Service

Maintenance

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Bora Variant 1999
Golf 1998
Golf Variant 1998
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Service Department. Technical Information

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Edition 05.2012

Service
Maintenance

Heading
1. Engine list
2. Service work
3. General
4. Descriptions of work

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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright 2012 Volkswagen AG, Wolfsburg

K0451015020

Bora 1999 , Bora Variant 1999 , Golf 1998 , Golf Variant 1998
Maintenance - Edition 05.2012

Contents

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1
Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Delivery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
Oil change service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4
Inspection service 1999 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5
Inspection service 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6
Additional work on natural gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3
Connecting vehicle diagnosis tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4
Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5
Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6
Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7
Information on long-life service or time- or distance-dependent service . . . . . . . . . . . . . .
3.8
Countries with elevated sulphur content in diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9
Countries with hot climate includes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11 RME fuel (biodiesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.12 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
Exhaust system: Perform visual check for leaks, security and damage . . . . . . . . . . . . . . . .
4.2
Swivel joints: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.3
Automatic gearbox:
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4.4
Automatic
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4.5
Automatic
gearbox: Check gear oil in finalradrive
(01M gearbox) . . . . . . . . . . . . . . . . . . . .
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4.6 autAutomatic
gearbox: Check ATF level, top-up ifornecessary
(01M gearbox) . . . . . . . . . . . .
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4.7 s Automatic gearbox: Check ATF level, top-up if necessary (09A gearbox) . . . . . . . . . . . .
4.8
Battery: Check battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . . .
4.9
Battery: Check using battery tester with printer VAS 5097A or VAS 6161 . . . . . . . . . . . . . .
4.10 Front airbag for the front passenger: Check activation / deactivation . . . . . . . . . . . . . . . .
4.11 Checking tyres: Condition, wear pattern, tyre pressure and tread depth . . . . . . . . . . . . . .
4.12 Brake system: Perform visual check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . .
4.13 Front and rear brake pads/linings: Check thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.14 Brake and clutch system: Change brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.15 Brake fluid level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.16 6-speed dual clutch gearbox 02E (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.17 Electric windows, 8-way memory seat: Perform initialisation (activation) . . . . . . . . . . . . . .
4.18 Vehicle system test: Perform test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.19 Protective bellows: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.20 Installing noise insulation: Golf R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.21 Haldex coupling: Renew oil filter (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.22 Haldex coupling: Change oil (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.23 Checking first aid box expiry date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.24 Rear lid: Lubricate left and right multi-joint hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.25 Fuel filter: Renew (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.26 Fuel filter: Drain water (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.27 Poly V-belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.28 Cooling system: Check frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . . .
4.29 Air filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.30 Engine cover panel -top-: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.31 Engine compartment cover (noise insulation) -bottom-: Removing and installing . . . . . . . .
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Contents

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Bora 1999 , Bora Variant 1999 , Golf 1998 , Golf Variant 1998
Maintenance - Edition 05.2012

Contents

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4.61
4.62
5
5.1
5.2
5.3
5.4
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4.58
4.59
4.60

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4.45
4.46
4.47
4.48
4.49
4.50
4.51
4.52
4.53
4.54
4.55
4.56

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4.38
4.39
4.40
4.41
4.42
4.43
4.44

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4.35
4.36

Engine oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil: Drain or extract and replenish; renew oil filter . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine and components in engine compartment (from above and below): Perform visual
check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performing road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radio and radio-navigation system: Stick serial number and code number onto unit card
........................................................................
Radio/radio-navigation system: Activate anti-theft coding . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel securing bolts: Tightengeto
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Tyre repair set: Check
. . . . . . . . . . . . . . . . . . . . . . . . . .ra.n.te. . . . . . . . . . . . . . . . . . . . . . . .
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u steering: Check oil/fluid level . . . . . . . . . . . .or.a . . . . . . . . . . . . . . . . . . . . .
Power assisted
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Sunroof: Check function, clean and grease guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sliding sunroof drains: Checking for blockage, cleaning if necessary . . . . . . . . . . . . . . . .
Windscreen wash/wipe system and headlight washer system: Check for damage, function
and spray jet settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiper blades: Check for damage, park position and setting angle if wiper blades judder . .
Manual gearbox/final drive: Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight adjustment: Check and adjust as necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service interval display: Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service interval display: Recode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Track rod ends: Check clearance, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dash panel insert: Adapt to required language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dust and pollen filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . .
Transportation device: Remove blocking pieces from front axle springs . . . . . . . . . . . . . .
Door arrester: Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clock: Set to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Underbody: Visual check for damage to underbody sealant, underbody panels, routing of
lines, plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toothed belt and camshaft drive tensioning roller: Renew . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft drive toothed belt: Check (4-cylinder petrol engine) . . . . . . . . . . . . . . . . . . . . . .
Toothed belt: Check for wear (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft drive toothed belt: Check condition and tension (diesel engine code ALH with
automatic gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional work on natural gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark plugs: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust emissions test for petrol engines without OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust emissions test for petrol engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust emissions test for diesel engines without OBD . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust emissions test for diesel engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.33
4.34

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