000 miles (12,000 to 16,000 km) or 12 months, depending on driving conditions and oil type used (consult manual for specific recommendations).
Timing Belt Replacement:
Critical for 1.8T and 1.9 TDI engines. Typically every 60,000 to 100,000 miles (96,000 to 160,000 km). Failure can cause catastrophic engine damage. The manual provides detailed replacement procedures and torque specifications.
Engine Oil Specification:
API Service category and viscosity grade vary by engine. Common specifications include VW 502 00 (gasoline) or VW 505 00/505 01 (diesel). Viscosities often 5W-40 or 5W-30. Refer to manual for exact specs.
Coolant Specification:
G12 (pink) or G12+ (purple) coolant, a 50/50 mix with distilled water. Manual provides capacity and bleed procedures.
Brake Fluid Specification:
DOT 4 hydraulic brake fluid. Manual details bleeding procedures and fluid specifications.
Common Issues 1.8T:
Oil sludge buildup (if maintenance neglected), ignition coil failures, PCV system issues, boost leaks, O2 sensor failures, coolant flange leaks.
Common Issues 1.9 Tdi:
N75 valve (boost control), EGR valve issues, turbocharger wear, glow plug failures, vacuum line leaks, DMF (Dual Mass Flywheel) wear on manual transmissions.
Common Issues 2.0L:
Oil consumption (especially on later models), valve cover gasket leaks, ignition switch failures.
Common Issues Vr6:
Coolant leaks (water pump, thermostat housing, coolant flange), ignition coil pack failures, intake manifold runner issues, oil pressure sensor failures.
Common Issues General:
Window regulator failures, door lock actuator failures, HVAC blower motor resistor failures, check engine light illumination due to various sensor faults.
