VW Golf & Bora (2001 to 2003) Haynes PDF Manual

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0 General Information - 2
About this website - 2
1 Safety first! - 5
2 Introduction - 10
3 Roadside repairs - 13
4 Weekly checks - 23
5 Lubricants, fluids and tyre pressures - 39

1a Routine maintenance and servicing - petrol models - 42
Degrees of difficulty - 42
Servicing specifications - petrol models - 43
Maintenance schedule - petrol models - 46
Component location - petrol models - 51
1 Introduction - 53
2 Regular maintenance - 54
Every 5000 miles (7500 km) or 6 months - 56
3 Engine oil and filter renewal - petrol models - 57
Every 10 000 miles (15 000 km) or 12 month, whichever comes first - 'Oil' on display - 60
4 Brake pad check - 61
5 Resetting the service interval display - petrol models - 63
Every 20 000 miles (30 000 km) or 2 years, whichever comes first - '01' on display - 64
6 Exhaust system check - 65
7 Hose and fluid leak check - 66
8 Auxiliary drivebelt check - 68
9 Antifreeze check - 69
10 Brake hydraulic circuit check - 70
11 Headlight beam adjustment - 71
12 Pollen filter element renewal - 72
13 Manual transmission oil level check - 74
14 Underbody protection check - 76
15 Driveshaft gaiter check - 77
16 Steering and suspension check - 78
17 Batterry check - 80
18 Hinge and lock lubrication - 82
19 Airbag unit check - 83
20 Windscreen/tailgate/headlight washer system check - 84
21 Engine management self-diagnosis memory fault check - 85
22 Sunroof check and lubrication - 86
23 Road test and exhaust emissions check - 87
Every 40 000 miles (60 000 km) or 4 years, whichever comes first - 89
24 Air filter element renewal - petrol models - 90
25 Spark plug renewal - petrol models - 92
26 Auxiliary drivebelt check and renewal - petrol models - 97
27 Power steering hydraulic fluid level check - 100
28 Automatic transmission fluid level check - 102
29 Automatic transmission final drive oil level check - 104
Every 60 000 miles (90 000 km) or 4 years, whichever comes first - 106
30 Timing belt renewal - 107
Every 2 years - 108
31 Brake (and clutch) fluid renewal - petrol models - 109
32 Coolant renewal - petrol models - 111

1b Routine maintenance and servicing - diesel models - 114
Degrees of difficulty - 114
Servicing specifications - diesel models - 115
Maintenance schedule - diesel models - 117
Component location - diesel models - 123
1 Introduction - 125
2 Regular maintenance - 126
Every 5000 miles (7500 km) or 6 months - 128
3 Engine oil and filter renewal - diesel models - 129
Every 10 000 miles (15 000 km) or 12 months, whichever comes first - 'Oil' on display - 133
4 Fuel filter water draining (vehicles using high sulphur fuels) - diesel models - 134
5 Brake pad check - 136
6 Resetting the service interval display - diesel models - 138
Every 20 000 miles (30 000 km) or 2 years, whichever comes first - '01' on display - 139
7 Exhaust system check - 141
8 Hose and fluid leak check - 142
9 Fuel filter water draining (vehicles using standard fuel) - diesel models - 144
10 Fuel filter renewal (vehicles using high sulphur diesel fuel) - 145
11 Auxiliary drivebelt check - 148
12 Antifreeze check - 149
13 Brake hydraulic circuit check - 150
14 Headlight beam adjustment - 151
15 Pollen filter element renewal - 152
16 Manual transmission oil level check - 154
17 Underbody protection check - 157
18 Driveshaft gaiter check - 158
19 Steering and suspension check - 159
20 Batterry check - 161
21 Hinge and lock lubrication - 163
22 Airbag unit check - 164
23 Windscreen/tailgate/headlight washer system check - 165
24 Engine management self-diagnosis memory fault check - 166
25 Sunroof check and lubrication - 167
26 Road test and exhaust emissions check - 168
Every 40 000 miles (60 000 km) or 4 years, whichever comes first - 170
27 Air filter element renewal - diesel models - 171
28 Fuel filter renewal (vehicles using standard diesel fuel) - 173
29 Auxiliary drivebelt check and renewal - diesel models - 174
30 Power steering hydraulic fluid level check - 177
31 Automatic transmission fluid level check - 179
32 Automatic transmission final drive oil level check - 181
Every 60 000 miles (90 000 km) - 183
33 Timing belt and tensioning roller renewal (engines with ‘unit’ injectors) - 184
Every 80 000 miles (120 000 km) - 185
34 Timing belt and tensioning roller renewal ( engines with injection pump) - 186
Every 2 years - 187
35 Brake (and clutch) fluid renewal - diesel models - 188
36 Coolant renewal - diesel models - 190

2a SOHC petrol engine in-car repair procedures - 193
Degrees of difficulty - 193
Specifications - 194
1 General Information - 199
2 Compression test - description and interpretation - 201
3 Engine assembly and valve timing marks - general information and usage - 203
4 Camshaft cover - removal and refitting - 206
5 Crankshaft pulley - removal and refitting - 208
6 Timing belt covers - removal and refitting - 210
7 Timing belt - removal and refitting - 213
8 Timing belt tensioner and sprockets - removal and refitting - 217
9 Camshaft - removal, inspection and refitting - 220
10 Hydraulic tappets/roller rocker fingers - removal, inspection and refitting - 226
11 Camshaft oil seal - renewal - 228
12 Cylinder head - removal, inspection and refitting - 229
13 Sump - removal and refitting - 234
14 Oil pump, drive chain and sprockets - removal, inspection and refitting - 237
15 Flywheel/driveplate - removal, inspection and refitting - 243
16 Crankshaft oil seals - renewal - 246
17 Engine/transmission mountings - inspection and renewal - 249
18 Engine oil cooler - removal and refitting - 255
19 Oil pressure relief valve - removal, inspection and refitting - 258
20 Oil pressure warning light switch - removal and refitting - 259
21 Oil level/temperature sender - removal and refitting - 260
22 Balancer shaft unit (2.0 litre AZJ engine) - removal and refitting - 263

2b DOHC petrol engine in-car repair procedures - 266
Degrees of difficulty - 266
Specifications - 267
1 General Information - 274
2 Compression test - description and interpretation - 277
3 Engine assembly and valve timing marks - general information and usage - 279
4 Camshaft cover (1.8 litre engines) - removal and refitting - 285
5 Crankshaft pulley - removal and refitting - 291
6 Timing belt covers - removal and refitting - 296
7 Timing belt(s) - removal and refitting - 302
8 Timing belt tensioner and sprockets - removal and refitting - 315
9 Inlet camshaft timing components/camshaft adjuster (1.8 litre engines) - 321
10 Camshaft carrier (1.4 and 1.6 litre engines) - removal and refitting - 322
11 Camshafts (1.4 and 1.6 litre engines) - removal, inspection and refitting - 328
12 Rockers and tappets (1.4 and 1.6 litre engines) - removal, inspection and refitting - 331
13 Camshafts and tappets (1.8 litre engines) - removal, inspection and refitting - 333
14 Camshaft oil seals - renewal - 342
15 Cylinder head - removal, inspection and refitting - 345
16 Sump - removal and refitting - 356
17 Oil pump (1.4 and 1.6 litre engines) - removal, inspection and refitting - 357
18 Oil pump and drive chain (1.8 litre engines) - removal, inspection and refitting - 363
19 Flywheel/driveplate - removal, inspection and refitting - 364
20 Crankshaft oil seals - renewal - 365
21 Engine/transmission mountings - inspection and renewal - 370
22 Engine oil cooler - removal and refitting - 371
23 Oil pressure relief valve - removal, inspection and refitting - 372
24 Oil pressure warning light switch - removal and refitting - 373
25 Oil level/temperature sender - removal and refitting - 375

2c Diesel engine in-car repair procedures - 377
Degrees of difficulty - 377
Specifications - 378
1 General Information - 384
2 Compression and leakdown tests - description and interpretation - 386
3 Engine assembly and valve timing marks - general information and usage - 389
4 Camshaft cover - removal and refitting - 395
5 Crankshaft pulley - removal and refitting - 400
6 Timing belt covers - removal and refitting - 402
7 Timing belt - removal, inspection and refitting - 405
8 Timing belt tensioner and sprockets - removal, inspection and refitting - 415
9 Pump injector rocker shaft assembly - removal and refitting - 421
10 Camshaft and hydraulic tappets - removal, inspection and refitting - 423
11 Hydraulic tappets - testing - 427
12 Camshaft oil seals - renewal - 429
13 Cylinder head - removal, inspection and refitting - 430
14 Sump - removal and refitting - 442
15 Oil pump and drive chain - removal, inspection and refitting - 443
16 Flywheel/driveplate/clutch pressure plate - removal, inspection and refitting - 444
17 Crankshaft oil seals - renewal - 445
18 Engine/transmission mountings - inspection and renewal - 449
19 Engine oil cooler - removal and refitting - 450
20 Oil pressure relief valve - removal, inspection and refitting - 453
21 Oil pressure warning light switch - removal and refitting - 454

2d Engine removal and overhaul procedures - 455
Degrees of difficulty - 455
Specifications - 456
1 General Information - 462
2 Engine overhaul - general information - 463
3 Engine/transmission removal - preparation and precautions - 465
4 Engine and transmission (SOHC petrol engines) - removal and refitting - 467
5 Engine and transmission (DOHC petrol engines) - removal and refitting - 473
6 Engine and transmission (diesel engines) - removal and refitting - 493
7 Engine overhaul - preliminary information - 498
8 Cylinder head - dismantling - 500
9 Cylinder head and valves - cleaning and inspection - 505
10 Cylinder head - reassembly - 509
11 Piston/connecting rod assemblies - removal - 515
12 Crankshaft - removal - 519
13 Cylinder block/crankcase - cleaning and inspection - 521
14 Piston/connecting rod assemblies - cleaning and inspection - 524
15 Crankshaft - checking endfloat and inspection - 529
16 Main and big-end bearings - inspection - 532
17 Engine overhaul - reassembly sequence - 535
18 Piston rings - refitting - 536
19 Crankshaft - refitting and main bearing clearance check - 538
20 Piston/connecting rod assemblies - refitting and big-end bearing clearance check - 542
21 Engine - initial start-up after overhaul and reassembly - 546

3 Cooling, heating and air conditioning systems - 548
Degrees of difficulty - 548
Specifications - 549
1 General information and precautions - 551
2 Cooling system hoses - disconnection and renewal - 553
3 Radiator - removal, inspection and refitting - 555
4 Thermostat - removal, testing and refitting - 558
5 Electric cooling fan - testing, removal and refitting - 563
6 Cooling system electrical switches and sensors - testing, removal and refitting - 565
7 Coolant pump - removal and refitting - 569
8 Heating and ventilation system - general information - 572
9 Heating/ventilation system components - removal and refitting - 573
10 Heating/ventilation system vents - removal and refitting - 584
11 Air conditioning system - general information and precautions - 585
12 Air conditioning system components - removal and refitting - 587
13 Climatronic system components - removal and refitting - 588

4a Petrol engine fuel system - 591
Degrees of difficulty - 591
Specifications - 592
1 General information and precautions - 595
2 Air cleaner and inlet system - removal and refitting - 598
3 Inlet air temperature control system - general information - 604
4 Accelerator cable - removal, refitting and adjustment - 605
5 Fuel system components - removal and refitting - 608
6 Fuel filter - renewal - 624
7 Fuel pump and gauge sender unit - removal and refitting - 626
8 Fuel tank - removal and refitting - 632
9 Fuel injection system - depressurisation - 635
10 Inlet manifold and associated components - removal and refitting - 637
11 Fuel injection system - testing and adjustment - 648
12 Unleaded petrol - general information and usage - 649
13 Cruise control system - general information - 650

4b Diesel engine fuel system - 651
Degrees of difficulty - 651
Specifications - 652
1 General information and precautions - 655
2 Air cleaner assembly - removal and refitting - 658
3 Accelerator cable - general information - 661
4 Diesel engine management system - component removal and refitting - 662
5 Injectors - general information, removal and refitting - 670
6 Injection pump - removal and refitting - 678
7 Fuel injection pump timing - checking and adjustment - 683
8 Fuel cut-off solenoid valve - removal and refitting - 684
9 Inlet manifold - removal and refitting - 686
10 Fuel filter - renewal - 691
11 Fuel gauge sender unit - removal and refitting - 692
12 Fuel tank - removal and refitting - 693
13 Tandem fuel pump - removal and refitting - 694
14 Inlet manifold changeover flap and valve - removal and refitting - 697

4c Emission control and exhaust systems - petrol engines - 700
Degrees of difficulty - 700
Specifications - 701
1 General Information - 703
2 Evaporative loss emission control system - information and component renewal - 706
3 Crankcase emission system - general information - 709
4 Exhaust Gas Recirculation (EGR) system - component removal - 710
5 Secondary air injection system - information and component renewal - 716
6 Turbocharger - general information, precautions, removal and refitting - 722
7 Intercooler - general information, removal and refitting - 727
8 Exhaust manifold - removal and refitting - 733
9 Exhaust system - component renewal - 741
10 Catalytic converter - general information and precautions - 747

4d Emission control and exhaust systems - diesel engines - 748
Degrees of difficulty - 748
Specifications - 749
1 General Information - 751
2 Crankcase emission system - general information - 753
3 Exhaust Gas Recirculation (EGR) system - component removal - 754
4 Turbocharger - general information and precautions - 758
5 Turbocharger - removal and refitting - 760
6 Turbocharger boost control system components - removal and refitting - 766
7 Intercooler - general information, removal and refitting - 770
8 Exhaust manifold - removal and refitting - 771
9 Exhaust system - component renewal - 774
10 Catalytic converter - general information and precautions - 777

5a Starting and charging systems - 778
Degrees of difficulty - 778
Specifications - 779
1 General information and precautions - 780
2 Battery - testing and charging - 782
3 Battery - removal and refitting - 785
4 Alternator/charging system - testing in vehicle - 787
5 Alternator - removal and refitting - 788
6 Alternator - brush holder/regulator module renewal - 790
7 Starting system - testing - 792
8 Starter motor - removal and refitting - 794
9 Starter motor - testing and overhaul - 797

5b Ignition system - petrol engines - 798
Degrees of difficulty - 798
Specifications - 799
1 General Information - 801
2 Ignition system - testing - 804
3 HT coil(s) - removal and refitting - 806
4 Ignition timing - checking and adjusting - 809
5 Knock sensor(s) - removal and refitting - 810

5c Preheating system - diesel engines - 812
Degrees of difficulty - 812
Specifications - 813
1 General Information - 814
2 Glow plugs - testing, removal and refitting - 815

6 Clutch - 818
Degrees of difficulty - 818
Specifications - 819
1 General Information - 821
2 Hydraulic system - bleeding - 823
3 Clutch pedal - removal and refitting - 825
4 Master cylinder - removal, overhaul and refitting - 827
5 Slave cylinder - removal, overhaul and refitting - 831
6 Clutch friction disc and pressure plate - removal, inspection and refitting - 834
7 Release bearing and lever - removal, inspection and refitting - 843

7a Manual transmission - 850
Degrees of difficulty - 850
Specifications - 851
1 General Information - 852
2 Gearchange linkage (02J and 02M transmissions) - adjustment - 855
3 Manual transmission - removal and refitting - 858
4 Manual transmission overhaul - general information - 865
5 Reversing light switch - testing, removal and refitting - 866
6 Roadspeed sensor/speedometer drive - removal and refitting - 868

7b Automatic transmission - 870
Degrees of difficulty - 870
Specifications - 871
1 General Information - 873
2 Automatic transmission - removal and refitting - 875
3 Automatic transmission overhaul - general information - 880
4 Selector cable - removal, refitting and adjustment - 881
5 Ignition key Park Lock system - description and cable renewal - 883

8 Driveshafts - 885
Degrees of difficulty - 885
Specifications - 886
1 General Information - 888
2 Driveshafts - removal and refitting - 889
3 Driveshaft rubber gaiters - renewal - 892
4 Driveshaft overhaul - general information - 906

9 Braking system - 907
Degrees of difficulty - 907
Specifications - 908
1 General information and precautions - 910
2 Hydraulic system - bleeding - 911
3 Hydraulic pipes and hoses - renewal - 916
4 Front brake pads - removal, inspection and refitting - 917
5 Front brake caliper - removal, overhaul and refitting - 924
6 Brake disc - inspection, removal and refitting - 927
7 Front brake disc shield - removal and refitting - 931
8 Rear brake pads - removal, inspection and refitting - 932
9 Rear brake caliper - removal, overhaul and refitting - 936
10 Brake pedal - removal and refitting - 939
11 Servo unit - testing, removal and refitting - 943
12 Servo non-return valve - testing, removal and refitting - 945
13 Master cylinder - removal, overhaul and refitting - 947
14 Handbrake - adjustment - 950
15 Handbrake lever - removal and refitting - 952
16 Handbrake cables - removal and refitting - 954
17 Handbrake ‘on’ warning light switch - removal and refitting - 956
18 Brake light switch - removal and refitting - 957
19 Anti-lock braking system (ABS) - general information and precautions - 959
20 Anti-lock braking system (ABS) components - removal and refitting - 961
21 Servo unit mechanical vacuum pump (diesel models) - testing, removal and refitting - 963
22 Servo unit electric vacuum pump (diesel models) - testing, removal and refitting - 966

10 Suspension and steering systems - 967
Degrees of difficulty - 967
Specifications - 968
1 General Information - 972
2 Front wheel bearing housing - removal and refitting - 974
3 Front hub bearings - renewal - 980
4 Front suspension strut - removal, overhaul and refitting - 982
5 Front suspension lower arm - removal, overhaul and refitting - 989
6 Front suspension lower arm balljoint - removal, inspection and refitting - 992
7 Front anti-roll bar - removal and refitting - 995
8 Front anti-roll bar connecting link - removal and refitting - 997
9 Rear hub assembly - removal and refitting - 999
10 Rear stub axle - removal and refitting - 1006
11 Rear suspension shock absorber and coil spring - removal and refitting - 1008
12 Rear anti-roll bar - removal and refitting - 1013
13 Rear axle assembly - removal and refitting - 1014
14 Rear axle rubber mountings - renewal - 1017
15 Vehicle level sender - removal and refitting - 1019
16 Steering wheel - removal and refitting - 1020
17 Steering column - removal, inspection and refitting - 1024
18 Ignition switch and steering column lock - removal and refitting - 1036
19 Steering gear assembly - removal, overhaul and refitting - 1039
20 Steering gear rubber gaiters and track rods - renewal - 1043
21 Power steering system - bleeding - 1045
22 Power steering pump - removal and refitting - 1046
23 Track rod end - removal and refitting - 1049
24 Wheel alignment and steering angles - general information - 1051

11 Bodywork and fittings - 1054
Degrees of difficulty - 1054
Specifications - 1055
1 General Information - 1056
2 Maintenance - bodywork and underframe - 1057
3 Maintenance - upholstery and carpets - 1059
4 Minor body damage - repair - 1060
5 Major body damage - repair - 1064
6 Front bumper - removal and refitting - 1065
7 Rear bumper - removal and refitting - 1069
8 Bonnet - removal, refitting and adjustment - 1072
9 Bonnet release cable - removal and refitting - 1074
10 Bonnet lock - removal and refitting - 1077
11 Door - removal, refitting and adjustment - 1079
12 Door inner trim panel - removal and refitting - 1082
13 Door handle and lock components - removal and refitting - 1086
14 Door window glass and regulator - removal and refitting - 1099
15 Tailgate and support struts - removal and refitting - 1103
16 Tailgate lock components - removal and refitting - 1108
17 Boot lid and support struts - removal and refitting - 1111
18 Boot lid lock components - removal and refitting - 1114
19 Central locking components - removal and refitting - 1117
20 Electric window components - removal and refitting - 1122
21 Exterior mirrors and associated components - removal and refitting - 1124
22 Windscreen, tailgate and fixed rear quarter window glass - general information - 1128
23 Sunroof - general information - 1129
24 Body exterior fittings - removal and refitting - 1130
25 Seats - removal and refitting - 1131
26 Front seat belt tensioning mechanism - general information - 1135
27 Seat belt components - removal and refitting - 1136
28 Interior trim - removal and refitting - 1146
29 Centre console - removal and refitting - 1148
30 Facia panel assembly - removal and refitting - 1153

12 Body electrical system - 1159
Degrees of difficulty - 1159
Specifications - 1160
1 General information and precautions - 1161
2 Electrical fault finding - general information - 1162
3 Fuses and relays - general information - 1165
4 Switches - removal and refitting - 1168
5 Bulbs (exterior lights) - renewal - 1177
6 Bulbs (interior lights) - renewal - 1193
7 Exterior light units - removal and refitting - 1199
8 Headlight beam adjustment components - removal and refitting - 1204
9 Headlight beam alignment - general information - 1207
10 Instrument panel - removal and refitting - 1209
11 Instrument panel components - removal and refitting - 1211
12 Service interval indicator - general information and resetting - 1212
13 Clock - removal and refitting - 1213
14 Cigarette lighter - removal and refitting - 1214
15 Horn - removal and refitting - 1215
16 Speedometer sensor - general information - 1216
17 Wiper arm - removal and refitting - 1217
18 Windscreen wiper motor and linkage - removal and refitting - 1218
19 Rear wiper motor - removal and refitting - 1220
20 Washer system components - removal and refitting - 1221
21 Radio/cassette/CD player/changer - removal and refitting - 1226
22 Loudspeakers - removal and refitting - 1230
23 Radio aerial - removal and refitting - 1232
24 Anti-theft alarm system and engine immobiliser - general information - 1233
25 Airbag system - general information and precautions - 1234
26 Airbag system components - removal and refitting - 1236
24 Parking aid components - general information, removal and refitting - 1240

Wiring Diagrams - 1242
Diagram 1 Key to symbols, earth points and fuses - 1242
Diagram 2 Starting and charging, audio - 1243
Diagram 3 Central locking, electric windows and mirrors - 1244
Diagram 4 Central locking and interior lights, horn, fuel tank release, cigarette lighter, 12V socket, radiator fan, diagnostic connector - 1245
Diagram 5 ABS, heater blower and heated read window, wash/wipe, brake lights, reversing lights - 1246
Diagram 6 Headlights, number plate lights, rear foglights, taillights and sidelights, foglight, hazard warning lights and direction indicators - 1247
Diagram 7 Headlight levelling, lighting rheostat, front foglights, gas discharge headlight range control - 1248
Diagram 8 Instrument panel, glovebox light, interior lights - 1249

13 Reference - 1250
1 Dimensions and weights - 1250
2 Buying spare parts - 1252
3 Vehicle identification numbers - 1254
4 General repair procedures - 1257
5 Jacking and vehicle support - 1260
6 Disconnecting the battery - 1262
7 Tools and working facilities - 1264
8 MOT test checks - 1272
9 Fault finding - 1286
10 Glossary of technical terms - 1307

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Ovaj pdf sam sam napravio tako da sam ručno svaki članak iz online priručnika "isprintao" u PDF i potom spojio u jedan, zbog toga nema sadržaja i zadnje stranice, a videozapisi nisu dostupni. Svejedno vjerujem da će mnogima ovdje koristiti.

Edited December 3, 2023 by MateV

[<TDI>]

Hvala na trudu i da si ga ovdje podijelio sa svima, vjerujem da će dobro doći. Već sam ga skinuo i prelistao, ima zanimljiva poglavlja pa uz online VW Service and Repair Manuals kojeg inače koristim dobro će poslužiti. Baš sam te htio pitati kada si ga spomenuo u dopisivanju da ga imaš ali zaboravio, no ovo je puno bolje da nam je svima dostupan.

[MateV]

Nema na čemu. Stvarno se nadam da će nekome pomoći. Jedino što me smeta je da forum nema spoilere, tako da se sadržaj pospremi u poglavlja, a onda si samo otvoriš onaj dio koji te zanima. Tebi sam ga spomenuo i tad sam već počeo pripremati pdf, ali sam s tim dosta odugovlačio ?