Automotive Manual PDF

We are writing to inform you of an emissions recall on some 2004-2005 model year Volkswagen Golf, Jetta and New Beetle TDI engine vehicles. Our records show that you are the owner of one of these vehicles.
What Is The Problem?
The EGR cooler on affected vehicles has the potential to develop an internal leak. If this happens, the MIL light may come on, and the vehicle may exceed Federal and/or California emissions standards.
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Please read the installation procedure listed below as it will save you time (and possibly parts) in the long run. After installation…enjoy! Caution! Be aware that E-PROM’s are static-sensitive devices, and so are the chips in your control unit. Avoid replacing chips in high static areas, and avoid touching the pins of any integrated circuit / E-PROM.

1. Open hood and remove the rubber seal laying on the top edge of the firewall. Remove the plastic raintray and locate the control unit. It is located on the driver’s side on Golf and Jetta 2 models, the passenger side on Passat and A3 models.
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This is a guide to cleaning the Mass Air Flow (MAF) sensor, infamously known to VW owners as a problem part. This problem seems to have become more widespread with the release of the Mk. IV platform, which is apparently due to a bad batch of sensors from the Bosch factory. Although most of the faulty MAFs have been weeded out after having failed on their owners, the more hardy MAFs often survive until just after the car’s warranty expires. In most cases the owner is left holding a bill for several hundred dollars for a new MAF and labor costs.
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VW Golf & Jetta Mk 2 models with petrol engines, including fuel injection, catalytic converter, Formel E, 16-valve and special/limited edition models 1043 cc, 1272 cc, 1595 cc & 1781 cc Covers mechanical features of Van. Does not cover Convertible, Rallye, Caddy, diesel engine, 4 -wheel drive, Mk 1 models or new Golf range introduced in February 1992 I M Coomber and Christopher Rogers
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The Mk. II Volkswagen Golf and Jetta range of models was introduced in March 1984, revised body and trim features being the main visual difference to the earlier range of models. The engine/transmission is mounted transversely at the front of the vehicle, drive being to the front wheels. Detailed improvements have been made throughout the years of manufacture to improve power output and economy.
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Fairly easy, suitable for beginner with some experience, Fairly difficult, suitable for competent DIY mechanic 3 Difficult, suitable for experienced DIY mechanic 4 Very difficult, suitable for expert DIY or professional 5 Specifications Brake system Type Hydraulic, dual circuit, split diagonally, pressure regulator on some models. Disc front brakes. Drum or disc rear brakes. Cable-operated handbrake on rear wheels. Front brakes Disc thickness: New: 1.05 and 1.3 litre 1.6 and 1.8 litre 1.8 litre with ventilated discs Minimum: 1.05 and 1.3 litre 1.6 and 1.8 litre 1.8 litre with ventilated discs Pad thickness: New - excluding backplate: 1.05 and 1.3 litre 1.6 and 1.8 litre 1.8 litre with ventilated discs Minimum - including backplate: All models 10.0 mm 12.0 mm 20.0 mm 8.0 mm 10.0 mm 18.0 mm 12.0 mm 14.0 mm 10.0 mm 7.0 mm
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