o 1 2 Overview, Maintenance Engine Engine Management, Exhaust, and Engine Electrical Important Safety Notice ii Foreword and Disclaimer v Vehicle Identification and VIN Decoder " vi Warnings and Cautions vii R32 Supplement back of book Index end of book 00 Golf, GTI and Jetta Product Familiarization o Maintenance General Information 15c Cylinder Head and Valvetrain 10 Engine-Removing and Installing (2.0L Engine) 13a Crankshaft/Cylinder Block (4-Cylinder) 15d Cylinder ~ead and Valvetrain 13b Crankshaft/Cylinder Block (6-Cylinder) (2.8L Engine) 15 CI ,d H d dV It' 15e Cylinder Head and Valvetrain a Yin er .ea an a ve rain (1.9L PO Engine) (1.8L Engine) , .. 15b Cylinder Head and Valvetrain 17 Enqine-Lubricatlon System (1.9L Engine) 19 Engine-Cooling System 2 Generallnformation 24c Fuellnjection-Motronic (2.8L Engine) 20 Fuel Storage and Supply 26 Exhaust System andEmission Controls 21 Turbocharger and Intercooler 27 Engine Electrical 23 Fuel Injection-Diesel (1.9L Engine) 28a Ignition System-Gasoline 24a Fuellnjection-Motronic (1.8L Engine) 28b Ignition System-Diesel 24b Fuellnjection-Motronic (2.0L Engine) 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 3 Clutch, Transmission, and Final Drive 30 Clutch 32 Torque Converter 34 Manual Transmission 40 Front Suspension and Drive Axles 42 Rear Suspension 44 Wheels-Tires, Wheel Alignment 45 Anti-Lock Brakes (ABS) 50 Body-Front 55 Hood and Lids 60 Sunroof 63 Bumpers 70 Trim-Interior 72 Seats 80 Heating and Ventilation 87 Air Conditioning 9 General Information 90 Instruments 91 Radio and Communication 92 Wipers and Washers 37 Automatic Transmission 39 Differential and Final Drive 46 Brakes-Mechanical Components 47 Brakes-Hydraulic System 48 Steering 57 Front Doors 58 Rear Doors 66 Body-Exterior Equipment 69 Seatbelts, Airbags 94 Lights, Accessories-Exterior 96 Lights, Accessories-Interior 97 Wiring Diagrams, Fuses and Relays ST 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 mid- 2005 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 in the preparation of this and other manuals. If you identify inconsistencies in the manual, you may have found an error. Please contact the publisher and we will endeavor to post applicable corrections on our website. Posted corrections (errata) should be reviewed before beginning work. Please see the following web address: http://www.BentleyPublishers.com/errata/ 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 car to 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. Bentley Publishers v
Vehicle Identification & VIN Decoder vi 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. WVWDE21JXYW671801 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 91a 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 91a 11 12 13 14 15 16 17 Jetta: DDDDDD~~DDD@]@]@]@]@]~ to DDDDDD~~DDD@J@J@J@J@J@J Golf: DDDDDD~QJDDD@]@]@]@]@]~ to DDDDDD~QJDDD@J@J@J@J@J@J Position Description Decoding Information 1 Country of origin 3 Mexico W Germany 9 Brazil 2 Manufacturer V Volkswagen 3 Vehicle Type W Passenger Car 4 Series Varies with model year 5 Engine See BentleyPublishers.com for more 6 Restraint system information 7 9M Jetta sedan Model 8 1J Golf, GTI, Jetta Wagon, R32 9 Check Digit 0-9 or X, calculated by NHTSA 10 Model Year X 1999 Y 2000 1 2001 2 2002 3 2003 4 2004 5 2005 11 Assembly Plant 4 Curitiba, Brazil H Hannover, Germany 8 Dresden, Germany M Puebla, Mexico D Bratislava, Slovakia P Mosel, Germany E Emden, Germany W Wolfsburg, Germany 12-17 Serial Number Sequential production number of the specific vehicle
Please read these WARNINGS and CAUTIONS before proceeding with maintenance and repair work. WARNING- • Read the Important Safety Notice on the copyright page at the beginning of the book. • Some repairs may be beyond your capability. If you lack the skills, tools and equipment, or a suitable workplace for any proce- dure described in this manual, we suggest you leave such repairs to an authorized Volkswagen dealer service department, or other qualified shop. • A thorough pre-reading of each procedure, and the WARNINGS and CAUTIONS that accompany the procedure is essential. Posted corrections (errata) should also be reviewed before beginning work. Please see www.BentleyPublishers.com/erratal. • Volkswagen is constantly improving its cars. Sometimes these changes, both in parts and specifications, are made applicable to earlier models. Therefore, before starting any major jobs or repairs to components on which passenger safety may depend, consult your authorized Volkswagen dealer about Technical Bulletins that may have been issued. • Do not re-use any fasteners that are worn or deformed in normal use. Many fasteners are designed to be used only once and become unreliable and may fail when used a second time. This includes, but is not limited to, nuts, bolts, washers, self-locking nuts or bolts, circlips and cotter pins. Always replace these fasteners with new parts. • Never work under a lifted car unless it is solidly supported on stands designed for the purpose. Do not support a car on cinder blocks, hollow tiles or other props that may crumble under contin- uous load. Never work under a car that is supported solely by a jack. Never work under the car while the engine is running. • If 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 roIl- ing. Disconnect the battery negative (-) terminal (Ground strap) 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, get caught in running machinery, or be crushed by heavy parts. • Tie 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. If your hair, clothing, or jewelry were to get caught in the machinery, severe injury could result. • Do not attempt to work on your car if you do not feel well. You increase the danger of injury to yourself and others if you are tired, upset or have taken medication or any other substance that may keep you from being fully alert. • Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the car. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally bro- ken 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 fire haz- ards. Wipe up spills at once, but do not store the oily rags, which can ignite and burn spontaneously. • Always 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 the 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 result in death. • Disconnect the battery negative (-) terminal (ground strap) whenever you work on the fuel system or the electrical 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 the 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, jumper cables or a bat- tery 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 than 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 volts. If the battery begins producing gas or boiling violently, reduce the charg- ing rate. Boosting a sulfated battery at a high charging rate can cause an explosion. • The air-conditioning system is filled with chemical refrigerant, which is hazardous. The AlC system should be serviced only by trained technicians using approved refrigerant recovery/recycling equipment, trained in related safety precautions, and familiar with regulations governing the discharging and disposal of automotive chemical refrigerants. • Do not expose any part of the AlC system to high temperatures such as open flame. Excessive heat will increase system pressure and may cause the system to burst. • Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Com- pletely remove the tire from the rim before attempting any repair. • Most cars covered by this manual are equipped with a supple- mental restraint system (SRS), that automatically deploys an airbag in the event of a frontal impact. The airbag is inflated by an explosive device. Handled improperly or without adequate safe- guards, it can be accidently activated and cause serious injury. • To prevent personal injury or airbag system failure, only factory trained Volkswagen service technicians should test, disas- semble or service the airbag system. continued on next page vii
Please read these WARNINGS and CAUTIONS before proceeding with maintenance and repair work. WARNING (continued)- • Disconnect the power supply before working on the airbag sys- tem, or when doing repairs that require removing airbag system components. Disconnect the battery negative (-) terminal and cover the battery. • 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. • 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 1551/1552 Scan Tool (ST) or an approved equivalent. The airbag unit must never be electrically tested while it is not installed in the car. CAUTION- • If you lack the skills, tools and equipment, or a suitable work- shop for any procedure described in this manual, we suggest you leave such repairs to an authorized Volkswagen dealer or other qualified 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 compo- nents 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 United 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 identifica- tion 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. • Before starting a job, make certain that you have all the neces- sary 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 specifications. 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, espe- cially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque specification listed. viii • Do not expose the airbag unit 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 directly 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. If 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. Wait at least one minute before boosting the bat- tery a second time. • Sealed or "maintenance free" batteries should be slow-charged only, at an amperage rate that is approximately 10 % of the bat- tery's ampere-hour (Ah) rating. • Do not allow battery charging voltage to exceed 16.5 volts. If the battery begins producing gas or boiling violently, reduce the charg- ing rate. Boosting a sulfated battery at a high charging rate can cause an explosion.
GOLF, GTI AND JETTA PRODUCT FA.MILIARIZATION 00-1 Golf, GTI and Jetta Product Familiarization The information included in this appendix is based on intro- ductory and preliminary sales information for A4 Golf, GTI, and Jetta vehicles sold in the USA/Canada. The content pro- vided is intended to serve a product familiarization quide, Note that the information given here is subject to change and should be used as a general reference only. INTRODUCTION INTRODUCTION WARNING- Always check the Volkswagen Worldwide Repair In- formation System or the publisher's website at www.bentleypublishers.com for information that may supersede any information included in this sec- tion. ABS (Anti-lock Brake System) 00-12 EDL (Electronic Differential Lock) 00-13 ESP (Electronic Stability Program) 00-13 BODY EXTERIOR 00-14 Fully galvanized body 00-14 High-strength steel body panels 00-14 Five step paint process 00-15 BODY INTERIOR 00-16 Airbags.............................. 00-16 Comfort electronics 00-17 CAN-bus 00-18 HEATING AND AIR CONDITIONING .00-19 ELECTRICAL SYSTEM 00-20 TECHNICAL SPECIFICATIONS 00-22 8927-047 SUSPENSION AND BRAKES 00-10 Front and rear suspension 00-11 Brakes, mechanical 00-12 ENGINE AND TRANSAXLE 00-7 Engines 00-7 Transaxles 00-9 INTRODUCTION 00-1 PRODUCT OVERVIEW 00-2 Golf and Jetta GL standard equipment (1999 model introduction) 00-3 Golf, GTI and Jetta GLS models standard equipment (1999 model introduction) ..... 00-3 GTI and Jetta GLX models standard equipment (1999 model introduction) 00-4 Feature Overview 00-5 Golf Dimensions 00-6 Jetta Dimensions 00-7
00-2 GOLF, GTI AND JETTA PRODUCT FAMILIARIZATION PRODUCT OVERVIEW The fourth generation of the Golf and Jetta, known as the A4 platform, was introduced in 1999. When introduced, three trim levels were offered (GL, GLS, and GLX). The Jetta was available in GL, GLS, and GLX trim levels, first as a 4-door sedan, and beginning in the 2001 , as a wagon. The Golf was available as both 2- and 4-door hatchbacks, in GL and GLS trim levels. GTI models were only available as 2-door hatch- backs (GLS, GLX models). External badging was not used to identify the different mod- els. The engine versions were however displayed on the rear of the vehicles. Available engines are listed below. All models feature chrome accents and soft-textured painted surfaces. The rear seat has a one third/two third split with a center seat head rest and shoulder belt. Side airbags for the front seats are also standard equipment for all models. The only individual option available during the model's intro- duction was the CD changer. All models are pre-wired for dealer installation. Additional optional equipment became available throughout the production span of the A4 vehicles. Late model high-tech options included ESP (Electronic Stabilization Program), Tiptronic 5-speed automatic transmission, 6-speed manual transmission, ASR (Anti Slip Regulation), Volkswagen PRODUCT OVERVIEW
The 2003 Volkswagen Golf Service & Repair Manual is a comprehensive guide designed to assist owners in maintaining and repairing their Volkswagen Golf 2003 model. This manual provides detailed explanations and step-by-step instructions for various repair procedures, ensuring that both experienced technicians and DIY enthusiasts can effectively troubleshoot and fix any issues that may arise.
The manual covers all aspects of the Volkswagen Golf 2003, including its engine, transmission, suspension, electrical system, and more. Detailed diagrams, illustrations, and specifications are provided to help users easily understand and follow the instructions. Whether performing routine maintenance or tackling complex repairs, this manual is an essential resource for ensuring optimal performance and longevity of your vehicle.
Some of the models covered in this manual include:
Volkswagen Golf 2003 1.4L
Volkswagen Golf 2003 1.6L
Volkswagen Golf 2003 1.8L
Volkswagen Golf 2003 1.9L TDI
Volkswagen Golf 2003 2.0L
With the 2003 Volkswagen Golf Service & Repair Manual, you can save time and money by performing repairs and maintenance tasks on your own. This manual is a must-have for any Volkswagen Golf 2003 owner who wants to keep their vehicle in top condition.