1996 VOLKSWAGEN GTI All Models Service and Repair Manual

Maintenance ',·-2· ''"''> ;···s . -./- /' , .. __ Engine Engine Management, Exhaust, and Engine Electrical Clutch, Transmission, arid Final Drive Suspension, Brakes, and Steering Body- Assembly Body- Components and Accessories Body- Interior Trim Heating and Air Conditioning Foreword .............................................................................. "' .............................. v Warnings and Cautions ......••.•.................... :........................................................ vii Index ................................... ·............................................................... back of book o Maintenance Program 1 Generalln!ormation 10 Engine-Removing and lnslalling 13 Crankshaft/Cylinder Block 15a Cylinder Head and Valvetrain (4-Cylinder Engines) 2 Generallnformation 20 Fuel Storage and Supply 21 Turbocharger and Intercooler · 23a Fuel Injection-Diesel 23b Fuel Injection-Diesel (TDI) 3 General Information SOa Clutch (ABA, ACC, AAZ Engines) 30b Clutch (AAA, AHU Engines) 34a Manual Transmission (ABA, ACC, AAZ Engines) 4 Generallnformation 40 Front Suspension and Drive Axles 42 Rear Suspension 44 Wheels-'fires, Wheel Alignment 5 Generallnformatlon 50 Body-Front 55 Hood and Uds 60 Sunroof 61 Convertible Top 63 Bumpers 70 Trim-interior 8 Generallnformation 80 Heating and Ventilation 15b Cylinder Head aitd Valvetrain (6-Cylinder Engine) 17 Engine-Lubrication System 19 Engin&-Cooling System 24a Fuel lnjectioo-Motronic 24b Fuel lnjection-Mono-Motronic 26 Exhaust System/Emission Controls 27 Engine Electrical 28a Ignition System-Gasoline 28b Ignition System-Diesel, 34b Manual Transmission (AAA, AHU Engines) 37 Automatic Transmission 39 Differential and Final Drive 45 (ABS) 48 Brakes-Mechanical Components 47 Brake&-Hydrautic System 48 Steering 57 Doors-Front 58 DoorS-Rear 66 Body Accessories-Exterior 69 Seatbeits; Airbags 72 Seats 87 Air Conditioning •.. 9 Electrical System 9 General Information 90 lnstrumants 91 Radio 92 Wipers and Washars 94 Ughts, Accessories-Extar!or 98 Lights, Accessorias-Jnterlor 97 Wiring Diagl'lims, Fuses and Relays t

Foreword 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, Cabrio Service Manual. This manual covers Volkswagen Jetta, Golf, GTI, GLX, Cabrio, TDI and special editions for the model years 1993 through early 1999. This manual was created specifically to cover only those models built for sale in the United States and Canada. Volkswagen and most aftermarket parts suppliers specializing in Volkswagens refer to the Jet- las, Golfs, GTis and Cabrios covered by this manual as the A3 models. The code "A3" is Volk- swagen's internal code for the basic platform shared by all of the cars covered by this manual. When ordering parts, especially body parts, knowing the A3 code may be helpful. For the Volkswagen owner with basic mechanical skills and tor 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 aim throughout has been clarity and completeness, with step-by-step procedures and accurate specifications. 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 tor 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 identified by their Volkswagen special tool number and illustrated. A thorough pre-reading of each procedure is recommended to determine in advance the need for particular tools and for essential replacement parts such as gaskets. v

vi Some of the information in this manual applies only to cars of a particular model year or range of years. For example, "1993 m.y." refers to the 1993 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. 3VWBA21 HXPM005678 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 1HXPM005678 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 1Oth character is the model year code. The letters "1", "0", "Q" and "U" are not used for model year designation, for example, "P" for 1993 m.y., "R" for 1994 m.y., etc. This manual covers Volkswagen "A3" Jetta, Golf, GTI, Gl.X, Cabrio, TDI and special editions for the model years 1993 through early 1999. The table below explains some of the various codes in the VIN numbers of models covered by this manual. a 1 v 1 w R A 8 1 I H X R M 11213141516 Manufactuer Body Engine Restraint Body Type Check Model Factory Sequential Information Type Type Digit Year Chassis No. 3VW-Mexican Depends on 0-Seatbelts, 1H-Golf or P-1993 M- Puebla, 000001-Begin Passenger car model year active front Jetta R-1994 Mexico production WVW-German 2-Seatbelts, 1E-Cabrio S-1995 K-Osnabruk, 999999-End passenger car passive front T-1996 Germany production 6-Airbag V-1997 W-Wolfsburg, front & side W-1998 Germany driver/pass. B-Airbag X-1999 front only driver/pass 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. The Publisher encourages comments from the readers of this manual with regard to errors, and also, suggestions for improvement in the presentation of the technical material. These communications have been and will be carefully considered in the preparation of this and other manuals. Please write or e-mail to Robert Bentley, Inc., at the address at the beginning of this manual. Volkswagen offers extensive warranties, especially on components of the fuel delivery and emission control systems. Therefore, before deciding to repair a Volkswagen that may be covered wholly or in part by any warranties issued by Volkswagen of America, Inc., consult your authorized Volkswagen dealer. You may find that the dealer can make the repair either free or at minimum cost. Regardless of its age, or whether it is under warranty, your Volkswagen is both an easy carlo service and an easy car to get serviced. So if at any time a repair is needed that you feel is too difficult to do yourself, a trained Volkswagen technician is ready to do the job for you.

Please read these warnings and before proceeding with maintenance and repair work. WARNING- • Some repairs may be beyond your capability. If you lack ihe skills, fool!\ and equipment, or a suitable workplace for any procedure described in this manual, we suggest you leave Sl!Ch repairs to an authorized Volkswagen dealer service department, or oiher qualmed shop. • Volkswagen is constantly improving ita cars. Sometimes these changes, both in parts and specilica!lons, are mad& applicable to earlier models. Therefore, before starting any major jobs or repairs to components on which passenger safety may dep&nd, your auihorlzed Volkswagen dealer about Technical Bulletins that may have been Issued since the editorial closing of this manual. • Do not re-use any fasteners !hal are worn or deformed In normal use. Many fasteners are designed to be used only once and become unreliable and may fail whan used a second 1ime. This includes, but is not limited to, nuts, boils, washers, sett-locklng nuts or bolts, clrclips and cotter pins. Always replace these lasteners with new parts. • Never work under a lifted car unless it is solidly supported on stands designed lor the purpose. Do not support a car on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a car that is supported solely by a jack. Never work under the car while the engine is running. • tt you are going to work under a car on the ground, make sure that the ground is level. Block the wheels to keep the car from ing. Disconnect !he battery negative (-)terminal (Ground sttap) to prevent others from starting the car while you are under it. • Never run the engine unless the work area is well ventilated. Carbon monoxide kills. • Finger rings, bracelets and other jewelry should be removed so that they cannot cause electrical shorts, gel caught In running machinery, or be crushed hy heavy parts. • TIS long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near machine tools or running engines. H your hair, clothing, or jewelry were to get caught In ihe machinery, severe injury could result. • Do not attempt to work on your car if you do not lael well. You Increase the danger of injury to yoursan and oihers ff you are tirad, upset or have taken medication or any other substance that may keep you from being fully alert. • Illuminate your work area adequately but sstely. Usli a portable safety light for working Inside or under the car. Make sure the bulb is enclosed hy a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. • Catch draining fuel, oil, or brake fluid in suitable containers. Do not use food or beverage containers that might mislead someone into drinking from them. Store flammable fluids away from !Ire hazards. Wipe up spills at once, but do not store !he oily rags, which can ignite and burn spontaneously. • /Oways observe good workshop practices. Wear goggles when you operate machine tools or work with battery acid. Gloves or other protective clothing should be worn whenever !he job requires working with harmful substances. • Friction materials such as brake or clutch discs may contain asbestos fibers. Do not create dust bY grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may resuU in death. • Disconnect the battery nega1ive (-) tenminal (ground strap) whenever you work on the fuel system or the eleatrlcal system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy. • Batteries give off explosive hydrogen gas during charging. Keep sparks, lighted matches and open flame away from ihe top of the battery. If hydrogen gas escaping from the cap vents Is ignited, it will Ignite gas trapped In the cells and cause the battery to explode. • Connect and disconnect battery cables, jumpar cables or a battery charger only with the ignition switched off, to prevent sparks. Do not disconnect the battery while the engine is running. • Do not quick-charge the battery (for boost starting) for longer !hen one minute. Wait at least one minute before boosting the bat· tery a second time. • Do not allow battery charging voltage to exceed 16.5 voits. If the battery begins producing gas or boiling vlolentiy, reduce the charg- Ing rate. Boosting a suWated battery at a high charging rate can cause an explosion. • • The air-conditioning system Is filled with chemical refrigerant, which is hazardous. The AJC system should be serviced only by trained technicians using approved refrigerant recovery/recycling equipment, trained in related safety precautions, and familiar with regulations governing ihe discharging and disposal of automotive chemical relrigeranta. • Do not expose any part of the AJC system to high temperaiures such as open flame. Excessive heat will increase system pressure and may cause the system to burst. • Some aerosol tire inflators are highly Be extremely cautious when repairing a tire that may have been inflated using an aerosol tire inflator. Keep sparks, opan ftarne or other sources of Ignition away from the tire repair area. Inflate and deflate the tire at leaal four times before breaking the baed from the rim. Com- pletely remove the tire from the rim before attempting any repair. • Most cars covered by !his manual are equipped with a supple- mental restraint system (SRS), that automatically deploys an alrbag in the event of a frontal impact. The alrbag Is inflated by an explosive device. Handled improperly or without adequate sale- guards, it can be accidently activated and cause serious injury. • To prevent personal Injury or iilrbag system failure, only 1aotory trained Volkswagen service technicians should test, disassemble or service the airbag system. • Disconnect the power supply be!ote working on the airbag system, or when doing repairs that require removing alrbag system components. Disccnneat the battery negative (-) terminal and cover the battery. continued on next page vii ' /

Please read these warnings and cautions before proceeding with maintenance and repair work. WARNING (continued}- e On airbag-equipped cars, never apply stickers or any other type of covering on the steering wheel. Do not let chemical cleaners, oil or grease come into contact with vinyl covering of the airbag unit. • Never open or otherwise attempt to repair airbag system parts. Always use new parts. Never leave airbag parts or the partially dis- assembled airbag system unattended. e Never use a test light to conduct electrical tests on the airbag system. The system must only be tested by trained Volkswagen Service technicians using the Volkswagen VAG 1551 Scan Tool (ST} or an approved equivalent. The airbag unit must never be electrically tested while it is not installed in the car. CAUTION- e If you lack the skills, tools and equipment, or a workshop for any procedure described in this manual, we suggest you leave such repairs to an authorized Volkswagen dealer or other qualnied shop. We especially urge you to consult an authorized Volkswagen dealer before beginning repairs on any car that may still be covered wholly or in part by any of the extensive warranties issued by Volkswagen of America. • Volkswagen offers extensive warranties, especially on components of fuel delivery and emission control systems. Therefore, before deciding to repair a Volkswagen that may still be covered wholly or in part by any warranties issued by Volkswagen Unfted States, Inc., consult your authorized Volkswagen dealer. You may find that he can make the repair for free, or at minimal cost. • Volkswagen part numbers listed in this manual are for identification purposes only, not for ordering. Always check with your authorized Volkswagen dealer to verify part numbers and availabil- ity before beginning service work that may require new parts. e Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the instructions thoroughly, do not attempt shortcuts. Use tools appropriate to the work and use only replacement parts meeting Volkswagen specffications. Makeshift tools, parts and procedures will not make good repairs. • Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque specification listed. viii • Do not expose the airbag unft to temperatures above 194"F (90"C), even for brief periods. Keep clear of heat sources such as hot plates, soldering irons, heat lamps and welding equipment. • When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident. • Greases, lubricants and other automotive chemicals contain toxic substances, many of which are absorbed direclly through the skin. Read manufacturer's instructions and warnings carefully. Use hand and eye protection. Avoid direct skin contact. • Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond or lake. Consult local ordinances that govern the disposal of wastes. • On cars equipped with anti-theft radios, make sure you know the correct radio activation code before disconnecting the battery or removing the· radio. II the wrong code is entered into the radio when power is restored, that radio may lock up and be rendered inoperable, even if the correct code is then entered. • Connect and disconnect a battery charger only with the battery charger switched off. • Do not quick-charge the battery (for boost starting) for longer than one minute. Waft at least one minute before boosting the battery a second time. • Sealed or "maintenance free" batteries should be slow-charged only, at an amperage rate that is approximately 1 0% of the battery's ampere-hour (Ah} rating. • Do not allow battery charging voftage to exceed 16.5 volts. If the battery begins producing gas or boiling violently, reduce the charging rate. Boosting a sulfated battery at a high charging rate can cause an explosion.

MAINTENANCE PROGRAM 0-1 0 Maintenance Program General ................................ o-2 How To Use This Manual .............. o-2 Warnings, cautions, and notes .............. 0-2 Work safety ............................. 0-3 Identification Plates and Labels . ....... o-3 Vehicle Identification Number (VIN) .......... 0-3 Engine code and engine number ............ 0-3 Transmission identification ................. 0-4 Towing ................................ 0-6 Lifting Vehicle ......................... o-6 To raise vehicle with jack . . . . . . . . . . . . . . . . . . 0-6 To work under car ........................ 0-7 Maintenance Schedules ............... o-7 Engine Compartment Maintenance ... 0-15 Engine oil level, checking ................. 0-15 Engine oil, changing ..................... 0-15 Oil filter, replacing (4-cylinder engines) ....... 0-16 Oil filter, replacing (6-cylinder engine) ....... 0-16 Coolant, checking ....................... 0-16 Brake fluid level, checking ................ 0-17 Brake fluid, replacing .................... 0-18 Power steering fluid level, checking ......... 0-18 Fluid leaks ............................. 0-18 Fuel filter, draining (diesel engines) ......... 0-18 Fuel filter, replacing (diesel engines) ........ 0-19 Fuel filter, replacing (gasoline engines) ...... 0-19 Dust and pollen filter, replacing ............. 0-19 Battery service . . . . . . . . . . . . . . . . . . . . . . . . . 0-19 Power steering V-belt, checking/adjusting (4-cylinder engines) .................... 0-20 Poly-ribbed belt, applications .............. 0-21 Poly-ribbed belt, adjusting (4-cylinder engines without belt tensioner) .................. 0-21 Poly-ribbed belt, removing and installing (4-cylinder engines) .................... 0-21 Poly-ribbed belt, removing and installing (6-cylinder engine) ..................... 0-22 Camshaft drive belt, checking (4-cylinder engines) .................... 0-23 Camshaft drive belt, adjusting (diesel engine) . 0-23 Spark plugs, replacing ................... 0-23 Air cleaner, removing and installing ......... 0-24 Distributor cap and rotor, inspecting (4-cylinder gasoline engines) ............. 0-24 Clutch cable, adjusting ................... 0-24 Under Car Maintenance .............. . 0-24 Tire service ............................ 0-24 Brake system, visual inspection ............. 0-24 Brake pads (front and rear), checking ........ 0-25 Brake linings (rear), checking .............. 0-25 Parking brake, adjusting .................. 0-25 Drive axle shafts, checking boots ........... 0-25 Front suspension components, checking ...... 0-25 Transmission, checking for leaks ............ 0-25 Final drive oil level, checking (cars with automatic transmission) .......... 0-26 Automatic transmission fluid (ATF) level, checking .................... 0-26 ATF, Changing (096 auto. transmission) ...... 0-26 ATF, Changing (01 M auto. transmission) ..... 0-27 Manual transmission oil (checking) .......... 0-28 Exhaust system, checking ................. 0-29 Underbody sealant, checking ............... 0-29 Body and Interior Maintenance . ....... 0-29 Body exterior ........................... 0-29 Exterior lights, checking ................... 0-29 Interior lights, checking ................... 0-29 Airbag unit, visual inspection ............... 0-29 Door check straps and hinges, greasing ...... 0-30 Windshield wipers and washers ............. 0-30 On board diagnostic (OBD) system .......... 0-30 Service reminder indicator (SRI), resetting .... 0-30 Road Test ............................. o-30 Automatic transmission shift lock ............ 0-30 Automatic park/neutral position switch ........ 0-30 Brake pedal and parking brake ............. 0-30 Manual gearshift ........................ 0-30 Steering ............................... 0-30 Kickdown operation ...................... 0-30 Air conditioner and heater ................. 0-30 TABLES a. 7,500/22,500 mile service (1993-1996 m.y.) ... 0-8 b. 15,000/45,000 mile service (1993-1996 m.y.) .. 0-8 c. 30,000/60,000 mile service (1993-1996 m.y.) .. 0-9 d. First 5,000 mile service (1997-1999 m.y.) .... 0-11 e. 10,000 mile service (1997-1999 m.y.) ....... 0-11 f. 20,000 mile service (1997-1999 m.y.) ....... 0-12 g. 40,000 mile service (1997-1999 m.y.) ....... 0-13 h. 2 year service (all models) ................ 0-14 i. at 4 years, 8 years, and every 2 years thereafter service (all models) .......... · · · 0-14

0-2 MAINTENANCE PROGRAM GENERAL All of the maintenance work described in this repair group is important and should be carried out at the specified time or mileage interval. The Owner's Manual, the Maintenance Record, and the Warranty Booklet originally supplied with the car contain the maintenance schedules that apply to your Volkswagen. Following these schedules will ensure safe and dependable operation. In addition, many of the maintenance procedures are necessary to maintain warranty protection. NOTE- Volkswagen is constantly updating their recommended maintenance procedures and requirements. The inforR mat/on contained here may not include updates or reR visions made by Volkswagen since publication of the Owner's Manual, the Maintenance Record, and the Warranty Booklet supplied with the car. If there is any doubt about what procedures apply to a specific model or model year, or what Intervals should be followed, member that an authorized Volkswagen dealer has the latest maintenance information. HOW TO USE THIS MANUAL The manual is divided into 1 0 main sections, or partitions: 0 Maintenance 1 Engine 2 Fuel, Ignition, and Exhaust Systems 3 Clutch, Transmission, and Final Drive 4 Suspension, Brakes, and Steering 5 Body-Assembly 6 Body-Components and Accessories 7 Body-Interior Trim 8 Heating and Air Conditioning 9 Electrical System 0 Maintenance Program covers the recommended schedules and service procedures needed to do the Volkswagen- specified scheduled maintenance work. The remaining nine partitions (1 through 9) are repair ori- ented and are broken down into individual repair groups. Each main partition begins with a general information group, e.g. 1 General Information. These general groups are mostly descriptive in nature, covering topics such as theory of operation and troubleshooting. The remainder of the repair groups contain the more involved and more detailed system repair information. GENERAL A master listing of the 1 0 partitions and the corresponding individual repair groups can be found on the inside book cover. Thumb tabs are used on the first page of each repair group page to help locate the groups quickly. Page numbers throughout the manual are organized according to the repair group system. For example, you can expect to find information on engine removal and installation (Repair Group 1 0) beginning on page 10-1. A comprehensive index can be found on the last pages of the manual. Warnings, Cautions and Notes Throughout this manual are many passages with the headings WARNING, CAUTION, or NOTE. These very important headings have different meanings. WARNING- The text under this heading warns of unsafe practio- es that are very likely to cause injury, either by direct threat to the person(s} doing the work or by in· creased risk of accident or mechanical failure while driving. Warnings are always contained In a box. CAUTION- A caution calfs attention to important precautions to be observed during the repair work that will help prevent accidentally damaging the car or its parts. Cautions are always contained in a box. NOTE- A note contains helpful information, tips that will help In doing a better job and completing it more easily. Please read every WARNING, CAUTION, and NOTE at the front of the manual and as they appear in repair procedures. They are very important. Read them before you begin any maintenance or repair job. Some WARNINGs and CAUTIONs are repeated wherever they apply. Read them all. Do not skip any. These messages are important, even to the owner who never intends to work on the car.

Work Safety Although an automobile presents many hazards, common sense and good equipment can help ensure safety. Many ac- cidents happen because of carelessness. Pay attention and stick to these few important safety rules. WARNING- • Never run the engine in the work area unless it is we/1-venfflated. The exhaust should be vented to the outside. Galban Monoxide (CO) in the exhaust kills. • Remove all neckties, scarfs, loose clothing, or jewelry when working near running engines or power tools. Tuck in shirts. Tie long hair and se- cure it under a cap. Severe injury can result from these things being caught in rotating parts. • Remove rings, watches, and bracelets. Aside from the dangers of moving parts, metallic jew- . elry conducts electricity and may cause shorts, sparks, burns, or damage to the electrical system when accidentally contacting the battery or other electrical terminals. • Disconnect the battery negative (-) cable whenever working on or near the fuel system, airbag system or anything that is electrically powered. Accidental electrical contact may damage the electrical system, cause fire, or result in serious personal injury. • Never work under a lifted car unless it is solidly supported on jack stands that are intended for that purpose. Do not support a car on cinder blocks, bricks, or other objects that may shift or crumble under continuous load. Never work under a car that Is supported only by a jack. • The fuel system retains pressure even when the ignition is off. Loosen the fuel lines very slowly to allow the residual pressure to dissipate gradually. Avoid spraying fuel. • Fuel is highly flammable. When working around fuel, do not smoke or work near fire hazards. Keep an approved fire extinguisher handy. • Illuminate the work area adequately and safely. Use a portable safety light for working inside or under the car. A fluorescent type light is best because ft gives off less heat. If using a light with a normal incandescent bulb, use rough service bulbs to avoid breakage. The hot filament of an accidentally broken bulb can ignfte spilled fuel or oil. • Keep sparks, lighted matches, and open flame away from the top of the battery. Hydrogen gas emitted by the battery is highly flammable. Any nearby source of ignition may cause the battery to explode. • Never Jay tools or parts in the engine ment or on top of the battery. They may tall and be difficult to retrieve, become caught in belts or other rotating parts, or cause electrical shorts and damage to the electrical system. MAINTENANCE PROGRAM 0-3 IDENTIFICATION PLATES AND LABELS Vehicle Identification Number (VIN) The vehicle year and model can be determined from the VIN or the identification plate. Because stickers can fall off, be painted over, or be moved, it is best to rely on numbers stamped into the chassis. The VIN (Chassis number) is stamped into the rear cross panel of the engine compartment. It is visible through a window in the plenum chamber cover. See Fig. 1. The identification plate is located on the driver's side of the padded dash panel. Additional vehicle identification information is also found on stickers attached to the driver's side door post and in the trunk. NOTE- Additional information on the 17 digit V/N is given in the Foreword on page vi, at the front of the manual . 0024180 Fig. 1. Partial vehicle identification number (A) stamped into rear cross panel of the engine compartment. Full VIN on plate on driver's side of padded dash panel. Engine code and engine number The engines used in the Volkswagens covered by this manual are identified by a three letter code. The engine code and the engine number are located on the engine block. Location depends on engine application. Engine codes • ACC ............................. 1 .8 Liter gas • AAZ, AHU ....................... 1.9 Liter diesel • ABA ............................. 2.0 Liter gas • AAA ............................. 2.8 Liter gas GENERAL

0-4 MAINTENANCE PROGRAM • ACC and ABA engine code letters and engine number are located on the front of the engine block, below the separation point between engine block and cylinder head. See Fig. 2. c I 0o2411sl 0024116 Fig. 2. Engine number location (arrow) on ACC and ABA engines. • AAZ and AHU engine code letters and engine number are located between the injection pump and vacuum pump on the cylinder block. See Fig. 3. • AAA (VR6) engine code letters and engine number are located on the cylinder block above the vibration damp- er. The number is visible by looking through the right suspension strut tower and air cleaner. See Fig. 4. NOTE- The engine codes often can also be found on a sticker on the camshaft drive belt guard (4-cy/. engines) or on the cylinder head cover {6-cy/. engines). 10-574 Fig. 3. Engine number location {arrow) on AAZ diesel engine shown. AHU diesel is similar. GENERAL I V10-1112 I V10-1112 Fig. 4. Engine number location (arrow) on VR6 engine. Transmission identification Two manual transmissions and two automatic transmissions are used in the cars covered by this manual. Application depends on engine and model year. 020 5-speed manual transmission is used in all cars with 4- cylinder engines and manual transmission, except TDI Diesel. See Fig.5. 02A 5-speed manual transmission i.s used in cars with 6- cylinder engine or TDI Diesel, and manual transmission. See Fig.6. 096 4-speed automatic transmission is used in Golf, Jet- ta and Cabrio models beginning in 1993. It may be installed in combination with either a 4-cylinder or a 6-cylinder engine. See Fig. 7. 01 M 4-speed automatic is installed in some 1995 and later cars with 4- or 6-cylinder engines. See Fig. 8.

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1996 VOLKSWAGEN GTI All Models Service and Repair Manual

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