Volkswagen Golf 1999 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Volkswagen Model: Golf Year: 1999 Codes Chassis Code: Mk4 (Typ 1J) 👋 Introduction Market Position Segment: Compact Family Car / Hot Hatch Reputation: Known for...

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Sku: 368904

Tags: 1999 Car Cars Golf Volkswagen Volkswagen VW

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Description

🏷️ Basic Information

Identification

Make:

Volkswagen

Model:

Year:

Codes

Chassis Code:

Mk4 (Typ 1J)

👋 Introduction

Market Position

Segment:

Compact Family Car / Hot Hatch

Reputation:

Known for quality, engineering, and sporty handling, particularly in GTI variants.

Competitive Analysis

Competitors:

Honda Civic, Ford Focus, Toyota Corolla, Mazda 323/Protege, Opel Astra

Key Features

Design:

Modern styling, good interior space, solid build quality

Engine Options:

Variety of gasoline and TDI diesel engines available across different markets

Gti Variant:

Performance-oriented version with enhanced engine, suspension, and styling

📋 Manual Details

Coverage Areas

Systems Covered:

Engine, Drivetrain, Suspension, Steering, Brakes, Electrical Systems, HVAC, Bodywork, Interior

Page Count

Page Count:

Extensive (typically 1000+ pages for full factory manual)

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, potentially searchable)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed diagnostics, disassembly, assembly, repair, and overhaul of all engine variants

Engine Performance:

Ignition timing, fuel delivery, emissions control, engine management systems (ECU)

Transmission Manual:

Shift linkage, clutch assembly, gearbox disassembly and repair

Transmission Automatic:

Torque converter, valve body, internal components, fluid service, electronic controls

Drivetrain:

Front-wheel drive axle shafts, differential components, AWD system (if applicable)

Suspension Front:

MacPherson struts, control arms, wheel bearings, spring and shock absorber replacement

Suspension Rear:

Torsion beam axle (FWD) or multi-link independent suspension (AWD), shock absorbers, bushings

Steering:

Power steering pump, rack and pinion, tie rods, steering column, alignment procedures

Brakes Hydraulic:

Master cylinder, brake lines, brake fluid flush, bleeding procedures

Brakes Disc:

Calipers, rotors, brake pads, parking brake mechanism

Electrical System:

Battery, charging system (alternator), starting system (starter motor)

Electrical Lighting:

Headlights, taillights, interior lighting, bulb replacement

Electrical Instruments:

Dashboard cluster, gauges, warning lights

Electrical Comfort:

Power windows, power locks, mirrors, seat adjustment mechanisms

HVAC System:

A/C compressor, refrigerant, evaporator, heater core, blower motor, climate controls

Bodywork Exterior:

Bumpers, fenders, doors, hood, trunk lid, glass replacement, seals

Bodywork Interior:

Dashboard removal, seat removal, trim panels, carpet replacement

Safety Systems:

Airbag system diagnostics and replacement, seat belt mechanisms

Procedures Included

Preventive Maintenance:

Oil changes, filter replacements, fluid checks and changes, belt inspection and replacement

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting, fault code interpretation (OBD-II)

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair

Assembly Disassembly:

Complete breakdown and reassembly of major vehicle components

Diagnostic Tests:

Procedures for testing sensors, actuators, and electrical circuits

Specification Checks:

Torque specifications, clearances, alignment angles, fluid capacities

Technical Depth

Depth:

Comprehensive (covers everything from basic fluid changes to complete engine and transmission rebuilds)

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution diagrams and text

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Example Gasoline:

AGN (2.0L 8v), AGU (1.8T 20v), APY (1.8T 20v GTI)

Engine Code Example Diesel:

AHF (1.9L TDI)

Engine Displacement

Displacement Range:

1.4L to 2.8L

Performance

Horsepower Range:

75 hp (1.4) to 204 hp (VR6)

Torque Range:

Approx. 125 Nm to 270 Nm

Fuel System

Injection Type:

Multi-point fuel injection (MPI) or Electronic Fuel Injection (EFI) for gasoline; Direct Injection (TDI)

Fuel Type:

Unleaded Gasoline (RON 91+), Diesel Fuel

Cooling System

Coolant Type:

G12/G12+ (Red or Purple Antifreeze)

Ignition System

Spark Plug Type Example:

NGK BKR6E or similar (varies by engine)

🔧 Transmission

Standard

Manual Transmission:

5-speed manual (e.g., 02A, 02J)

Optional

Automatic Transmission:

4-speed automatic (e.g., 01M)

Features

Clutch Type:

Hydraulic dry single-plate clutch

Transmission Fluid Manual:

API GL-4 SAE 75W-90 or 75W-80 (check specific transmission)

Transmission Fluid Automatic:

G 052 162 A2 (VW Automatic Transmission Fluid - ATF)

📐 Dimensions

Exterior

Length Approx:

4149 mm

Width Approx:

1759 mm

Height Approx:

1438 mm

Wheelbase Approx:

2518 mm

Weights

Curb Weight Range:

1150 kg - 1400 kg (depending on engine/trim)

Gross Vehicle Weight Rating Gvwr:

Approx. 1750 kg - 1900 kg

Cargo

Cargo Volume Hatchback Rear Seats Up:

Approx. 330 liters

Cargo Volume Hatchback Rear Seats Down:

Approx. 1160 liters

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4/5 Stars (Varies by testing year and specific configuration)

IIHS Side Impact:

Acceptable to Good (Varies by testing year and specific configuration)

Active Features

Standard on most models

Traction Control Asr:

Optional on some models, standard on GTI/VR6

Electronic Stability Control Esc:

Rarely standard on 1999 models, potentially optional on later Mk4 years.

Passive Features

Airbags Front:

Driver and Passenger airbags standard

Airbags Side:

Optional side airbags for front occupants on some trims

Seatbelts:

3-point front seatbelts with pre-tensioners, 3-point rear seatbelts

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM radio with CD player or cassette tape, optional premium sound systems

Navigation:

Rarely factory-installed in 1999, likely aftermarket units

Driver Assistance

Cruise Control:

Optional on many trims

Rain Sensing Wipers:

Not typically available in 1999

Connectivity

Bluetooth:

Not factory available in 1999

Usb Ports:

Not factory available in 1999

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10,000 miles (15,000 km) or 12 months, whichever comes first (under normal driving conditions)

Engine Oil Filter Interval:

Replace with every oil change

Air Filter Interval:

Every 20,000-30,000 miles (30,000-50,000 km)

Cabin Air Filter Interval:

Every 15,000-20,000 miles (25,000-30,000 km) or annually

Timing Belt Interval Gasoline:

Every 60,000-100,000 miles (100,000-160,000 km) or 5-7 years (CRITICAL - check specific engine code)

Timing Belt Interval Tdi:

Every 60,000-70,000 miles (100,000-120,000 km) or 5 years (CRITICAL - check specific engine code)

Fluid Specifications

Engine Oil Viscosity:

5W-40 or 5W-30 (synthetic recommended, check manual for exact specs per engine)

Coolant Capacity:

Approx. 6.5 - 7.5 liters

Brake Fluid Type:

DOT 4

Known Issues

Ignition Coil Failure:

Common failure point, especially on 1.8T engines, leading to misfires.

Window Regulator Failure:

Plastic components can break, causing windows to fall into door panels.

Mass Air Flow Sensor Maf:

Can become dirty or fail, causing rough idle and poor acceleration.

ABS Sensor Failure:

Wheel speed sensors can fail, illuminating ABS warning light.

Catalytic Converter Failure:

Can fail due to age or engine issues, leading to poor performance.

Evaporative Emissions System Evap:

Canister purge valve or vent valve issues can trigger check engine lights.

Cv Axle Boots:

Rubber boots can tear, leading to grease loss and eventual CV joint failure.

Rear Axle Bushings:

Worn bushings can cause clunking noises and affect handling.

📚 Vehicle History

Brand Heritage

Volkswagen Legacy:

Long history of producing reliable, practical, and fun-to-drive vehicles.

Model Evolution

Golf Lineage:

The Golf is Volkswagen's iconic compact hatchback, a successor to the Golf Mk3.

Mk4 Introduction:

The Mk4 (Typ 1J) was introduced in late 1997 for the 1998 model year in Europe, and in 1999 for North America.

Production

Production Years:

1997-2006 (globally, phased out earlier in some markets)

Manufacturing Locations:

Germany (Wolfsburg), Mexico, South Africa, China, Brazil, etc.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Golf GTI models often appeared on Car and Driver's 10Best list in previous generations, setting a precedent for the Mk4.

Safety Awards:

Achieved good safety ratings for its time, contributing to Volkswagen's reputation.

Ratings

Reliability Perception:

Mixed; generally good when maintained but some models had specific electronic or mechanical quirks.

Certifications

Emissions Standards:

Meets prevailing emissions standards for the 1999 model year (e.g., OBD-II compliance in North America).