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Manual Coverage
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Engine
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Systems Covered:
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Engine System, Fuel Charging and Controls, Accessory Drive, Starting System, Engine Ignition, Engine Emission Control, Intake Air Distribution, Emissions, Electronic Engine Controls
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Transmission
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Systems Covered:
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Manual Transmission, Clutch Controls, Automatic Transmission (if applicable to specific models covered)
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Drivetrain
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Systems Covered:
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Driveline System, Driveshaft, Bearings
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Suspension Steering Brakes
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Systems Covered:
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Suspension, Wheels and Tyres, Brake System, Anti-Lock Control, Steering System
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Electrical Electronics
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Systems Covered:
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Full Wiring Manual, Battery and Charging System, Information and Entertainment Systems, Lighting, Electrical Distribution, Electronic Feature Group
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Body Chassis
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Systems Covered:
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Body System, Body Panels, Interior Trim, Mirrors, Seating, Glass, Frames and Mechanisms, Instrument Panel and Console, Wipers and Washers, Roof, Bumpers, Safety Belt System, Body Repairs, Metal Repairs, Subframe and Mounting System
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Climate Control
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Systems Covered:
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Climate Control System, Air Distribution, Control Components
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General Maintenance
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Procedures Included:
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Service Information, Noise Vibration and Harshness, Jacking and Lifting
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Performance Control
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Procedures Included:
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Acceleration Control, Speed Control
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Diagnostics Troubleshooting
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Technical Depth:
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Comprehensive diagnostic procedures, fault code interpretation, troubleshooting flowcharts
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Repair Procedures
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Technical Depth:
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Detailed step-by-step repair instructions for all major systems
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Wiring Diagrams
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Technical Depth:
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Complete and detailed wiring schematics for all vehicle electrical systems
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Engine Specifics
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Systems Covered:
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Detailed coverage for all listed petrol (1.6, 1.8, 1.8T) and diesel (1.9 TDI) engines, including component identification, removal, installation, and calibration.
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Transmission Specifics
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Systems Covered:
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Comprehensive coverage of manual and automatic transmissions, including clutch assembly, gear linkage, transmission fluid changes, and repair of internal components.
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Suspension Wheel Alignment
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Procedures Included:
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Front and rear suspension component replacement (struts, shocks, control arms, bushings), wheel bearing replacement, steering rack and tie rod end replacement, wheel alignment specifications.
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Brake System Diagnostics
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Procedures Included:
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Brake pad and rotor replacement, caliper servicing, brake fluid flush, ABS system diagnosis and component testing, parking brake adjustment.
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Electrical Diagnostics
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Procedures Included:
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Troubleshooting of all electrical systems using wiring diagrams, diagnostic procedures for ECUs, sensors, actuators, lighting circuits, infotainment systems, and power distribution.
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Body Repair Interior Trim
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Procedures Included:
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Removal and installation of body panels, door mechanisms, interior trim pieces, dashboard components, seat removal, glass replacement, bumper repair.
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Climate Control Repair
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Procedures Included:
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Refrigerant system diagnosis and servicing (with appropriate tools and safety precautions), HVAC blower motor replacement, heater core removal, climate control module troubleshooting.
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Engine Control Modules
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Technical Depth:
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Detailed information on engine control module (ECU) identification, function, and diagnostic procedures, including sensor data interpretation.
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Emissions Control
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Systems Covered:
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Catalytic converter systems, exhaust gas recirculation (EGR), secondary air injection (where applicable), evaporative emission control (EVAP) systems, oxygen sensors (Lambda sensors).
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Jacks Lifting Points
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Procedures Included:
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Specific jack and lift point locations for safe vehicle servicing and repair.
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Engine Specifications
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Petrol Engines
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Primary Engine Options:
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1.6L (8v and 16v variants), 1.8L (Naturally Aspirated and Turbocharged - 150 PS/110 kW, 180 PS/132 kW variants)
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Diesel Engines
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Primary Engine Options:
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1.9L TDI (various power outputs including 90 PS/66 kW and 110 PS/81 kW, PD and VE variants)
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Performance 1.8T
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Engine Variant:
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1.8L Turbocharged (APU/AUM/AUQ etc.)
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Horsepower:
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150 PS (110 kW) / 180 PS (132 kW)
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Torque:
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Approx. 210 Nm (155 lb-ft) for 150 PS, Approx. 235 Nm (173 lb-ft) for 180 PS
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Performance 1.9Tdi
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Engine Variant:
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1.9L TDI (e.g., AHU/AGR/ALH/ASV etc.)
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Horsepower:
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90 PS (66 kW) / 110 PS (81 kW)
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Torque:
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Approx. 202 Nm (149 lb-ft) for 90 PS, Approx. 235 Nm (173 lb-ft) for 110 PS
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Fuel System
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Fuel System:
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Multi-Point Fuel Injection (MPI) for petrol, Direct Injection (TDI) for diesel
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Engine Management
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Engine Management System:
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Electronic Engine Control Units (ECU) - specific models vary by engine and market
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Maintenance
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Service Intervals Oil
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Engine Oil Service Interval:
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Typically 15,000 km (9,375 miles) or 1 year, whichever comes first (with specific oil type). Refer to manual for LongLife service (variable intervals).
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Service Intervals Filters
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Oil Filter Replacement:
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At every engine oil service
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Air Filter Replacement:
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Every 30,000 km (18,750 miles) or as needed based on conditions
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Fuel Filter Replacement:
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Every 60,000 km (37,500 miles) for petrol, every 30,000 km (18,750 miles) for diesel (subject to fuel quality)
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Pollen Filter Replacement:
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Every 30,000 km (18,750 miles) or 1 year
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Fluid Specifications
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Engine Oil Specification:
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API SN/SM/SL or ACEA A3/B4, SAE 5W-40 or 5W-30 (depending on engine and climate). Consult manual for exact VW 50x.xx approvals like VW 502 00 / 505 00.
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Coolant Specification:
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G 12 or G 12+ (Pink colored ethylene glycol based coolant)
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Brake Fluid Specification:
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DOT 4
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Known Issues
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Known Issues:
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Coil pack failures (especially on 1.8T), ABS sensor failures, window regulator issues, PCV valve problems (especially on 1.8T), cam follower wear (1.8T FSI variant - though FSI was less common in the 2002 model year compared to later iterations), catalytic converter issues, coolant leaks from plastic components (e.g., coolant flange).
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Timing Belt
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Timing Belt Replacement Interval:
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For 1.6L and 1.9 TDI engines: typically 90,000 km (56,000 miles) or 5 years. For 1.8T engines: typically 120,000 km (75,000 miles) or 5 years. **Crucially, consult the manual for the specific engine code.**
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