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1996 Volkswagen Golf All Categories All Sections

Title List for Volkswagen Technical Site


Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:01AM
* A/C-HEATER SYSTEM UNIFORM INSPECTION GUIDELINES *
* ANTI-LOCK BRAKES UNIFORM INSPECTION GUIDELINE *
* BRAKE SYSTEM UNIFORM INSPECTION GUIDELINES *
* ELECTRICAL SYSTEM UNIFORM INSPECTION GUIDELINES *
* ENGINE SYSTEMS UNIFORM INSPECTION GUIDELINES *
* EXHAUST SYSTEM UNIFORM INSPECTION GUIDELINES *
* STEERING UNIFORM INSPECTION GUIDELINES *
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
* SYMPTOM CHECK LIST *
A - ENGINE/VIN ID
A/C-HEATER SYSTEM - MANUAL
AA - USING THIS SECTION (GENERAL HELP INFORMATION)
ABBREVIATIONS
AIR BAG RESTRAINT SYSTEM
ALTERNATOR & REGULATOR
ANTI-LOCK BRAKE SAFETY PRECAUTIONS
ANTI-LOCK BRAKE SYSTEM & TRACTION CONTROL
AUTO TRANS DIAGNOSIS - 01M
AXLE SHAFT
B - EMISSION APPLICATION
BRAKE SYSTEM
C - SPECIFICATIONS
CLUTCH
COMPUTER RELEARN PROCEDURES
D - ADJUSTMENTS
E - THEORY/OPERATION - GASOLINE
ELECTRICAL COMPONENT LOCATOR - 2.0L 4-CYL
ELECTROSTATIC DISCHARGE WARNING - BASIC INFORMATION
ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
F - BASIC TESTING - GASOLINE
FUSES & CIRCUIT BREAKERS
G - TESTS W/CODES - GASOLINE
GEAR TOOTH CONTACT PATTERNS
GENERAL COOLING SYSTEM SERVICING
H - TESTS W/O CODES - GASOLINE
HEATER SYSTEM
HOW TO USE SYSTEM WIRING DIAGRAMS
I - SYSTEM/COMPONENT TESTS - GASOLINE
INTERFERENCE VERIFICATION CHECK FOR OHC ENGINE
J - PIN VOLTAGE CHARTS
K - SENSOR RANGE CHARTS
L - WIRING DIAGRAMS
M - VACUUM DIAGRAMS - GASOLINE
MAINTENANCE INFORMATION
MAINTENANCE REMINDER LIGHT RESET PROCEDURES
METRIC CONVERSIONS
N - REMOVE/INSTALL/OVERHAUL - GASOLINE
SCHEDULED SERVICES
STARTER
STEERING COLUMN
STEERING SYSTEM - POWER RACK & PINION
SUSPENSION - FRONT
SUSPENSION - REAR
SYSTEM WIRING DIAGRAMS
TRANSMISSION REMOVAL & INSTALLATION - A/T
TRANSMISSION REMOVAL & INSTALLATION - M/T
TRANSMISSION SERVICING - A/T
TRANSMISSION SERVICING - M/T
TROUBLE SHOOTING - BASIC PROCEDURES
WAVEFORMS - INJECTOR PATTERN TUTORIAL
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
WHEEL ALIGNMENT THEORY/OPERATION
POOR PERFORMANCE/EXHAUST SMOKE VISIBLE
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:07AM
ARTICLE BEGINNING
TECHNI CAL SERVI CE BULLETI N
POOR PERFORMANCE, EXHAUST SMOKE VI SI BLE
Model ( s) : 1993- 97 Vol kswagen Gol f , J et t a wi t h ( engi ne Code AAZ)
1993 & 1995 Vol kswagen Passat wi t h ( engi ne code AAZ)
Gr oup: 13 - Engi ne - Cr ankshaf t / Cr ankcase
Bul l et i n No. : 97- 07
Dat e: November 12, 1997
NOTE: Thi s bul l et i n super sedes Techni cal Bul l et i n Gr oup 13, No. 97- 02
dat ed J anuar y 28, 1997.
CONDITION
Poor per f or mance, vi si bl e smoke f r omexhaust syst em.
May be caused by t he cr ankshaf t spr ocket bol t ( M14 x 1. 5 x 47)
l ooseni ng.
PRODUCTION
Cr ankshaf t spr ocket bol t t ensi l e st r engt h i ncr eased t o 12. 9.
SERVICE
I f t hi s condi t i on exi st s:
- Check i nj ect i on pump t i mi ng.
I f t i mi ng i s i ncor r ect :
- Tur n cr ankshaf t t o TDC f or No. 1 cyl .
- Remove cr ankshaf t spr ocket , see appl i cabl e Repai r Manual f or Model s
l i st ed above.
- Check Cr ankshaf t and spr ocket f or wear .
I f cr ankshaf t or cr ankshaf t spr ocket show si gns of wear :
- Repl ace cr ankshaf t , cr ankshaf t spr ocket and bol t . See appl i cabl e
Repai r Manual f or Model s l i st ed.
END OF ARTICLE
NEW COOLANT G 012 A8D A1
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:07AM
ARTICLE BEGINNING
TECHNI CAL SERVI CE BULLETI N
NEWCOOLANT
Model ( s) : Vol kswagen, Al l Wat er cool ed Model s
Gr oup: 19 - Engi ne - Cool i ng Syst em
Bul l et i n No. : 96- 01
Dat e: Oct ober 30, 1996
PRODUCTION
A new cool ant , G 012 A8D A1 i s bei ng used i n pr oduct i on as f ol l ows:
* Ger man pr oduct i on: f r om07. 96
* Mexi can pr oduct i on: r unni ng change schedul ed f or 01. 97
Cool ant G 012 A8D A1 i s r ed i n col or .
Thi s newl y devel oped pr oduct per mi t s a cool i ng syst emf i l l t hat
l ast s t he ser vi ce l i f e of t he engi ne and was desi gned wi t h
al l - al umi numengi nes i n mi nd.
ADVANTAGES
* I mpr oved cor r osi on pr ot ect i on
* I mpr oved t her mal st abi l i t y
* I mpr oved heat t r ansf er / cont r ol
* I mpr oved har d wat er t ol er ance
* I mpr oved envi r onment al pr ot ect i on
CAUTI ON: G 012 A8D A1 must NEVER be mi xed wi t h ANY ot her cool ant .
Engi ne damage wi l l r esul t !
Cont ami nat i on of G 012 A8D A1 wi t h ot her col or ed cool ant s i s
i dent i f i abl e by di scol or at i on ( br own, pur pl e et c. ) . Thi s mi xt ur e
causes a f oamy deposi t t o appear i n t he expansi on t ank/ r adi at or .
Thi s mi xt ur e i s t o be dr ai ned i mmedi at el y and t he cool i ng syst em
f l ushed as descr i bed bel ow.
FLUSHING PROCEDURE
Engi ne at oper at i ng t emper at ur e ( ol der vehi cl es wi t h heat er val ve:
heat er on) .
- Dr ai n cool ant . See Repai r Manual , Gener al Engi ne, Repai r Gr oup 19.
- Appl y compr essed ai r t o expansi on t ank or r adi at or t o bl ow out
r emai ni ng cool ant .
NEW COOLANT G 012 A8D A1
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:07AM
- Cl ose cool i ng syst em, f i l l wi t h di st i l l ed wat er .
- Run engi ne f or a mi ni mumof 2 mi nut es.
- Dr ai n wat er and appl y compr essed ai r t o expansi on t ank as bef or e.
- Cl ose cool i ng syst emand f i l l wi t h appr opr i at e mi xt ur e r at i o of
G 012 A8D A1 and di st i l l ed wat er . See Repai r Manual , Gener al Engi ne,
Repai r Gr oup 19.
- Test dr i ve, check cool ant l evel and add i f necessar y.
NOTE: Cool ant G 012 A8D 01 may be used i n ol der vehi cl es when t he
or i gi nal cool ant i s dr ai ned and cool i ng syst emf l ushed as
descr i bed above.
- I nf or mcust omer t hat a new cool ant i s used and t hat ONLY wat er or
G 012 A8D A1 be used t o r epl eni sh.
CAUTI ON: * Never r euse ol d cool ant when per f or mi ng engi ne r epai r s.
* Di spose of ol d cool ant pr oper l y.
Fl ushi ng as speci f i ed above, or engi ne damage r esul t i ng f r omt he use
of a mi xt ur e of G 012 A8D A1 and ot her cool ant s i s not cover ed by t he
new vehi cl e war r ant y.
CAUTI ON: Par t number s ar e f or r ef er ence onl y. Al ways check wi t h your
Par t s Dept . f or t he l at est par t s i nf or mat i on.
END OF ARTICLE
MAIN BEARING CAP TIGHTENING TORQUE
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:07AM
ARTICLE BEGINNING
TECHNI CAL SERVI CE BULLETI N
MAI N BEARI NG CAP TI GHTENI NG TORQUE
Model ( s) : 1993- on Vol kswagen Gol f , GTI , J et t a, Cabr i o
wi t h 2. 0 l i t er engi ne code ABA
Gr oup: 13 - Engi ne - Cr ankshaf t / Cr ankcase
Bul l et i n No. : 96- 01
Dat e: J ul y 1, 1996
Fi l e t hi s Techni cal Bul l et i n i n Repai r Manual No. : W42 011 294 105.
SERVICE INFORMATION
The f ol l owi ng r epai r i nf or mat i on i ncl udes a cor r ect ed t i ght eni ng
t or que speci f i cat i on t hat wi l l be i nt egr at ed wi t h t he next Repai r
Manual updat e.
Thi s i nf or mat i on r epl ace pages 13- 2 and 13- 26 i n t he cur r ent 04. 94
edi t i on Repai r Manual 2. 0 Li t er Gener al , Engi ne ( W42 011 294 105) .
CRANKSHAFT, REMOVI NG AND I NSTALLI NG
Ref er t o Fi g. 1.
1 - Mai n bear i ng shel l s 1, 2, 4, 5
* Wi t hout oi l gr oove: f or mai n bear i ng caps 1, 2 and 5.
* Wi t h oi l gr oove: f or mai n bear i ng cap 4 and cyl i nder bl ock.
* Do not i nt er change used mai n bear i ng shel l s.
2 - 65 N. m( 48 f t - l b) pl us addi t i onal 1/ 4- t ur n ( 90)
3 - Mai n bear i ng caps
* Mai n bear i ng cap 1: pul l ey si de.
* Mai n bear i ng cap 3 wi t h r ecesses f or t hr ust washer s.
* Hol di ng t abs on cyl i nder bl ock/ mai n bear i ng cap, bear i ng shel l s
must f ace each ot her .
4 - Mai n bear i ng shel l 3
* Wi t hout oi l gr oove: f or mai n bear i ng cap.
* Wi t h oi l gr oove: f or cyl i nder bl ock.
5 - Thr ust washer
* For mai n bear i ng cap 3.
* Not e i nst al l at i on posi t i ons.
6 - Sensor gear
* For Engi ne Speed ( RPM) Sensor - G28- .
* Al ways r epl ace.
MAIN BEARING CAP TIGHTENING TORQUE
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:07AM
7 - 10 N. m( 7 f t - l b) pl us 1/ 4 t ur n ( 90)
* Al ways r epl ace.
8 - Cr ankshaf t
* Axi al cl ear ance new: 0. 07 - 0. 17 mm( 0. 0028 - 0. 0067 i n. )
* Recondi t i oni ng l i mi t : 0. 25 mm( 0. 0098 i n. ) .
* Measur e r adi al cl ear ance wi t h Pl ast i gage.
- new: 0. 02 - 0. 06 mm( 0. 0008. - 0. 0024 i n. )
- wear l i mi t : 0. 17 mm( 0. 0067 i n)
CAUTI ON: Do Not t ur n cr ankshaf t when measur i ng r adi al cl ear ance.
9 - Thr ust washer
* For cyl i nder bl ock, mai n bear i ng 3.
Fi g. 1: Cr ankshaf t & Mai n Bear i ngs Assembl y
END OF ARTICLE
FLUID CAPACITY CHART
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM
ARTICLE BEGINNING
TECHNI CAL SERVI CE BULLETI N
FLUI D CAPACI TY CHART
Model ( s) : 1990- on Vol kswagen, Al l Model s
Gr oup: 00 - Gener al
Bul l et i n No. : 97- 08
Dat e: Sept ember 17, 1997
NOTE: Thi s bul l et i n super sedes Techni cal Bul l et i n Gr oup 00, No. 97- 04
dat ed May 16, 1997.
SERVICE INFORMATION
The f ol l owi ng f l ui d capaci t y i nf or mat i on cover s al l vehi cl es f r om
1991 and some f r om1990.
Ret ai n t he f l ui d char t , cover i ng vehi cl es f r om1980 t hr ough 1990, as
a suppl ement f or ol der vehi cl es.
CAUTI ON: Par t number s ar e f or r ef er ence onl y. Al ways check wi t h your
Par t s Depar t ment f or l at est i nf or mat i on.
FLUI D CAPACI TY CHART

J ETTA/ GOLF - 1991- 95

Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . . 4 cyl . 4. 0L ( 4. 2 qt . )
V6 5. 0L ( 5. 3 qt . )
Di esel 4. 5L ( 4. 7 qt . )
Manual Tr ans. . . . . . . . . . . . . . . . . . . ( 1993- 1995)
02A Tr ans. 2. 0L ( 2. 1 qt . )
G50 synt het i c oi l , SAE 75W/ 90
VR6 02A Tr ans. 2. 0L ( 2. 1 qt . )
G 005 100 A1
( 1995- 1997)
020 Tr ans. 1. 9L ( 2. 0 qt . )
G50 synt het i c oi l , SAE 75W/ 90
VR6 020 Tr ans. 1. 9L ( 2. 0 qt . )
G 005 100 A1
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . ( 1993- 1995)
096 t r an. 3. 0L ( 3. 2 qt . )
0. 7L ( 0. 74 qt . )
Dexr on I I / I I I or
VWATF G052 162 A2
( 1995- 1997)
01M Dr y Fi l l 5. 3L ( 5. 5 qt . )
Ref i l l 3. 0L ( 3. 2 qt . )
VWATF G052 162 A2 ONLY
FLUID CAPACITY CHART
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . ( 1993- 1995)
0. 75L ( 0. 79 qt . )
G052 145 A2 ( Synt het i c Oi l )
( 1995- 1997)
0. 75L ( 0. 79 qt . )
G052 145 A2 ( Synt het i c Oi l )
Cool i ng Syst em( 2) . . . . . . . . . . . . . 1. 9 TD 6. 5L ( 6. 8 qt . )
1. 8 Gas 5. 5L ( 5. 8 qt . )
2L Eng. 5. 8L ( 6. 1 qt . )
2. 8 V6 10L ( 10. 6 qt . )
Power St eer i ng ( 3) . . . . . . . . . . . . . . . 77L ( . 85 qt . ) ATF Dexr on I I
Wi ndshi el d Washer ( 4) . . . . . . . . . . . 4. 2L ( 4. 5 qt . )
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . 800 50 gr ams ( 28. 2 oz. 1. 8 oz. )
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 115 cc 15cc ( 3. 9oz 0. 5 oz. )
Use PAG Oi l Wi t h R 134a.

VANAGON 1991

Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . Wat er Cool ed 4. 3L ( 4. 8 qt . ) / Fi l t er


Di esel 3. 5L ( 3. 7 qt . ) 3. 8L ( 4. 2 qt . )
Manual Tr ans. . . . . . . . . . . . . . . . . . . Wat er Cool ed - 3. 4L ( 3. 8 qt . )
SAE 80/ 80W/ 90, MI L- L- 2105.
API / GL- 4 or G50
Di esel - 3. 4L ( 3. 8 qt . )
SAE 75W90, MI L- L- 2105,
API / GL- 4 or G50
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . Dr y Fi l l 6. 0L ( 6. 3 qt . )
Ref i l l : 3. 0L ( 3. 2 qt . )
ATF Dexr on I I / I I I or
VWATF G052 162 A2
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . 1. 2L ( 1. 3 qt . )
G052 145 A2 ( Synt het i c oi l )
Cool i ng Syst em( 2) . . . . . . . . . . . . . 16. 7L ( 18. 6 qt . )
Power St eer i ng ( 3) . . . . . . . . . . . . . 1. 2L ( 1. 3 qt . ) ATF Dexr on I I
Wi ndshi el d Washer ( 4) . . . . . . . . . . 3. 9L ( 4. 3 qt . ) - Fr ont
1. 0L ( 1. 1 qt . ) - Rear
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . Gas Engi ne 1190 + 85 gr ams
( 42. 0 + 3. 0 oz. )
Di esel Engi ne 1438 gr ams ( 50. 75 oz. )
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . Gas Engi ne 135 cc ( 4. 7 oz. )
Di esel Engi ne 237 cc ( 8. 0 oz. )

EUROVAN - 1992- 95

Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . Gas 5. 0L ( 5. 7 qt . )
Di esel 5. 5 qt . ( 6. 0 qt . ) ( Canada)
V6 W/ FI . 5. 5L ( 5. 8 qt . )
Manual Tr ans. . . . . . . . . . . . . . . . . . . 2. 3L ( 2. 5 qt . )
G50 Synt het i c oi l SAE 75W90 or
GL4 SAE 75W90 ( 1992- 1995)
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . 098 t r an. 3. 0L ( 3. 2 qt . )
0. 7L ( 0. 74 qt . )
FLUID CAPACITY CHART
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM
Dexr on I I / I I I or
VWATF G052 162 A2
( 1992- 1995)
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . 1. 15L ( 1. 22 qt . )
G052 145 A2 ( Synt het i c Oi l )
( 1992- 1995)
Cool i ng Syst em( 2) . . . . . . . . . . . . . Di esel 11. 5L ( 12. 2 qt . )
5 cyl . 9L ( 9. 5 qt . )
V6 1 heat / ex 9L ( 9. 5 qt . )
2 heat / ex 10. 8L ( 11. 4 qt . ) ( 6)
Power St eer i ng ( 3) . . . . . . . . . . . . . 1L ( 1. 05 qt . ) P/ N G 002 000
Do not use ATF f l ui d
Wi ndshi el d Washer ( 4) . . . . . . . . . . 7. 0L ( 7. 3 qt . )
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . 950 + 50 gr ams ( 33. 25 + 1. 75 oz. )
One evapor at or
1350 + 50 gr ams ( 47. 25 + 1. 75 oz. )
Two evapor at or s
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 135 cm3 4. 72 oz One evapor at or
240 cm3 8. 4 oz Two evapor at or s
Use PAG oi l wi t h R 134a.

EUROVAN - 1995- 97

Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . Gas 5. 0L ( 5. 7 qt . )
Di esel 5. 5 qt . ( 6. 0 qt . ) ( Canada)
V6 W/ FI . 5. 5L ( 5. 8 qt . )
Manual Tr ans. . . . . . . . . . . . . . . . . . . 2. 3L ( 2. 5 qt . )
G50 SAE 75W90 ( Synt het i c) or
GL4 SAE 75W90
( 1995- 1997)
02B 2. 5L ( 2. 7 qt ) G50
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . 01P Dr y Fi l l 5. 3 ( 5. 5 qt . )
Ref i l l 3. 0L ( 3. 2 qt . )
VWATF G052 162 A3 ONLY
( 1995- 1997)
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . 1. 15L ( 1. 22 qt . )
G052 145 A2 ( Synt het i c)
( 1995- 1997)
Cool i ng Syst em( 2) . . . . . . . . . . . . . Di esel 11. 5L ( 12. 2 qt . )
5 cyl . 9L ( 9. 5 qt . )
V6 1 heat / ex 9L ( 9. 5 qt . )
2 heat / ex 10. 8L ( 11. 4 qt . ) ( 6)
Power St eer i ng ( 3) . . . . . . . . . . . . . 1L ( 1. 05 qt . ) P/ N G 002 000
Do not use ATF f l ui d
Wi ndshi el d Washer ( 4) . . . . . . . . . . 7. 0L ( 7. 3 qt . )
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . 950 + 50 gr ams ( 33. 25 + 1. 75 oz. )
One evapor at or
1350 + 50 gr ams ( 47. 25 + 1. 75 oz. )
Two evapor at or s
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 135 cm3 4. 72 oz One evapor at or
240 cm3 8. 4 oz Two evapor at or s
Use PAG oi l wi t h R 134a.
FLUID CAPACITY CHART
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM

CABRI O 1995- 97

Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . 4 cyl . 4. 0L ( 4. 2 qt . )
V6 5. 0L ( 5. 3 qt . )
Di esel 4. 5L ( 4. 7 qt . )
Manual Tr ans. . . . . . . . . . . . . . . . . . . 020 Tr ans. 1. 9L ( 2. 0 qt . ) 75W90.
MI L- L- 2105. API GL- 4 or
G50 synt het i c 75W90
020 Tr ans. 1. 9L ( 2. 0 qt . ) 75W90.
MI L- L- 2105. API GL- 4 or
G50 synt het i c 75W90
( 1995- 1997)
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . 096 t r an. 3. 0L ( 3. 2 qt . )
0. 7L ( 0. 74 qt . )
Dexr on I I / I I I or
VWATF G052 162 A2
01M Dr y Fi l l 5. 3L ( 5. 5 qt . )
Ref i l l 3. 0L ( 3. 2 qt . )
VWATF G052 162 A2 ONLY
( 1995- 1997)
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . 0. 75L ( 0. 79 qt . )
G052 145 A2 ( Synt het i c Oi l )
0. 75L ( 0. 79 qt . )
G052 145 A2 ( Synt het i c Oi l )
( 1995- 1997)
Cool i ng Syst em( 2) . . . . . . . . . . . . . 1. 9 TD 6. 5L ( 6. 8 qt . )
1. 8 Gas 5. 5L ( 5. 8 qt . )
2L Eng. 5. 8L ( 6. 1 qt . )
2. 8 V6 10L ( 10. 6 qt . )
Power St eer i ng ( 3) . . . . . . . . . . . . . . 77L ( . 85 qt . ) ATF Dexr on I I
Wi ndshi el d Washer ( 4) . . . . . . . . . . 4. 2L ( 4. 5 qt . )
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . 800 50 gr ams ( 28. 2 oz. 1. 8 oz. )
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 115 cc 15cc ( 3. 9oz 0. 5 oz. )
Use PAG Oi l Wi t h R 134a.

CABRI OLET 1985- 94

Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . 3. 5L ( 3. 7 qt . ) 4. 0L ( 4. 3 qt . ) / Fi l t er
Manual Tr ans. . . . . . . . . . . . . . . . . . . 020 Tr ans. 1. 9L ( 2. 0 qt . ) 75W90.
MI L- L- 2105. API GL- 4 or
G50 synt het i c 75W90
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . ATF Dexr onI I / I I I or VWATF G052 162 A2
Dr y Fi l l 6. 0L ( 6. 3 qt . )
Ref i l l 3. 0L ( 3. 1 qt . )
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . . 75L ( . 8 qt . )
G052 145 A2 ( synt het i c oi l )
Cool i ng Syst em( 2) . . . . . . . . . . . . . 4. 6L ( 5. 1 qt . )
Power St eer i ng ( 3) . . . . . . . . . . . . . . 77L ( . 85 qt . ) ATF Dexr on I I
Wi ndshi el d Washer ( 4) . . . . . . . . . . 1. 6L ( 1. 8 qt . ) Fr ont
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . 1134 56 gr ams ( 33. 0 oz. 3. 0 oz. )
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 135 cc ( 4. 75 oz )
FLUID CAPACITY CHART
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:07AM
Use PAG oi l wi t h R 134a.

PASSAT 1991- 95

Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . 4 cyl . 3. 5L ( 3. 7 qt . ) W/ O Fi l t er ,
4. 0L ( 4. 3 qt . ) W/ Fi l t er
V6 5. 0L ( 5. 3 qt . ) W/ O Fi l t er ,
6. 0L ( 6. 3 qt . ) W/ Fi l t er
Manual Tr ans. . . . . . . . . . . . . . . . . . . ( 1990- 1995)
02A Tr ans. 2. 0L ( 2. 1 qt . )
02C Tr ans. 2. 4L ( 2. 5 qt . )
API GL 4 MI L- L2105, SAE 75W/ 90 or
G50 Synt het i c SAE 75W/ 90
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . ( 1990- 1995)
Dexr on I I / I I I or VWATF G052 162 A2
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . ( 1990- 1995)
0. 75L ( 0. 79 qt . )
G052 145 A2 ( Synt het i c Oi l )
Cool i ng Syst em( 2) . . . . . . . . . . . . . 4 cyl . 5. 6L ( 5. 9 qt . )
V6 8. 6L ( 9. 1 qt . )
Power St eer i ng ( 3) . . . . . . . . . . . . . 07- 0. 9L ( 0. 74- 0. 5 qt . )
Wi ndshi el d Washer ( 4) . . . . . . . . . . 5. 0L ( 5. 3 qt . )
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . 1150 50 gr ams ( 40. 25 oz. 1. 7 oz. )
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 115 cc ( 4. 02 oz. )
Use PAG oi l wi t h R- 134- a.

PASSAT 1995- 97

Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . 4 cyl . 3. 5L ( 3. 7 qt . ) W/ O Fi l t er ,
4. 0L ( 4. 3 qt . ) W/ Fi l t er
V6 5. 0L ( 5. 3 qt . ) W/ O Fi l t er ,
5. 5L ( 5. 7 qt . ) W/ Fi l t er
Di esel 4. 5L ( 4. 75 qt . )
TDI N/ A 1997
Manual Tr ans. . . . . . . . . . . . . . . . . . . VR6 eng. G 005 100 A1
02A Tr ans. 2. 0L ( 2. 1 qt . )
02C Tr ans. 2. 4L ( 2. 5 qt . )
API GL 4 Mi l - L2105, or
G50 Synt het i c SAE 75W90
( 1995- 1997)
02A Tr ans. 2. 0L ( 2. 1 qt . )
G50 or GL4 ( 1997)
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . ( 1995- 1997)
01M Dr y Fi l l 5. 3L ( 5. 5 qt . )
Ref i l l 3. 0L ( 3. 2 qt . )
VWATF G052 162 A2 ONLY
( 1995- 1997)
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . 0. 75L ( 0. 79 qt . ) G052 145 A2
( Synt het i c Oi l )
( 1995- 1997)
Cool i ng Syst em( 2) . . . . . . . . . . . . . 4 cyl . W/ Aut o Tr . 6. 2L ( 6. 5 qt . )
W/ St d. Tr . 5. 6L ( 5. 8 qt . )
FLUID CAPACITY CHART
Article Text (p. 6)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:07AM
V6 10. 0L ( 10. 4 qt . )
1. 9 TDI 6. 5L ( 6. 8 qt . )
Power St eer i ng ( 3) . . . . . . . . . . . . . 07- 0. 9L ( 0. 74- 0. 5 qt . )
Wi ndshi el d Washer ( 4) . . . . . . . . . . 5. 0L ( 5. 3 qt . )
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . 950 + 50 gr ams ( 33. 25 oz. + 1. 75 oz. )
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 115 cc ( 4. 02 oz. )
Use PAG oi l wi t h R- 134- a.

CORRADO - 1991- 94

Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . 4 cyl . 3. 5L ( 3. 7 qt . ) W/ O Fi l t er ,
4. 0L ( 4. 3 qt . ) W/ Fi l t er
V6 5. 0L ( 5. 3 qt . ) W/ O Fi l t er ,
5. 5L ( 5. 7 qt . ) W/ Fi l t er
Manual Tr ans. . . . . . . . . . . . . . . . . . . 02A Tr ans. 2. 0L ( 2. 1 qt . )
G50 Synt het i c Gear Oi l , 75W/ 90
VR6 Eng. G 005 100 A1
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . 096 t r an. 3. 0L ( 3. 2 qt . )
0. 7L ( 0. 74 qt . )
Dexr on I I / I I I or
VWATF G052 162 A2
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . 0. 75L ( 0. 79 qt . )
G052 162 A2 ( Synt het i c Oi l )
Cool i ng Syst em( 2) . . . . . . . . . . . . . 6. 5L ( 1. 7 gal . )
Power St eer i ng ( 3) . . . . . . . . . . . . . . 77L ( . 85 qt . ) ATF Dexr on I I
Wi ndshi el d Washer ( 4) . . . . . . . . . . 4. 2L ( 4. 4 qt . )
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . 850 + 50 gr ams ( 29. 75 oz. 1. 7 oz. )
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 135 cc ( 4. 7 oz. )
Use PAG oi l wi t h R- 134- a.

FOX - 1991- 93

Engi ne Oi l ( 1) . . . . . . . . . . . . . . . . . 3. 0L ( 3. 2 qt ) W/ O Fi l t er
3. 5L ( 3. 7 qt . ) W/ Fi l t er
Manual Tr ans. . . . . . . . . . . . . . . . . . . 1. 6L ( 1. 8 qt ) 75W90,
MI L- L- 2105, API GL- 4
Aut o Tr ans. . . . . . . . . . . . . . . . . . . . . N/ A
Aut o Di f f . . . . . . . . . . . . . . . . . . . . . . N/ A
Cool i ng Syst em( 2) . . . . . . . . . . . . . 6. 2L ( 6. 9 qt . ) w/ A/ C
Power St eer i ng ( 3) . . . . . . . . . . . . . N/ A
Wi ndshi el d Washer ( 4) . . . . . . . . . . 2. 5L ( 2. 8 qt . ) - Fr ont
1. 5L ( 1. 7 qt . ) - Rear
A/ C Ref r i ger ant R- 12/ R- 134 ( 5) . . 1134 + 50 gr ams ( 38. 0 oz. 1. 7 oz. )
A/ C Ref r i ger ant Oi l . . . . . . . . . . . . 170cc ( 6. 0 oz. )

( 1) = Use " API SERVI CE SG or SH" f or gasol i ne engi nes. Use " API
SERVI CE CF or CG4" f or Di esel engi nes.
( 2) = COOLANT: Use onl y phosphat e f r ee cool ant ZVW237 105 ( G11) up t o
10. 96, f r om10. 96 use ZVW237 ( G12) DO NOT I NTERCHANGE OR MI X
G11 & G12.
( 3) = POWER STEERI NG: Hydr aul i c oi l G002 000 / G002 012 i nst ead of
ATF.
FLUID CAPACITY CHART
Article Text (p. 7)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:07AM
( 4) = WASHER SOLVENT: 9. 0L ( 9. 5 QT. ) w/ headl i ght washer s. Concent r at ed
ZVW177 901/ 903/ 904/ 906.
( 5) = A/ C REFRI GERANT. Use R- 12 t hr ough 1992, R 134a begi ns i n 1993.
( 6) = 2 heat / ex & aux. heat er 11. 4L ( 12. 1 qt . )

CAUTI ON: Par t number s ar e f or r ef er ence onl y. Al ways check wi t h your


Par t s Depar t ment or l at est i nf or mat i on.
END OF ARTICLE
COOLING SYSTEM ANTI-FREEZE PROTECTION LEVEL CHECKING
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM
ARTICLE BEGINNING
TECHNI CAL SERVI CE BULLETI N
COOLI NG SYSTEM ANTI - FREEZE PROTECTI ON LEVEL, CHECKI NG
Model ( s) : 1993- on Vol kswagen Gol f , GTI , J et t a, Cabr i o
Gr oup: Mai nt enance Bul l et i n
Bul l et i n No. : 96- 04
Dat e: November 9, 1996
Fi l e t hi s Techni cal Bul l et i n i n Repai r Manual No. : W42 011 294 118.
COOLING SYSTEM ANTI-FREEZE PROTECTION LEVEL, CHECKING
Speci al t ool CEN5021 ( Fi g. 1) , Lei ca Hand- Hel d Ref r act omet er , i s
avai l abl e and r ecommended f or use as t he onl y accur at e way of
det er mi ni ng t he ant i - f r eeze pr ot ect i on of t he new Vol kswagen engi ne
cool ant G 012 A8D A1.
Thi s t ool aut omat i cal l y pr ovi des i mmedi at e t emper at ur e compensat i on
and di r ect r eadi ng of t he cool ant wi t h onl y a f ew dr ops of sampl e.
Check your t est equi pment i nvent or y t o make sur e you have t hi s
mi ni mumr equi r ement t ool . Speci al Tool CEN5021 can be or der ed t hr ough
Equi pment Sol ut i ons at ( 800) 892- 9650.
Ref er t o Techni cal Bul l et i n, GROUP 19, NO. 96- 01, Oct ober 30, 1996,
f or i nf or mat i on about Vol kswagen cool ant G 012 A8D A1.
Fi g. 1: Speci al Tool CEN5021
END OF ARTICLE
2.0L - METAL CYLINDER HEAD GASKET
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM
ARTICLE BEGINNING
TECHNI CAL SERVI CE BULLETI N
METAL CYLI NDER HEAD GASKET
Model ( s) : 1995- on Vol kswagen Gol f , GTI , J et t a bui l t f r om03/ 95
wi t h 2. 0 l i t er , engi ne code ABA
Gr oup: 15 - Engi ne - Cyl i nder Heads Val ve Dr i ve
Bul l et i n No. : 96- 03
Dat e: May 15, 1996
Fi l e t hi s Techni cal Bul l et i n i n Repai r Manual No. : W42 011 294 105.
SERVICE INFORMATION
The f ol l owi ng Repai r Manual i nf or mat i on i s new and wi l l be
i nt egr at ed wi t h t he next Repai r Manual updat e.
CYLI NDER HEAD, REMOVI NG AND I NSTALLI NG
Ref er t o Fi g. 1.
11 - Cyl i nder head bol t
* Al ways r epl ace.
* Di f f er ent ver si ons dependi ng on cyl i nder head gasket t ype.
14 - Cyl i nder head gasket
* Al ways r epl ace.
* New met al gasket f r om03/ 95.
* I nst al l i ng r epl acement met al gasket r equi r es di f f er ent cyl i nder
head bol t s.
* When r epl aci ng gasket , r epl ace engi ne cool ant .
CHECKING CYLINDER HEAD FOR DISTORTION
Maxi mumper mi ssi bl e di st or t i on: 0. 1 mm( 0. 004 i n. ) See Fi g. 2.
CYLINDER HEAD BOLT IDENTIFYING FEATURES
See Fi g. 3.
A - Bol t wi t h smoot h head
For pr evi ous ver si on cyl i nder head gasket
B - Bol t wi t h r ai sed mar ki ngs on bol t head ( ar r ows)
For met al cyl i nder head gasket
CYLINDER HEAD, REMOVING AND INSTALLING
Speci al t ool s, t est er s and auxi l i ar y i t ems
2.0L - METAL CYLINDER HEAD GASKET
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM
* Gui de pi n 3070
* Tor que wr ench - 40- 200 N. m( 30- 150 f t - l b)
Condi t i ons
* Engi ne col d
* Pi st ons not at Top Dead Cent er ( TDC)
CAUTI ON: * Onl y r emove t he new cyl i nder head gasket f r omi t s package
i mmedi at el y bef or e i nst al l i ng.
* Handl e t he new gasket wi t h ext r eme car e. Damage t o t he
si l i cone coat i ng or ar ound t he beadi ng wi l l l ead t o l eaks.
* I f a met al gasket i s bei ng i nst al l ed as a r epl acement
f or t he pr evi ous sof t er gasket , new cyl i nder head bol t s
must al so be i nst al l ed.
REMOVING
- Fol l ow sequence when l ooseni ng cyl i nder head. See Fi g. 4.
- Car ef ul l y r emove r emai ns of gasket , maki ng sur e t hat no scor i ng or
l ong scr at ches ar e f or med ( abr asi ve mat er i al s must be 100 gr i t
mi ni mum) .
- Car ef ul l y r emove met al par t i cl es and r emai ns of abr asi ve mat er i al s.
INSTALLING
- To al i gn cyl i nder head, i nst al l gui de pi ns f r om3070 i nt o hol es f or
cyl i nder head bol t s - 8- and - 10- . See Fi g. 5.
- I nst al l cyl i nder head gasket .
* Let t er i ng ( Par t No. ) f aces up.
- I nst al l cyl i nder head and 8 r emai ni ng bol t s, and t i ght en by hand.
- Remove gui de pi ns usi ng r emoval t ool f r om3070, t hen i nst al l 2
r emai ni ng cyl i nder head bol t s.
- Ti ght en cyl i nder head i n sequence shown i n Fi g. 6, f ol l owi ng same
sequence f or each of f or st ages.
- Fi r st pr e- t i ght en wi t h t or que wr ench.
* St age I = 40 N. m( 30 f t - l b)
* St age I I = 60 N. m( 44 f t - l b)
- Tur n f ur t her wi t h st andar d wr ench.
* St age I I I = 1/ 4 t ur n ( 90)
* St age I V = 1/ 4 t ur n ( 90)
2.0L - METAL CYLINDER HEAD GASKET
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM
Fi g. 1: Cyl i nder Head, Gasket s & Cover s
Fi g. 2: Checki ng Cyl i nder Head Di st or t i on
2.0L - METAL CYLINDER HEAD GASKET
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM
Fi g. 3: Cyl i nder Head Bol t I dent i f i cat i on
Fi g. 4: Cyl i nder Head Bol t Looseni ng Sequence
2.0L - METAL CYLINDER HEAD GASKET
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM
Fi g. 5: Gui de Pi n Locat i ons
Fi g. 6: Cyl i nder Head Bol t Ti ght eni ng Sequence
END OF ARTICLE
2.0L (ENGINE CODE ABA) - LUBRICATION SYSTEM
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM
ARTICLE BEGINNING
TECHNI CAL SERVI CE BULLETI N
ENGI NE LUBRI CATI ON SYSTEM - 2. 0 LI TER ENGI NE CODE ABA
Model ( s) : 1996- on Vol kswagen Gol f I I I , J et t a I I I , Cabr i o
Gr oup: 17 - Engi ne - Lubr i cat i on Syst em
Bul l et i n No. : 95- 01
Dat e: Oct ober 16, 1995
Fi l e t hi s Techni cal Bul l et i n i n Repai r Manual No. : W42 011 294 105.
SERVICE INFORMATION
Thi s i nf or mat i on descr i bes changes i n engi ne component s and
speci f i cat i ons f or t he 2. 0 l i t er engi ne st ar t i ng wi t h August , 1995
pr oduct i on ( OBD I I ) .
The f ol l owi ng i nf or mat i on wi l l be i nt egr at ed i nt o t he Repai r Manual
dur i ng t he next updat e.
LUBRICATION SYSTEM, COMPONENTS
Ref er t o Fi g. 1.
5 - 0. 3 bar oi l pr essur e swi t ch - F22-
* 25 N. m( 18 f t - l b)
* Wi r e: bl ue/ bl ack
* I f l eaki ng, cut seal and r epl ace.
Engi nes up t o 07. 95
* 0. 3 bar ( 4. 4 psi )
* Housi ng: br own
Engi nes 08. 95- on
* 0. 25 bar ( 3. 6 psi )
* Housi ng: bl ue
6 - Oi l pr essur e swi t ch - F1-
* 1. 8 bar ( 26 psi )
* 25 N. m( 18 f t - l b)
* Housi ng: whi t e
* Wi r e: yel l ow
* I f l eaki ng, cut seal and r epl ace.
23 - Sound def l ect or
* To r emove, r emove oi l pump cover or suct i on l i ne.
* Not appl i cabl e f r om08. 95- on.
25 - Pr essur e r el i ef val ve
* 25 N. m( 18 f t - l b)
* Not appl i cabl e f r om08. 95- on.
26 - Oi l spr ay nozzl e
* For pi st on cool i ng.
2.0L (ENGINE CODE ABA) - LUBRICATION SYSTEM
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM
* Not appl i cabl e f r om08. 95- on.
OIL PRESSURE AND OIL PRESSURE SWITCHES CHECKING
For f unct i onal t est i ng and r epai r of t he opt i cal war ni ng l i ght ) and
acoust i c ( buzzer ) oi l pr essur e war ni ng syst ems, see El ect r i cal Wi r i ng
Di agr ams, Tr oubl eshoot i ng & Component Locat i ons bi nder .
- Remove 0. 3 bar oi l pr essur e swi t ch - F22- ( br own i nsul at i on) and
i nst al l i n VAG 1342 t est er . See Fi g. 2.
NOTE: Fr om08. 95: 0. 25 bar oi l pr essur e swi t ch - F22- wi t h bl ue
i nsul at i on.
- Connect t est er t o cyl i nder head i n pl ace of oi l pr essur e swi t ch
- F22- .
- Connect br own wi r e - 3- f r omt est er t o Gr ound ( GND.
- Connect VAG 1527B vol t age t est er t o bat t er y posi t i ve vol t age ( B+)
and oi l pr essur e swi t ch - A- usi ng adapt er s f r omVW1594 connect or
t est ki t . See Fi g. 2.
* LED shoul d l i ght up.
- St ar t engi ne and i ncr ease RPM sl owl y.
* At 0. 15- 0. 45 bar ( 2. 1- 6. 5 psi ) LED shoul d go out .
I f NO:
- Repl ace oi l pr essur e swi t ch - F22- .
- Connect vol t age t est er wi t h 1. 8 bar oi l pr essur e swi t ch - F1- ( whi t e
i nsul at i on) - B- .
* At 1. 6- 2. 0 bar ( 23- 29 psi ) LED must l i ght up.
- Repl ace oi l pr essur e swi t ch - F1- .
- I ncr ease RPM f ur t her .
* At 2000 RPM and 80C ( 176F) oi l t emper at ur e, oi l pr essur e must be
mi n. 2. 0 bar ( 29 psi ) .
* At hi gher RPM, oi l pr essur e must not exceed 7. 0 bar ( 101 psi ) . I f
necessar y, r epl ace oi l pump cover wi t h pr essur e r el i ef val ve.
2.0L (ENGINE CODE ABA) - LUBRICATION SYSTEM
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:06AM
Fi g. 1: Lubr i cat i on Syst emComponent s
Fi g. 2: VAG 1342 Test er Connect i ons
END OF ARTICLE
2.0L (ENGINE CODE ABA) - CYLINDER HEAD, VALVE DRIVE
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:05AM
ARTICLE BEGINNING
TECHNI CAL SERVI CE BULLETI N
ENGI NE CYLI NDER HEAD VALVE DRI VE - 2. 0 LI TER ENGI NE CODE ABA
Model ( s) : 1996- on Vol kswagen Gol f I I I , J et t a I I I , Cabr i o
Gr oup: 15 - Engi ne - Cyl i nder Heads Val ve Dr i ve
Bul l et i n No. : 95- 01
Dat e: Oct ober 16, 1995
Fi l e t hi s Techni cal Bul l et i n i n Repai r Manual No. : W42 011 294 105.
SERVICE INFORMATION
Thi s i nf or mat i on descr i bes changes i n engi ne component s and
speci f i cat i ons f or t he 2. 0 l i t er engi ne st ar t i ng wi t h August , 1995
pr oduct i on ( OBD I I ) .
The f ol l owi ng i nf or mat i on wi l l be i nt egr at ed i n t o t he Repai r Manual
dur i ng t he next updat e.
CYLI NDER HEAD DI SASSEMBLI NG AND ASSEMBLI NG
Ref er t o Fi g. 1.
2 - up t o 07. 95: 20 N. m( 15 f t - l b)
08. 95- on: 35 N. m( 26 f t - l b)
Fi g. 1: Expl oded Vi ew Of Cyl i nder Head Assembl y
END OF ARTICLE
2.0L (ENGINE CODE ABA) - CRANKSHAFT, CYLINDER BLOCK
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:05AM
ARTICLE BEGINNING
TECHNI CAL SERVI CE BULLETI N
ENGI NE CRANKSHAFT CYLI NDER BLOCK - 2. 0 LI TER ENGI NE CODE ABA
Model ( s) : 1996- on Vol kswagen Gol f I I I , J et t a I I I , Cabr i o
Gr oup: 13 - Engi ne - Cr ankshaf t / Cr ankcase
Bul l et i n No. : 95- 01
Dat e: Oct ober 16, 1995
Fi l e t hi s Techni cal Bul l et i n i n Repai r Manual No. : W42 011 294 105.
SERVICE INFORMATION
Thi s i nf or mat i on descr i bes changes i n engi ne component s and
speci f i cat i ons f or t he 2. 0 l i t er engi ne st ar t i ng wi t h August , 1995
pr oduct i on ( OBD I I ) .
The f ol l owi ng i nf or mat i on wi l l be i nt egr at ed i nt o t he Repai r Manual
dur i ng t he next updat e.
PI STON AND CONNECTI NG ROD DI SASSEMBLI NG/ ASSEMBLI NG
Ref er t o Fi g. 1.
6 - Pr essur e r el i ef val ve
* Ti ght eni ng t or que: 27 N. m( 20 f t - l b)
* Openi ng pr essur e: 2. 5 - 3. 2 bar ( 36 - 46 psi )
* Not appl i cabl e f r om08. 95- on.
7 - Oi l spr ay nozzl e
* For pi st on cool i ng.
* Not appl i cabl e f r om08. 95- on.
NOTE: The oi l spr ay nozzl es and pr essur e r el i ef val ves have been
di scont i nued wi t h pr oduct i on f r om08. 95.
PI STON DI MENSI ONS
Ref er t o Fi g. 2.
PI STON DI MENSI ONS TABLE

Engi ne Code ABA ABA


up t o 07. 95 08. 95- on

Di mensi on - a- mm( i n. ) 20. 1 20. 1


( 0. 791) ( . 791)

Di mensi on - b- mm( i n. ) 5. 5 7. 1
2.0L (ENGINE CODE ABA) - CRANKSHAFT, CYLINDER BLOCK
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:05AM
( 0. 217) ( 0. 280)

Combust i on Chamber Di a. - c- mm( i n. ) 64. 0 65. 0


( 2. 520) ( 2. 559)

Pi st on Pi n Di amet er - d- mm( i n. ) 21. 0 21. 0


( 0. 827) ( 0. 827)

NOTE: Onl y pi st ons and pi st on r i ngs of t he same t ype and pi st ons of


t he same wei ght cl ass may be i nst al l ed.
PI STON AND CYLI NDER DI MENSI ONS TABLE - UP TO > 07. 95

Recondi t i oni ng Di mensi on Pi st on Cyl i nder Bor e


di amet er Di amet er

Basi c di mensi on mm( i n. ) 82. 485 82. 51


( 3. 24744) ( 3. 2484)

1st over si ze mm( i n. ) 82. 735 82. 76


( 3. 25728) ( 3. 2583)

2nd over si ze mm( i n. ) 82. 985 83. 01


( 3. 26713) ( 3. 2681)

PI STON AND CYLI NDER DI MENSI ONS TABLE - 08. 95- ON

Recondi t i oni ng Di mensi on ( 1) Pi st on Cyl i nder Bor e


di amet er Di amet er

Basi c di mensi on mm( i n. ) 82. 470 82. 51


( 3. 24685) ( 3. 2484)

1st over si ze mm( i n. ) 82. 720 82. 76


( 3. 25669) ( 3. 2583)

2nd over si ze mm( i n. ) 82. 970 83. 01


( 3. 26654) ( 3. 2681)

( 1) = Add 0. 015 mm( 0. 00059 i n. ) f or phosphat e l ayer

2.0L (ENGINE CODE ABA) - CRANKSHAFT, CYLINDER BLOCK


Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:05AM
Fi g. 1: Expl oded Vi ew Of Pi st on/ Connect i ng Rod Assembl y
2.0L (ENGINE CODE ABA) - CRANKSHAFT, CYLINDER BLOCK
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:05AM
Fi g. 2: Pi st on Di mensi ons
END OF ARTICLE
1.9L - TOOTHED BELT RUNS TOWARDS OUTSIDE/JUMPS OFF
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:05AM
ARTICLE BEGINNING
TECHNI CAL SERVI CE BULLETI N
TOOTHED BELT RUNS TOWARDS OUTSI DE, WEARS OUT, J UMPS OFF, CRACKS
Model ( s) : 1994- 97 Vol kswagen Gol f , J et t a, Passat wi t h 1. 9L
( Engi ne code AAZ, 1Z)
Gr oup: 15 - Engi ne - Cyl i nder Heads Val ve Dr i ve
Bul l et i n No. : 97- 01
Dat e: J une 4, 1997
NOTE: Thi s bul l et i n super sedes Techni cal Bul l et i n Gr oup 13, No. 97- 01
dat ed J anuar y 28, 1997.
CONDITION
Toot hed bel t r uns t owar d out si de and wear s out , j umps of f , cr acks or
i s noi sy.
SERVICE
I f t hi s condi t i on exi st s:
- Repl ace t oot hed bel t and aut omat i c t ensi oni ng r ol l er
Par t No: 028 109 243F see t he appr opr i at e Repai r Manual f or Model s
l i st ed above.
NOTE: Pr i or t o i nst al l i ng t he new bel t , cl ean i dl er pul l ey,
cr ankshaf t and Di esel I nj ect i on pump spr ocket s.
Af t er i nst al l i ng new bel t but pr i or t o i nst al l i ng vi br at i on damper
pul l ey:
- Usi ng a second Techni ci an, st ar t and r un engi ne ( AT I DLE) f or a f ew
seconds whi l e obser vi ng t oot hed bel t .
- Swi t ch i gni t i on OFF, t hen check t oot hed bel t .
* Bel t must NOT pr ot r ude beyond f ace of cr ankshaf t spr ocket .
I f bel t pr ot r udes beyond f ace of cr ankshaf t spr ocket , adj ust Di esel
I nj ect i on pump mount i ng br acket as f ol l ows:
- Remove i nj ect i on pump.
- Sl i ght l y l oosen t hr ee f ast ener s secur i ng br acket t o engi ne. See
Fi g. 1, - ar r ows- .
- Pr ess br acket down at poi nt - A- and l i f t at poi nt - B- whi l e a second
Techni ci an t or ques f ast ener s - ar r ows- t o 25 N. m. ( 18 f t - l b. ) . See
1.9L - TOOTHED BELT RUNS TOWARDS OUTSIDE/JUMPS OFF
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:05AM
Fi g. 1.
- Rei nst al l i nj ect i on pump.
Af t er i nst al l i ng bel t but pr i or t o i nst al l i ng vi br at i on damper
pul l ey:
- Usi ng a second Techni ci an, st ar t and r un engi ne ( AT I DLE) f or a f ew
seconds whi l e obser vi ng t oot hed bel t .
- Swi t ch i gni t i on OFF, t hen check t oot hed bel t .
* Bel t must NOT pr ot r ude beyond f ace of cr ankshaf t spr ocket .
I f bel t i s cor r ect l y posi t i oned:
- Rei nst al l r emai ni ng par t s as out l i ned i n appl i cabl e Repai r Manual .
I f bel t pr ot r udes beyond f ace of cr ankshaf t spr ocket :
- Cont act t he VWTechni ci ans Hel pl i ne at :
US 1- 800- 678- 2389
CAN 1- 800- 697- 8655
WARRANTY INFORMATION
When pr ocedur e appl i es t o vehi cl es wi t hi n war r ant y use t he
f ol l owi ng:
PART I DENTI FI ER: 1527
LABOR OPERATI ON: 1527510 200 TU
Fi g. 1: I nj ect i on Pump Br acket & Mount i ng Bol t s
END OF ARTICLE
SYSTEM WIRING DIAGRAMS
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
ARTICLE BEGINNING
1996 Syst emWi r i ng Di agr ams
Vol kswagen - Gol f
AIR CONDITIONING
2.0L
2. 0L, A/ C Ci r cui t
SYSTEM WIRING DIAGRAMS
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
2. 0L, Heat er Ci r cui t
ANTI-LOCK BRAKES
SYSTEM WIRING DIAGRAMS
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Ant i - l ock Br ake Ci r cui t s
ANTI-THEFT
SYSTEM WIRING DIAGRAMS
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Ant i - t hef t Ci r cui t
COMPUTER DATA LINES
SYSTEM WIRING DIAGRAMS
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Comput er Dat a Li nes
COOLING FAN
SYSTEM WIRING DIAGRAMS
Article Text (p. 6)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
2.0L
2. 0L, Cool i ng Fan Ci r cui t
CRUISE CONTROL
SYSTEM WIRING DIAGRAMS
Article Text (p. 7)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Cr ui se Cont r ol Ci r cui t
DEFOGGERS
SYSTEM WIRING DIAGRAMS
Article Text (p. 8)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Def ogger Ci r cui t
SYSTEM WIRING DIAGRAMS
Article Text (p. 9)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
ENGINE PERFORMANCE
2.0L
2. 0L, Engi ne Per f or mance Ci r cui t s ( 1 of 2)
SYSTEM WIRING DIAGRAMS
Article Text (p. 10)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
2. 0L, Engi ne Per f or mance Ci r cui t s ( 2 of 2)
EXTERIOR LIGHTS
SYSTEM WIRING DIAGRAMS
Article Text (p. 11)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Back- up Lamps Ci r cui t
SYSTEM WIRING DIAGRAMS
Article Text (p. 12)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Ext er i or Lamps Ci r cui t ( 1 of 2)
SYSTEM WIRING DIAGRAMS
Article Text (p. 13)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Ext er i or Lamps Ci r cui t ( 2 of 2)
GROUND DISTRIBUTION
SYSTEM WIRING DIAGRAMS
Article Text (p. 14)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Gr ound Di st r i but i on Ci r cui t ( 1 of 6)
SYSTEM WIRING DIAGRAMS
Article Text (p. 15)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Gr ound Di st r i but i on Ci r cui t ( 2 of 6)
SYSTEM WIRING DIAGRAMS
Article Text (p. 16)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Gr ound Di st r i but i on Ci r cui t ( 3 of 6)
SYSTEM WIRING DIAGRAMS
Article Text (p. 17)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Gr ound Di st r i but i on Ci r cui t ( 4 of 6)
SYSTEM WIRING DIAGRAMS
Article Text (p. 18)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Gr ound Di st r i but i on Ci r cui t ( 5 of 6)
SYSTEM WIRING DIAGRAMS
Article Text (p. 19)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Gr ound Di st r i but i on Ci r cui t ( 6 of 6)
HEADLIGHTS
SYSTEM WIRING DIAGRAMS
Article Text (p. 20)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Headl i ght Ci r cui t , W/ DRL
HORN
SYSTEM WIRING DIAGRAMS
Article Text (p. 21)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Hor n Ci r cui t
INSTRUMENT CLUSTER
SYSTEM WIRING DIAGRAMS
Article Text (p. 22)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
I nst r ument Cl ust er Ci r cui t ( 1 of 2)
SYSTEM WIRING DIAGRAMS
Article Text (p. 23)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
I nst r ument Cl ust er Ci r cui t ( 2 of 2)
INTERIOR LIGHTS
SYSTEM WIRING DIAGRAMS
Article Text (p. 24)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Cour t esy Lamp Ci r cui t
SYSTEM WIRING DIAGRAMS
Article Text (p. 25)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
I nst r ument I l l umi nat i on Ci r cui t
POWER DISTRIBUTION
SYSTEM WIRING DIAGRAMS
Article Text (p. 26)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Power Di st r i but i on Ci r cui t ( 1 of 3)
SYSTEM WIRING DIAGRAMS
Article Text (p. 27)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Power Di st r i but i on Ci r cui t ( 2 of 3)
SYSTEM WIRING DIAGRAMS
Article Text (p. 28)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Power Di st r i but i on Ci r cui t ( 3 of 3)
POWER DOOR LOCKS
SYSTEM WIRING DIAGRAMS
Article Text (p. 29)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Power Door Lock Ci r cui t
POWER MIRRORS
SYSTEM WIRING DIAGRAMS
Article Text (p. 30)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Power Mi r r or Ci r cui t
SYSTEM WIRING DIAGRAMS
Article Text (p. 31)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
POWER SEATS
Heat ed Seat s Ci r cui t
SYSTEM WIRING DIAGRAMS
Article Text (p. 32)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
POWER TOP/SUNROOF
Sunr oof Ci r cui t
SYSTEM WIRING DIAGRAMS
Article Text (p. 33)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
POWER WINDOWS
Power Wi ndow Ci r cui t ( 1 of 2)
SYSTEM WIRING DIAGRAMS
Article Text (p. 34)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Power Wi ndow Ci r cui t ( 2 of 2)
SHIFT INTERLOCKS
SYSTEM WIRING DIAGRAMS
Article Text (p. 35)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Shi f t I nt er l ock Ci r cui t
STARTING/CHARGING
SYSTEM WIRING DIAGRAMS
Article Text (p. 36)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Char gi ng Ci r cui t
SYSTEM WIRING DIAGRAMS
Article Text (p. 37)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
St ar t i ng Ci r cui t
SUPPLEMENTAL RESTRAINTS
SYSTEM WIRING DIAGRAMS
Article Text (p. 38)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:01AM
Suppl ement al Rest r ai nt Ci r cui t , Ear l y Pr oduct i on
SYSTEM WIRING DIAGRAMS
Article Text (p. 39)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:01AM
Suppl ement al Rest r ai nt Ci r cui t , Lat e Pr oduct i on
TRANSMISSION
SYSTEM WIRING DIAGRAMS
Article Text (p. 40)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:01AM
2.0L
2. 0L, Tr ansmi ssi on Ci r cui t
TRUNK, TAILGATE, FUEL DOOR
SYSTEM WIRING DIAGRAMS
Article Text (p. 41)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:01AM
Tr unk Rel ease Ci r cui t
WARNING SYSTEMS
SYSTEM WIRING DIAGRAMS
Article Text (p. 42)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:01AM
War ni ng Syst emCi r cui t s
WIPER/WASHER
SYSTEM WIRING DIAGRAMS
Article Text (p. 43)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:01AM
Heat ed Wi ndshi el d Washer Ci r cui t
SYSTEM WIRING DIAGRAMS
Article Text (p. 44)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:01AM
Wi per / Washer Ci r cui t
END OF ARTICLE
HOW TO USE SYSTEM WIRING DIAGRAMS
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
ARTICLE BEGINNING
GENERAL I NFORMATI ON
Usi ng Wi r i ng Di agr ams
Al l Model s
INTRODUCTION
Mi t chel l obt ai ns wi r i ng di agr ams and t echni cal ser vi ce
bul l et i ns, cont ai ni ng wi r i ng di agr amchanges f r omt he domest i c and
i mpor t manuf act ur er s. These ar e checked f or accur acy and ar e al l
r edr awn i nt o a consi st ent f or mat f or easy use.
I n t he past , when car s wer e si mpl er , di agr ams wer e si mpl er .
Al l component s wer e connect ed by wi r es and di agr ams sel domexceeded 4
pages i n l engt h. Today, some wi r i ng di agr ams r equi r e mor e t han 16
pages. I t woul d be i mpr act i cal t o expect a ser vi ce t echni ci an t o t r ace
a wi r e f r ompage 1 acr oss ever y page t o page 16.
Removi ng some of t he wi r i ng maze r educes eyest r ai n and t i me
wast ed sear chi ng acr oss sever al pages. Today t he maj or i t y of Mi t chel l
di agr ams f ol l ow a much i mpr oved f or mat , whi ch per mi t s space f or
i nt er nal swi t ch det ai l s.
Wi r i ng di agr ams ar e dr awn i n a " t op- down" f or mat . The
di agr ams ar e dr awn wi t h t he power sour ce at t he t op of t he di agr amand
t he gr ound poi nt at t he bot t omof t he di agr am. Component s l ocat i ons
ar e i dent i f i ed on t he wi r i ng di agr ams. Any wi r es t hat don' t connect
di r ect l y t o a component ar e i dent i f i ed on t he di agr amt o i ndi cat e
wher e t hey go.
COLOR ABBREVIATIONS
COLOR ABBREVI ATI ONS TABLE

Col or Nor mal Opt i onal


Bl ack . . . . . . . . . . . . . . . . BLK . . . . . . . . . . . . . . . . . . . . . . . . . . BK
Bl ue . . . . . . . . . . . . . . . . . BLU . . . . . . . . . . . . . . . . . . . . . . . . . . BU
Br own . . . . . . . . . . . . . . . . BRN . . . . . . . . . . . . . . . . . . . . . . . . . . BN
Cl ear . . . . . . . . . . . . . . . . CLR . . . . . . . . . . . . . . . . . . . . . . . . . . CR
Dar k Bl ue . . . . . . . . . . DK BLU . . . . . . . . . . . . . . . . . . . . . . DK BU
Dar k Gr een . . . . . . . . . DK GRN . . . . . . . . . . . . . . . . . . . . . . DK GN
Gr een . . . . . . . . . . . . . . . . GRN . . . . . . . . . . . . . . . . . . . . . . . . . . GN
Gr ay . . . . . . . . . . . . . . . . . GRY . . . . . . . . . . . . . . . . . . . . . . . . . . GY
Li ght Bl ue . . . . . . . . . LT BLU . . . . . . . . . . . . . . . . . . . . . . LT BU
Li ght Gr een . . . . . . . . LT GRN . . . . . . . . . . . . . . . . . . . . . . LT GN
Or ange . . . . . . . . . . . . . . . ORG . . . . . . . . . . . . . . . . . . . . . . . . . . OG
Pi nk . . . . . . . . . . . . . . . . . PNK . . . . . . . . . . . . . . . . . . . . . . . . . . PK
Pur pl e . . . . . . . . . . . . . . . PPL . . . . . . . . . . . . . . . . . . . . . . . . . . PL
Red . . . . . . . . . . . . . . . . . . RED . . . . . . . . . . . . . . . . . . . . . . . . . . RD
Tan . . . . . . . . . . . . . . . . . . TAN . . . . . . . . . . . . . . . . . . . . . . . . . . TN
HOW TO USE SYSTEM WIRING DIAGRAMS
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Vi ol et . . . . . . . . . . . . . . . VI O . . . . . . . . . . . . . . . . . . . . . . . . . . VI
Whi t e . . . . . . . . . . . . . . . . WHT . . . . . . . . . . . . . . . . . . . . . . . . . . WT
Yel l ow . . . . . . . . . . . . . . . YEL . . . . . . . . . . . . . . . . . . . . . . . . . . YL

IDENTIFYING WIRING DIAGRAM ABBREVIATIONS


NOTE: Abbr evi at i ons used on Mi t chel l di agr ams ar e nor mal l y
sel f - expl anat or y. I f necessar y see ABBREVI ATI ONS
ar t i cl e i n GENERAL I NFORMATI ON.
IDENTIFYING WIRING DIAGRAM SYMBOLS
NOTE: St andar d wi r i ng symbol ar e used i n Mi t chel l di agr ams. The
i l l ust r at i on bel ow wi l l hel p cl ar i f y any symbol s t hat ar e
not easi l y under st ood at a gl ance. Most component s ar e
l abel ed " Mot or " , " Swi t ch" or " Rel ay" i n addi t i on t o bei ng
dr awn wi t h t he st andar d symbol .
HOW TO USE SYSTEM WIRING DIAGRAMS
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Fi g. 1: I dent i f yi ng Wi r i ng Di agr amSymbol s
WIRING DIAGRAM COMPONENT LOCATIONS
HOW TO USE SYSTEM WIRING DIAGRAMS
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
When t r yi ng t o l ocat e a component i n a wi r i ng di agr amand you
don' t know t he speci f i c syst emwher e i t i s l ocat ed, use t hi s handy
component l ocat or t o f i nd t he syst emwi r i ng di agr ami n whi ch t he
component i s l ocat ed. Then, go t o t hat syst emand l ocat e t he component
wi t hi n t he wi r i ng di agr am.
For exampl e, i f you don' t know t he speci f i c syst emi n whi ch
t he i gni t i on swi t ch i s l ocat ed, l ook up i gni t i on swi t ch i n t he wi r i ng
di agr amcomponent l ocat i on t abl es and go t o t he appr opr i at e wi r i ng
di agr am( s) whi ch cont ai n ei t her f ul l or par t i al vi ews of t he i gni t i on
swi t ch. The f ul l vi ew of t he i gni t i on swi t ch i s l ocat ed i n Power
Di st r i but i on.
The f i r st l i st i ng f or t he component wi l l be t he f ul l or most
compl et e vi ew of t he component . Addi t i onal l i st i ngs wi l l be par t i al
vi ews of t he component . Not al l component s ar e used on al l model s.
Al l component s wi l l have a par t i al vi ew i n Gr ound
Di st r i but i on and Power Di st r i but i on. Dat a Li nk Connect or s show
connect i ng ci r cui t s bet ween modul es. Al t er nat e names f or component s
may be l i st ed i n wi r i ng di agr amcomponent l ocat i ons t abl es.
WI RI NG DI AGRAM COMPONENT LOCATI ONS TABLE

Component Wi r i ng Di agr am
ABS El ect r oni c Cont r ol Uni t . . . . . . . . . . . . . . . . . . . . . . . Ant i - Lock Br akes
Dat a Li nk Connect or s
ABS Hydr aul i c Uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ant i - Lock Br akes
Accel er at i on Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ant i - Lock Br akes
Accessor y Del ay Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wi ndows
A/ C Compr essor Cl ut ch Rel ay . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
A/ C Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
A/ C Pr essur e Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Adapt i ve Lamp Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Ai r Bag( s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Ai r Bag Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Ai r Bag Sensor ( s) . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Ai r I nj ect i on Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Ai r Temper at ur e Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over head Consol e
Al t er nat or ( Gener at or ) . . . . . . . . . . . . . . . . . . . . . Gener at or s & Regul at or s
Ant i - Thef t Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . . Ant i - Thef t Syst em
St ar t er s
Aut ol amp Cont r ol Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Syst ems
Dayt i me Runni ng Li ght s
Aut omat i c Shut down ( ASD) Rel ay . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Gener at or s & Regul at or s
Aut ost i ck Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Auxi l i ar y Bat t er y Rel ay . . . . . . . . . . . . . . . . . . . . Gener at or s & Regul at or s
Back- Up Li ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back- Up Li ght s
Ext er i or Li ght s
Bar omet r i c ( BARO) Pr essur e Sensor . . . . . . . . . . . . . . . Engi ne Per f or mance
Bat t er y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
Bat t er y Temper at ur e Sensor . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
HOW TO USE SYSTEM WIRING DIAGRAMS
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Body Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . Body Cont r ol Comput er
Ant i - Thef t Syst em
Dayt i me Runni ng Li ght s
Engi ne Per f or mance
Headl i ght Syst ems
War ni ng Syst ems
Boost Cont r ol Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Boost Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Br ake Fl ui d Level Swi t ch . . . . . . . . . . . . . . . . . . Anal og I nst r ument Panel s
Br ake On/ Of f ( BOO) Swi t ch . . . . . . . . . . . . . . . . . . . Cr ui se Cont r ol Syst ems
Engi ne Per f or mance
Shi f t I nt er l ock Syst ems
Buzzer Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . War ni ng Syst ems
Camshaf t Posi t i on ( CMP) Sensor . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Cent r al Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . Ant i - Thef t Syst em
Cl ockspr i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Cr ui se Cont r ol Syst ems
St eer i ng Col umn Swi t ches
Cl ut ch Pedal Posi t i on Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Cl ut ch St ar t Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Combi nat i on Met er . . . . . . . . . . . . . . . . . . . . . . . . . Anal og I nst r ument Panel s
Const ant Cont r ol Rel ay Modul e ( CCRM) . . . . . . . . . . . . Engi ne Per f or mance
El ect r i c Cool i ng Fans
Conveni ence Cent er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
I l l umi nat i on/ I nt er i or Li ght s
Conver t i bl e Top Mot or . . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Conver t i bl e Top Swi t ch . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Cr ankshaf t Posi t i on ( CKP) Sensor . . . . . . . . . . . . . . . . Engi ne Per f or mance
Cr ui se Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . Cr ui se Cont r ol Syst ems
Cr ui se Cont r ol Swi t ch . . . . . . . . . . . . . . . . . . . . . . . Cr ui se Cont r ol Syst ems
Condenser Fan Rel ay( s) . . . . . . . . . . . . . . . . . . . . . . . El ect r i c Cool i ng Fans
Dat a Li nk Connect or ( DLC) . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Dayt i me Runni ng Li ght s Modul e . . . . . . . . . . . . . . . Dayt i me Runni ng Li ght s
Ext er i or Li ght s
Def ogger Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wi ndow Def ogger
Di agnost i c Ener gy Reser ve Modul e ( DERM) . . . Ai r Bag Rest r ai nt Syst em
Di scr i mi nat i ng Sensor ( Ai r Bag) . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Di st r i but or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Door Lock Act uat or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Door Locks
Remot e Keyl ess Ent r y
Door Lock Rel ay( s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Door Locks
El ect r ochr omi c Mi r r or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Mi r r or s
El ect r oni c Level Cont r ol ( ELC)
Hei ght Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . El ect r oni c Suspensi on
El ect r oni c Level Cont r ol ( ELC) Modul e . . . . . . . . El ect r oni c Suspensi on
Engi ne Cool ant Temper at ur e ( ECT)
Sendi ng Uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anal og I nst r ument Panel s
Engi ne Cool ant Temper at ur e ( ECT) Sensor . . . . . . . . . Engi ne Per f or mance
Engi ne Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Gener at or s & Regul at or s
St ar t er s
ETACS ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . War ni ng Syst ems
HOW TO USE SYSTEM WIRING DIAGRAMS
Article Text (p. 6)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Power Wi ndows
Remot e Keyl ess Ent r y
Evapor at i ve ( EVAP) Emi ssi ons Cani st er . . . . . . . . . . . Engi ne Per f or mance
EVAP Cani st er Pur ge Sol enoi d . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
EVAP Cani st er Vent Sol enoi d . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Exhaust Gas Reci r cul at i on ( EGR) Val ve . . . . . . . . . . . Engi ne Per f or mance
Fuel Tank VacuumSensor . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Fog Li ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Syst ems
Dayt i me Runni ng Li ght s
Fog Li ght Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Syst ems
Dayt i me Runni ng Li ght s
Fuel Door Rel ease Sol enoi d . . . . . . . . . . . . . . . . . Power Fuel Door Rel ease
Fuel Gauge Sendi ng Uni t . . . . . . . . . . . . . . . . . . . Anal og I nst r ument Panel s
Fuel I nj ect or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Power Di st r i but i on
Fuse/ Rel ay Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
Fusi bl e Li nks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
Gener at or s & Regul at or s
St ar t er s
Gener at or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gener at or s & Regul at or s
Engi ne Per f or mance
Power Di st r i but i on
Gener i c El ect r oni c Modul e ( GEM) . . . . . . . . . . . . . . . Body Cont r ol Modul es
El ect r oni c Suspensi on
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Gl ow Pl ugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Gr ounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gr ound Di st r i but i on
Headl i ght Door Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Door s
Headl i ght Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Syst ems
Dayt i me Runni ng Li ght s
Headl i ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Syst ems
Dayt i me Runni ng Li ght s
Heat ed Oxygen Sensor ( s) ( HO2S) . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Heat ed Wi ndshi el d Cont r ol Modul e . . . . . . . . . . . . . . . . Heat ed Wi ndshi el ds
Hei ght Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . El ect r oni c Suspensi on
Hor ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St eer i ng Col umn Swi t ches
Hor n Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St eer i ng Col umn Swi t ches
I dl e Ai r Cont r ol ( I AC) Mot or / Val ve . . . . . . . . . . . . . . Engi ne Per f or mance
I gni t i on Coi l ( s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
I gni t i on Key Lock Cyl i nder . . . . . . . . . . . . . . . . . . . . . . . Ant i - Thef t Syst em
I gni t i on Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
I gni t i on Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
Engi ne Per f or mance
Gener at or s & Regul at or s
St ar t er s
I l l umi nat ed Ent r y Modul e . . . . . . . . . . . . . . I l l umi nat i on/ I nt er i or Li ght s
I l l umi nat i on Li ght s . . . . . . . . . . . . . . . . . . . I l l umi nat i on/ I nt er i or Li ght s
I mpact Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
I ner t i a Fuel Shut of f Swi t ch . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
I nhi bi t Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
HOW TO USE SYSTEM WIRING DIAGRAMS
Article Text (p. 7)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
I nst r ument Cl ust er . . . . . . . . . . . . . . . . . . . . . . . . Anal og I nst r ument Panel s
I nt ake Ai r Temper at ur e ( I AT) Sensor . . . . . . . . . . . . . Engi ne Per f or mance
I nt er i or Li ght s . . . . . . . . . . . . . . . . . . . . . . . I l l umi nat i on/ I nt er i or Li ght s
I nt er l ock Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
J unct i on Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
Keyl ess Ent r y Recei ver . . . . . . . . . . . . . . . . . . . . . . . . Remot e Keyl ess Ent r y
Key Remi nder Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Lamp Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Li cense Pl at e Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Li ght i ng Cont r ol Modul e . . . . . . . . . . . . . . . . . . . Li ght i ng Cont r ol Modul es
Ant i - Thef t Syst em
Dayt i me Runni ng Li ght s
Headl i ght Syst ems
Lower Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Mal f unct i on I ndi cat or Li ght ( MI L) . . . . . . . . . . . . . . . Engi ne Per f or mance
I nst r ument Panel s
Mani f ol d Absol ut e Pr essur e ( MAP) Sensor . . . . . . . . . Engi ne Per f or mance
Mass Ai r f l ow ( MAF) Sensor . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Mega Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gener at or s & Regul at or s
Memor y Seat / Mi r r or Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . Memor y Syst ems
Mi r r or Def ogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wi ndow Def ogger
Moon Roof Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Moon Roof
Moon Roof Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Moon Roof
Mul t i - Funct i on Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . War ni ng Syst ems
Neut r al Saf et y Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Oi l Level Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Oi l Pr essur e Swi t ch/ Sendi ng Uni t . . . . . . . . . . Anal og I nst r ument Panel s
Engi ne Per f or mance
Over head Consol e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over head Consol e
Oxygen Sensor ( s) ( O2S) . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Par ki ng Br ake Swi t ch . . . . . . . . . . . . . . . . . . . . . . Anal og I nst r ument Panel s
Par k Li ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Par k/ Neut r al Posi t i on Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Engi ne Per f or mance
Ant i - Thef t Syst em
Body Cont r ol Modul e
Per i met er Li ght i ng Cont r ol Rel ay . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Power Ampl i f i er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Ant ennas
Power Ant enna Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Ant ennas
Power Ant enna Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Ant ennas
Power Di st r i but i on Cent er . . . . . . . . . . . . . . . . . . . . . . . Power Di st r i but i on
Gener at or s & Regul at or s
St ar t er s
Power Door Lock Mot or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Door Locks
Power Mi r r or Mot or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Mi r r or s
Memor y Syst ems
Power Sl i di ng Door Cont r ol l er . . . . . . . . . . . . . . Power Sl i di ng Si de Door
Power Seat Mot or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Seat s
Memor y Syst ems
Power St eer i ng Pr essur e Swi t ch . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Power Top Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
HOW TO USE SYSTEM WIRING DIAGRAMS
Article Text (p. 8)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Power Top Rel ay( s) . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Power t r ai n Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Anal og I nst r ument Panel s
Cr ui se Cont r ol Syst ems
Dat a Li nk Connect or s
Gener at or s & Regul at or s
St ar t er s
Power Wi ndow Mot or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wi ndows
Power Wi ndow Rel ay( s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wi ndows
Radi at or Fan Mot or ( s) . . . . . . . . . . . . . . . . . . . . . . . . El ect r i c Cool i ng Fans
Radi at or Fan Rel ay( s) . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
El ect r i c Cool i ng Fans
Rai nsense Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wi per / Washer Syst ems
Rai se Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Remot e Ant i - Thef t Per sonal i t y ( RAP) Modul e . . . . . . . Ant i - Thef t Syst em
St ar t er s
War ni ng Syst ems
Seat Bel t Pr et ensi oner s . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Seat Bel t Ret r act or Sol enoi d . . . . . . . . . . . . . . . . . . . . Passi ve Rest r ai nt s
Seat Bel t Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Passi ve Rest r ai nt s
Shi f t I nt er l ock Sol enoi d . . . . . . . . . . . . . . . . . . . Shi f t I nt er l ock Syst ems
Shi f t Lock Act uat or . . . . . . . . . . . . . . . . . . . . . . . . Shi f t I nt er l ock Syst ems
Si de Mar ker Li ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
SI R Coi l Assembl y ( Cl ockspr i ng) . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
Sl i p Ri ng ( Cl ockspr i ng) . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
St eer i ng Col umn Swi t ches
SRS Cont r ol Modul e . . . . . . . . . . . . . . . . . . . . . . . . Ai r Bag Rest r ai nt Syst em
St ar t er Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
St ar t er I nt er r upt Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
St ar t er Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
St ar t er Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
St eer i ng Wheel Posi t i on Sensor . . . . . . . . . . . . . . . . . . . . Ant i - Lock Br akes
St opl i ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
St opl i ght Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Cr ui se Cont r ol Syst ems
Ant i - Lock Br akes
Sun Roof ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Sun Roof
Sun Roof Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Sun Roof
Sun Roof Posi t i on Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Sun Roof
Tai l l i ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Thr ot t l e Posi t i on ( TP) Sensor . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Tor que Conver t er Cl ut ch Sol enoi d/ Swi t ch . . . . . . . . . Engi ne Per f or mance
Tr act i on Cont r ol Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . Ant i - Lock Br akes
Tr ai l er Tow Connect or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Tr ai l er Tow Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Tr ansmi ssi on/ Tr ansaxl e . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Tr ansmi ssi on Cont r ol Modul e ( TCM) . . . . . . . . . . . . . . . Engi ne Per f or mance
St ar t er s
Tr ansmi ssi on Range Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St ar t er s
Back- Up Li ght s
Engi ne Per f or mance
HOW TO USE SYSTEM WIRING DIAGRAMS
Article Text (p. 9)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Friday, August 20, 1999 12:00AM
Tr ansmi ssi on Range Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . . . Back- Up Li ght s
Engi ne Per f or mance
Ant i - Thef t Syst em
Tur n Si gnal Fl asher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Tur n Si gnal Li ght s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ext er i or Li ght s
Twi l i ght Sent i nel Swi t ch . . . . . . . . . . . . . . . . . . . . . . . . . Headl i ght Syst ems
Dayt i me Runni ng Li ght s
Vapor Cani st er Leak Det ect i on Pump . . . . . . . . . . . . . . Engi ne Per f or mance
Vehi cl e Cont r ol Modul e ( VCM) . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Vehi cl e Dynami c Modul e . . . . . . . . . . . . . . . . . . . . . . . El ect r oni c Suspensi on
Vehi cl e Speed Cont r ol Ser vo . . . . . . . . . . . . . . . . . Cr ui se Cont r ol Syst ems
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . Dat a Li nk Connect or s
Anal og I nst r ument Panel s
Cr ui se Cont r ol Syst ems
El ect r oni c Suspensi on
Vol t age Regul at or . . . . . . . . . . . . . . . . . . . . . . . . . . Gener at or s & Regul at or s
Wat er - I n- Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi ne Per f or mance
Anal og I nst r ument Panel s
Wheel Speed Sensor s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ant i - Lock Br akes
Wi ndow Ti mer Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . Power Conver t i bl e Top
Wi ndshi el d I nt er mi t t ent Wi per Rel ay . . . . . . . . . . . Wi per / Washer Syst ems
Wi ndshi el d Washer Mot or . . . . . . . . . . . . . . . . . . . . . . . Wi per / Washer Syst ems
Wi per Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wi per / Washer Syst ems

END OF ARTICLE
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
ARTICLE BEGINNING
1995- 96 WHEEL ALI GNMENT
Vol kswagen - Speci f i cat i ons & Pr ocedur es
Gol f
* PLEASE READ FIRST *
NOTE: Pr i or t o per f or mi ng wheel al i gnment , per f or mpr el i mi nar y
vi sual and mechani cal i nspect i on of wheel s, t i r es and
suspensi on component s. See PRE- ALI GNMENT I NSTRUCTI ONS i n
WHEEL ALI GNMENT THEORY/ OPERATI ON ar t i cl e.
RIDING HEIGHT ADJUSTMENT
NOTE: On vehi cl es wi t h el ect r oni c chassi s cont r ol s, al l syst ems
shoul d be f unct i onal bef or e at t empt i ng r i di ng hei ght or
wheel al i gnment adj ust ment .
Bef or e adj ust i ng al i gnment , ensur e di f f er ence i n r i di ng
hei ght bet ween l ef t and r i ght si des of vehi cl e i s l ess t han 1" ( 25. 4
mm) . Ri di ng hei ght must be checked wi t h vehi cl e on l evel f l oor and
t i r es pr oper l y i nf l at ed. Bounce vehi cl e sever al t i mes and al l ow
suspensi on t o set t l e.
Vi sual l y i nspect vehi cl e f or si gns of abnor mal hei ght f r om
f r ont t o r ear or si de t o si de. Check passenger and l uggage
compar t ment s f or ext r a heavy i t ems and r emove i f pr esent . I f
di f f er ence i n r i di ng hei ght bet ween l ef t and r i ght si des of vehi cl e i s
NOT l ess t han 1" ( 25. 4 mm) , check suspensi on component s and r epai r or
r epl ace as necessar y.
WHEEL ALIGNMENT PROCEDURES
CAMBER ADJUSTMENT
To adj ust f r ont camber , l oosen l ower st r ut mount i ng bol t / nut .
Usi ng Camber Adj ust i ng Tool ( 3270) move st r ut t o al i gn and r et i ght en
bol t / nut t o 70 f t . l bs. ( 95 N. m) . Addi t i onal i nf or mat i on i s not
avai l abl e at t i me of publ i cat i on.
CASTER ADJUSTMENT
Cast er i s not adj ust abl e. Addi t i onal i nf or mat i on i s not
avai l abl e at t i me of publ i cat i on.
TOE-IN ADJUSTMENT
To adj ust f r ont t oe- i n, r ot at e r i ght t i e r od end onl y.
Addi t i onal i nf or mat i on i s not avai l abl e at t i me of publ i cat i on.
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
WHEEL ALIGNMENT SPECIFICATIONS
WHEEL ALI GNMENT SPECI FI CATI ONS TABLE

Appl i cat i on Pr ef er r ed Range


1995
Camber ( 1)
Fr ont . . . . . . . . . . . . . . . . - 0. 67 . . . . . . . . . . . . - 1 To - 0. 33
Rear . . . . . . . . . . . . . . . . . - 1. 5 . . . . . . . . . . - 1. 67 To - 1. 33
Cast er ( Fr ont ) ( 1) . . . . 3. 42 . . . . . . . . . . . . 2. 92 To 3. 92
Toe- I n ( 2)
Fr ont . . . . . . . . . . . . . . . . 0 ( 0) . . . . . . . . . . - 0. 08 To 0. 08
( - 2 To 2)
Rear . . . . . . . . . . . . . . 0. 17 ( 4) . . . . . . . . . . . 0. 08 To 0. 25
( 2 To 6. 5)
Toe- I n ( 1)
Fr ont . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . - 0. 17 To 0. 17
Rear . . . . . . . . . . . . . . . . . 0. 33 . . . . . . . . . . . . . 0. 17 To 0. 5
1996 ( 3)
1. 9L
Camber ( 1)
Fr ont . . . . . . . . . . . . . . - 0. 5 . . . . . . . . . . - 0. 83 To - 0. 17
Rear . . . . . . . . . . . . . . . - 1. 5 . . . . . . . . . . - 1. 67 To - 1. 33
Cast er ( Fr ont ) ( 1) . . . 1. 75 . . . . . . . . . . . . 1. 25 To 2. 25
Toe- I n ( 2)
Fr ont . . . . . . . . . . . . . . 0 ( 0) . . . . . . . . . . - 0. 08 To 0. 08
( - 2 To 2)
Rear . . . . . . . . . . . . 0. 17 ( 4) . . . . . . . . . . . 0. 08 To 0. 25
( 2 To 6. 5)
Toe- I n ( 1)
Fr ont . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . - 0. 17 To 0. 17
Rear . . . . . . . . . . . . . . . 0. 33 . . . . . . . . . . . . . 0. 17 To 0. 5
2. 0L
Camber ( 1)
Fr ont . . . . . . . . . . . . . . - 0. 58 . . . . . . . . . - 0. 92 To - 0. 25
Rear . . . . . . . . . . . . . . . - 1. 5 . . . . . . . . . . - 1. 67 To - 1. 33
Cast er ( Fr ont ) ( 1) . . . 1. 83 . . . . . . . . . . . . 1. 33 To 2. 33
Toe- I n ( 2)
Fr ont . . . . . . . . . . . . . . 0 ( 0) . . . . . . . . . . - 0. 08 To 0. 08
( - 2 To 2)
Rear . . . . . . . . . . . . 0. 17 ( 4) . . . . . . . . . . . 0. 08 To 0. 25
( 2 To 6. 5)
Toe- I n ( 1)
Fr ont . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . - 0. 17 To 0. 17
Rear . . . . . . . . . . . . . . . 0. 33 . . . . . . . . . . . . . 0. 17 To 0. 5
2. 8L
Camber ( 1)
Fr ont . . . . . . . . . . . . . . - 0. 5 . . . . . . . . . . - 0. 83 To - 0. 17
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
Rear . . . . . . . . . . . . . . . - 1. 5 . . . . . . . . . . - 1. 67 To - 1. 33
Cast er ( Fr ont ) ( 1) . . . 3. 27 . . . . . . . . . . . . 2. 77 To 3. 37
Toe- I n ( 2)
Fr ont . . . . . . . . . . . . . . 0 ( 0) . . . . . . . . . . - 0. 08 To 0. 08
( - 2 To 2)
Rear . . . . . . . . . . . . 0. 17 ( 4) . . . . . . . . . . . 0. 08 To 0. 25
( 2 To 6. 5)
Toe- I n ( 1)
Fr ont . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . - 0. 17 To 0. 17
Rear . . . . . . . . . . . . . . . 0. 33 . . . . . . . . . . . . . 0. 17 To 0. 5
( 1) - Measur ement i s i n degr ees.
( 2) - Measur ement i s i n i nches ( mm) .
( 3) - Not al l engi ne si zes ar e avai l abl e f or al l model s.

END OF ARTICLE
SUSPENSION - REAR
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
ARTICLE BEGINNING
1995- 96 SUSPENSI ON
Rear
Gol f I I I
DESCRIPTION
Suspensi on uses cont r ol ar ms and axl e beamf or st abi l i zat i on.
Cont r ol ar ms and axl e beamar e combi ned as one uni t . Br ake dr ums or
di scs r ot at e on st ub axl es bol t ed t o cont r ol ar ms. See Fi g. 1.
Fi g. 1: I dent i f yi ng Rear Suspensi on Component s ( Typi cal )
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
ADJUSTMENTS & INSPECTION
SUSPENSION - REAR
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
NOTE: See WHEEL ALI GNMENT SPECI FI CATI ONS & PROCEDURES ar t i cl e i n
WHEEL ALI GNMENT sect i on.
WHEEL BEARING
Whi l e r ot at i ng br ake di sc or dr umby hand, i nser t t i p of
scr ewdr i ver bet ween t hr ust washer and hub. Adj ust ment i s cor r ect when
l i ght f i nger pr essur e agai nst scr ewdr i ver moves t hr ust washer . Tur n
hub nut t o adj ust . I nst al l cast el l at ed nut and NEWcot t er pi n.
REMOVAL & INSTALLATION
AXLE BEAM PIVOT BUSHING
NOTE: The f ol l owi ng pr ocedur e i s f or r epl aci ng bushi ng wi t h axl e
beami nst al l ed i n vehi cl e.
Removal
Rai se and suppor t vehi cl e. Wi t h no pr essur e on beam, r emove
axl e beam- t o- body nut s. Tap out pi vot bol t . Usi ng Bushi ng
Remover / I nst al l er ( VW3111) , pr ess out bushi ng. Pr ess new bushi ng i nt o
pl ace.
I nst al l at i on
1) Loosel y i nst al l mount i ng pad ont o axl e beam. Usi ng
r emover / i nst al l er , i nst al l bushi ng unt i l i t pr ot r udes f r omaxl e beam.
28- . 35" ( 7. 0- 9. 0 mm) . Concave washer and bol t head must f ace t owar d
out si de of vehi cl e. Bol t head must r ecess i nt o washer .
2) Usi ng Mount i ng Br acket Al i gner ( 3021) , al i gn mount unt i l
al i gner r eads about 12 degr ees. I f al i gner i s not avai l abl e, f ol l ow
di r ect i ons i n i l l ust r at i on. See Fi g. 2. Wi t h vehi cl e on gr ound,
t i ght en pi vot bol t nut t o speci f i cat i on.
Fi g. 2: Al i gni ng Axl e BeamMount i ng Pad
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
SUSPENSION - REAR
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
STRUT ASSEMBLY
Removal
1) Wi t h vehi cl e on f l oor , r emove pl ast i c cap cover i ng upper
st r ut nut s. Remove st r ut upper nut s. Sl owl y r ai se vehi cl e unt i l wei ght
i s of f spr i ng. Remove st r ut - t o- axl e beambol t . Rai se vehi cl e unt i l
st r ut can be r emoved. Pl ace st r ut assembl y i n vi se.
2) Hol d pi st on r od. Remove pi st on r od nut and r el at ed
component s. See Fi g. 1. Remove sl ot t ed nut ( some model s) . Remove
spacer and coi l spr i ng. I f coi l spr i ng i s t o be r epl aced, ensur e pai nt
st r i pe col or on r epl acement spr i ng mat ches or i gi nal spr i ng col or
st r i pe.
I nst al l at i on
1) I nst al l pr ot ect i ve cap and t ube ont o shock absor ber .
I nst al l r ubber bumper wi t h smal l end downwar d. I nst al l snap r i ng and
washer . Pl ace spr i ng i nt o l ower seat . I nst al l upper r et ai ner wi t h
spacer sl eeve.
2) Ti ght en pi st on r od nut . I nst al l upper mount i ng har dwar e.
Ti ght en pi st on r od. To compl et e i nst al l at i on, r ever se r emoval
pr ocedur e. Ti ght en bol t s and nut s t o speci f i cat i on. See TORQUE
SPECI FI CATI ONS.
SUSPENSION ASSEMBLY
CAUTI ON: When r emovi ng suspensi on assembl y, add wei ght t o r ear of
vehi cl e t o pr event t i ppi ng due t o change i n cent er of
gr avi t y.
Removal
1) Wi t h vehi cl e on f l oor , r emove pl ast i c cap cover i ng upper
st r ut nut s. Remove st r ut nut s. Rai se and suppor t vehi cl e. Di sconnect
par ki ng br ake at br acket near axl e mount .
2) Di sconnect and pl ug br akel i nes. Leave f l ex hose at t ached
t o suspensi on. Separ at e br ake pr essur e r egul at or spr i ng f r omaxl e
beam. Remove axl e beam- t o- body nut s.
NOTE: DO NOT i nst al l bol t s and nut s f oul ed wi t h under coat i ng. Wi t h
waxy coat i ng on t hr eads, t r ue t i ght eni ng t or que cannot be
measur ed. Cl ean or r epl ace bol t s and nut s.
I nst al l at i on
1) I f axl e beammount i ng has been r emoved, adj ust mount i ng
pad. See st ep 2) under I NSTALLATI ON under AXLE BEAM PI VOT BUSHI NG. I f
pad i s not cor r ect l y al i gned, t or si onal pr el oad of mount i ng bushi ngs
wi l l be i ncor r ect .
2) Posi t i on r ear suspensi on assembl y on body. I nst al l axl e
beam- t o- body nut s. Rai se wheel . Gui de upper end of st r ut i nt o body
mount .
3) Connect par ki ng br ake cabl es. Connect br akel i nes. Lower
vehi cl e. Ti ght en upper st r ut nut s. Ti ght en al l bol t s and nut s t o
speci f i cat i on. See TORQUE SPECI FI CATI ONS. Bl eed br ake syst em.
SUSPENSION - REAR
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
WHEEL BEARING
Removal ( Di sc Br akes)
Rai se and suppor t vehi cl e. Remove wheel . Remove cal i per
assembl y and suppor t i t asi de. Remove dust cap, cot t er pi n, hub nut ,
and t hr ust washer . Remove br ake di sc. Usi ng a l ong dr i f t , t ap
bear i ngs, r aces, and gr ease seal f r omdi sc hub.
I nst al l at i on
1) Cl ean hub cavi t y t hor oughl y. Usi ng Bear i ng Race I nst al l er
( VW411 and VW432) , pr ess i nner and out er bear i ng r aces i nt o bor e.
Lubr i cat e and i nst al l i nner bear i ng. Usi ng Seal I nst al l er ( VW295 and
3074) , t ap gr ease seal i nt o bor e.
2) I nst al l br ake di sc, out er bear i ng, t hr ust washer , and hub
nut . Rever se r emoval pr ocedur e t o compl et e i nst al l at i on. Adj ust wheel
bear i ng. See WHEEL BEARI NG under ADJ USTMENTS & I NSPECTI ON. I nst al l NEW
cot t er pi n.
Removal ( Dr umBr akes)
Rai se and suppor t vehi cl e. Remove wheel . Remove dust cap,
cot t er pi n, hub nut , and t hr ust washer . Remove br ake dr um. Usi ng a
l ong dr i f t , t ap bear i ngs, r aces, and gr ease seal f r omhub.
I nst al l at i on
1) Cl ean hub cavi t y t hor oughl y. Usi ng Bear i ng Race I nst al l er
( VW411 and VW432) , pr ess out er bear i ng r ace i nt o bor e. Usi ng same
bear i ng r ace i nst al l er , pr ess i nner bear i ng r ace i nt o bor e. Lubr i cat e
and i nst al l i nner bear i ng. Usi ng Seal I nst al l er ( VW295 and 3074) , t ap
gr ease seal i nt o bor e.
2) I nst al l br ake dr um, out er bear i ng, t hr ust washer , and hub
nut . Rever se r emoval pr ocedur e t o compl et e i nst al l at i on. Adj ust wheel
bear i ng. See WHEEL BEARI NG under ADJ USTMENTS & I NSPECTI ON. I nst al l NEW
cot t er pi n.
TORQUE SPECIFICATIONS
TORQUE SPECI FI CATI ONS

Appl i cat i on Ft . Lbs. ( N. m)


Br ake Backi ng Pl at e Bol t . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Br ake Cal i per Br acket Bol t . . . . . . . . . . . . . . . . . . . . . . . 41 ( 56)
Coi l Spr i ng Ret ai ner - To- Pi st on Rod Nut . . . . . . . . . . . 11 ( 15)
Rear Axl e BeamPi vot Bushi ng Bol t . . . . . . . . . . . . . . . . 60 ( 80)
Rear Axl e Mount i ng Pad- To- Body Bol t . . . . . . . . . . . . . . 63 ( 85)
St r ut - To- Axl e BeamNut . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ( 70)
St r ut - To- Body Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
St ub Axl e- To- Cont r ol Ar mBol t . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Wheel Lug Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 ( 110)

SUSPENSION - REAR
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
END OF ARTICLE
SUSPENSION - FRONT
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
ARTICLE BEGINNING
1995- 96 SUSPENSI ON
Fr ont
Gol f I I I
DESCRIPTION
FWD suspensi on syst emi s equi pped wi t h MacPher son st r ut s.
St eer i ng knuckl es ar e suppor t ed by l ower cont r ol ar ms and ver t i cal l y
mount ed st r ut assembl i es. See Fi g. 1.
Fi g. 1: Expl oded Vi ew Of Fr ont Suspensi on ( Typi cal )
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
ADJUSTMENTS & INSPECTION
SUSPENSION - FRONT
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
NOTE: See WHEEL ALI GNMENT SPECI FI CATI ONS & PROCEDURES ar t i cl e i n
WHEEL ALI GNMENT sect i on.
WHEEL BEARING
Wheel bear i ng i s not adj ust abl e.
BALL JOINT CHECKING
Rai se and suppor t vehi cl e. I nspect bal l j oi nt s f or excessi ve
pl ay and damaged r ubber boot s. Ther e shoul d be no ver t i cal or
hor i zont al bal l j oi nt pl ay. Repl ace bal l j oi nt i f any pl ay i s pr esent .
REMOVAL & INSTALLATION
HUB & KNUCKLE ASSEMBLY
Use expl oded vi ew i l l ust r at i on when r emovi ng or i nst al l i ng
hub and knuckl e assembl y. See Fi g. 1.
LOWER CONTROL ARM & BALL JOINT
Removal
1) Rai se and suppor t vehi cl e. Remove bal l j oi nt - t o- st eer i ng
knuckl e bol t s. Separ at e bal l j oi nt f r omhousi ng. Leave cont r ol ar m
hangi ng i n mount s at subf r ame.
NOTE: On vehi cl es wi t h aut omat i c t r ansmi ssi on, engi ne may have t o
be l i f t ed sl i ght l y t o gai n access t o pi vot bol t s.
2) I f bal l j oi nt i s t o be r emoved, r emove bal l j oi nt bol t s.
Remove bal l j oi nt . I f cont r ol ar mi s t o be r emoved f r omvehi cl e,
r emove st abi l i zer bar l i nk r od nut , washer s, and bushi ngs. Remove
pi vot bol t and " U" br acket housi ng i nner pi vot pi n. Sl i de out cont r ol
ar m.
I nspect i on
Check l ower cont r ol ar mbushi ngs f or excessi ve wear , cr acks
or cont ami nat i on. Repl ace bushi ngs i f necessar y. To r epl ace bushi ngs,
pr ess out wor n bushi ng. Sel ect new bushi ng and pr ess i nt o posi t i on.
Ensur e bushi ng does not t wi st when seat i ng i nt o pl ace.
I nst al l at i on
Sl i de new bal l j oi nt i nt o sl ot i n cont r ol ar m. I nst al l and
t i ght en bal l j oi nt bol t s. I nst al l l ower cont r ol ar mt o subf r ame.
I nst al l bal l j oi nt i nt o st eer i ng knuckl e. To compl et e i nst al l at i on,
r ever se r emoval pr ocedur e. Ti ght en cont r ol ar mbol t s wi t h vehi cl e on
gr ound. Ti ght en al l bol t s and nut s t o speci f i cat i on. See TORQUE
SPECI FI CATI ONS. Check wheel al i gnment . See WHEEL ALI GNMENT
SPECI FI CATI ONS & PROCEDURES ar t i cl e i n WHEEL ALI GNMENT sect i on.
SUSPENSION - FRONT
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
STRUT ASSEMBLY
Removal
1) Rai se and suppor t vehi cl e. Remove wheel . Di sconnect and
wi r e cal i per asi de. Remove st r ut - t o- st eer i ng knuckl e bol t s.
2) Suppor t f r ont suspensi on ar mand component s. Pr y st r ut
f r omst eer i ng knuckl e. Remove upper st r ut nut s f r omi nsi de engi ne
compar t ment . Remove st r ut .
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ti ght en bol t s and nut s
t o speci f i cat i on. See TORQUE SPECI FI CATI ONS. Check wheel al i gnment .
See WHEEL ALI GNMENT SPECI FI CATI ONS & PROCEDURES ar t i cl e i n WHEEL
ALI GNMENT sect i on.
FRONT SUSPENSION ASSEMBLY
Removal
1) Rai se and suppor t vehi cl e at cent er wi t h saf et y st ands.
Di sconnect br ake l i ne and pl ug openi ngs. Leave f l ex l i ne i n pl ace.
Remove st abi l i zer l i nk r od nut , bushi ngs and washer s.
2) Remove t i e r od nut . Separ at e t i e r od f r omst eer i ng
knuckl e. Di sconnect i nner por t i on of const ant vel oci t y j oi nt f r om
t r ansaxl e dr i ve f l ange.
NOTE: On vehi cl es wi t h aut omat i c t r ansmi ssi on, engi ne may have t o
be l i f t ed sl i ght l y t o gai n access t o pi vot bol t s.
3) Remove l ower cont r ol ar mf r ont pi vot bol t . Remove " U"
shaped br acket bol t s at cont r ol ar mr ear pi vot .
4) Suppor t suspensi on assembl y. Remove upper st r ut nut s.
Remove suspensi on assembl y f r omvehi cl e.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ensur e convex si de of
t hr ust washer f aces pi vot bol t head. Ti ght en bol t s and nut s t o
speci f i cat i on. See TORQUE SPECI FI CATI ONS. Check wheel al i gnment . See
WHEEL ALI GNMENT SPECI FI CATI ONS & PROCEDURES ar t i cl e i n WHEEL ALI GNMENT
sect i on.
WHEEL BEARING
Removal
1) Remove axl e shaf t nut wi t h f r ont wheel s on gr ound. Rai se
and suppor t vehi cl e. Al l ow suspensi on t o hang f r ee. Remove wheel .
Remove br ake cal i per bol t s. Remove cal i per and wi r e asi de. Remove
br ake di sc scr ew and r emove di sc.
2) Di sconnect t i e r od f r omst eer i ng knuckl e. Remove bal l
j oi nt cl amp nut and bol t . Di sconnect bal l j oi nt f r omst eer i ng knuckl e.
Remove st eer i ng knuckl e.
3) Remove 2 wheel bear i ng ci r cl i ps. Usi ng Hub Remover ( VW
SUSPENSION - FRONT
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
295a) , pr ess wheel bear i ng out of st eer i ng knuckl e. See Fi g. 2. Usi ng
a bear i ng pul l er , r emove wheel bear i ng i nner r ace f r omhub assembl y.
See Fi g. 3. Usi ng Bear i ng Remover ( 40- 105) , pr ess wheel bear i ng f r om
out boar d si de of st eer i ng knuckl e.
Fi g. 2: Pr essi ng Wheel Bear i ng Out Of St eer i ng Knuckl e
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
Fi g. 3: Removi ng Wheel Bear i ng I nner Race
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
NOTE: When i nst al l i ng hub, ensur e pr ess adapt er cont act s i nner
bear i ng r ace onl y.
I nst al l at i on
1) Pr ess new wheel bear i ng r ace ont o hub. Usi ng Bear i ng & Hub
I nst al l er ( VW412) , and Adapt er ( VW472/ 1) , pr ess new bear i ng i nt o
st eer i ng knuckl e f r omout boar d si de. Usi ng same i nst al l er and adapt er ,
pr ess wheel hub i nt o st eer i ng knuckl e. See Fi g. 4. Appl y a smal l bead
of l ocki ng compound t o axl e spl i nes bef or e i nst al l i ng axl e i nt o hub.
2) To compl et e i nst al l at i on, r ever se r emoval pr ocedur e.
Al ways r epl ace sel f - l ocki ng axl e shaf t nut . Ti ght en bol t s and nut s t o
speci f i cat i on. See TORQUE SPECI FI CATI ONS. Check wheel al i gnment . See
WHEEL ALI GNMENT SPECI FI CATI ONS & PROCEDURES ar t i cl e i n WHEEL ALI GNMENT
sect i on.
SUSPENSION - FRONT
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:59PM
Fi g. 4: Pr essi ng Wheel Hub I nt o St eer i ng Knuckl e
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
TORQUE SPECIFICATIONS
TORQUE SPECI FI CATI ONS

Appl i cat i on Ft . Lbs. ( N. m)


Axl e Nut
4- Cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 ( 265)
VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 ( 90) pl us 1/ 8 t ur n
Axl e Shaf t - To- Tr ansaxl e Bol t . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Bal l J oi nt Cl amp Bol t ( 4- Cyl . ) . . . . . . . . . . . . . . . . . . . 37 ( 50)
Bal l J oi nt Nut ( VR6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Bal l J oi nt - To- Cont r ol Ar mBol t . . . . . . . . . . . . . . . . . . . 26 ( 35)
Cal i per Pi n Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ( 35)
Cal i per Br acket Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 ( 125)
Cont r ol Ar mFr ont Bushi ng Bol t
4- Cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ( 70)
VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50) pl us 1/ 4 t ur n
Cont r ol Ar m- To- Subf r ame Rear Bushi ng Bol t . . . . . . . 96 ( 130)
St r ut Pi st on Rod Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
St r ut - To- St eer i ng Knuckl e Bol t . . . . . . . . . . . . . . . . . . . 70 ( 95)
Subf r ame Bol t s
4- Cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 ( 65)
VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ( 70) pl us 1/ 4 t ur n
Ti e Rod Cast l e Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ( 35)
Wheel Lug Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 ( 110)

END OF ARTICLE
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
ARTICLE BEGINNING
GENERAL I NFORMATI ON
St eer i ng & Suspensi on Syst ems - ( I ncl udi ng Wheel s & Ti r es)
Al l Makes & Model s
Updat ed: J anuar y, 1997
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Mot or i st Assur ance Pr ogr am( MAP) i s t he consumer out r each
ef f or t of t he Aut omot i ve Mai nt enance and Repai r Associ at i on, I nc.
( AMRA) . Par t i ci pat i on i n t he Mot or i st Assur ance Pr ogr ami s dr awn f r om
r et ai l er s, suppl i er s, i ndependent r epai r f aci l i t i es, vehi cl e
manuf act ur er s and i ndust r y associ at i ons.
The Mot or i st Assur ance Pr ogr amwas est abl i shed as an
i ndust r y- wi de ef f or t t o addr ess concer ns r ai sed by r egul at or s, t he
medi a and consumer s quest i oni ng our et hi cs and met hods of doi ng
busi ness. The aut omot i ve r epai r i ndust r y had been bombar ded by mont hs
of negat i ve st or i es i n t he medi a and scr ut i ny f r omst at e and f eder al
r egul at or s who f ocused on how t he need f or r epai r s i s det er mi ned. MAP
was f or med as an i ndust r y r esponse t o t hi s i ssue.
Our mi ssi on i s t o st r engt hen t he r el at i onshi p bet ween t he
consumer and t he aut o r epai r i ndust r y. We pr oduce mat er i al s t hat gi ve
mot or i st s t he i nf or mat i on and encour agement t o t ake r esponsi bi l i t y f or
t hei r vehi cl es - t hr ough pr oper , manuf act ur er - r ecommended,
mai nt enance. We encour age par t i ci pat i nf ser vi ce and r epai r shops
( i ncl udi ng f r anchi sees and deal er s) t o adopt a Pl edge t o t hei r
Cust omer s and t he Mot or i st Assur ance Pr ogr amdevel oped St andar ds of
Ser vi ce. Al l par t i ci pat i ng ser vi ce pr ovi der s have agr eed t o subscr i be
t o t hi s Pl edge and t o adher e t o t he pr omul gat ed St andar ds of Ser vi ce
whi ch demonst r at es t o t hei r cust omer s t hat t hey ar e ser i ous about
cust omer sat i sf act i on.
These St andar ds of Ser vi ce r equi r e t hat an i nspect i on of t he
vehi cl e' s ( pr obl em) syst embe made accor di ng t o i ndust r y gui del i nes.
Af t er l ear ni ng t hat nei t her t he car manuf act ur er s nor any ot her sour ce
had compl et e gui del i nes, l eadi ng i ndust r y or gani zat i ons, al ong wi t h
ot her i ndust r y par t i ci pant s banded t oget her t o addr ess t hi s
chal l engi ng t ask. Dur i ng t he past t wo and a hal f year s, t hey
successf ul l y devel oped i ndust r y i nspect i on gui del i nes f or t he
f ol l owi ng syst ems: Exhaust , Br akes, ABS, St eer i ng and Suspensi on,
Engi ne Mai nt enance and Per f or mance, HVAC, and El ect r i cal syst ems.
Gui del i nes f or Dr i ve Tr ai n and Tr ansmi si on ar e cur r ent l y bei ng
pr omul gat ed. Revi si ons t o t he i nspect i on gui del i nes f or Exhaust ,
Br akes/ ABS and St eer i ng and Suspensi on Syst ems, whi ch wer e i ssued t wo
year s ago, ar e now bei ng publ i shed f or i mpl ement at i on begi nni ng spr i ng
1997. Par t i ci pat i ng shops ut i l i ze t hese Uni f or mI nspect i on Gui del i nes
as par t of t he i nspect i on pr ocess and f or communi cat i ng t hei r f i ndi ngs
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
t o t hei r cust omer s.
The Mot or i st Assur ance Pr ogr amcont i nues t o wor k
cooper at i vel y and pr oact i vel y wi t h gover nment agenci es and consumer
gr oups t owar d sol ut i ons t hat bot h benef i t t he cust omer and ar e
mut ual l y accept abl e t o bot h r egul at or s and i ndust r y. We mai nt ai n t he
bel i ef t hat i ndust r y must r et ai n cont r ol over how we conduct our
busi ness, and we must be vi ewed as par t of t he sol ut i on and not par t
of t he pr obl em. Meet i ngs wi t h st at e and ot her gover nment of f i ci al s
concer ned wi t h aut o r epai r and/ or consumer pr ot ect i on ar e conduct ed.
Feedback f r omt hese r epr esent at i ves ar e br ought back t o member s, and
t he pr ogr amadj ust ed as needed.
To assur e aut o r epai r cust omer s r ecour se i f t hey wer e not
sat i sf i ed wi t h a r epai r t r ansact i on, t he Mot or i st Assur ance Pr ogr am
of f er s ar bi t r at i on t hr ough MAP/ BBB- CARE i n cooper at i on wi t h t he
Counci l of Bet t er Busi ness Bur eaus and i ndi vi dual par t i ci pat i ng
Bur eaus. MAP " pi l ot ed" i n I ndi anapol i s and Pi t t sbur gh dur i ng spr i ng,
1996 - and publ i ci zed " r ol l - out s" i n New J er sey, Det r oi t ( MI ) , Chi cago
( I L) and Ri chmond ( VA) wer e conduct ed. To put some " t eet h" i n t he
pr ogr am, and accr edi t at i on r equi r ement f or shops was i ni t i at ed. The
r equi r ement s ar e st r i ngent and a sel f - pol i ci ng met hod has been
i ncor por at ed whi ch i ncl udes t he " myst er y shoppi ng" of out l et s. I n
addi t i on, a commi t t ee of ser vi ce pr ovi der s had been wor ki ng di l i gent l y
devel opi ng st andar ds f or newspaper , t el evi si on and I nt er net
adver t i si ng.
We wel come you t o j oi n us as we cont i nue our out r each . . .
wi t h your suppor t , bot h t he aut omot i ve r epai r i ndust r y and your
cust omer s wi l l r eap t he benef i t s. Pl ease vi si t MAP at our I nt er net
si t e: www. hunt er . com/ map. ht mor cont act us at :
808 17t h St r eet , NW Sui t e 200
Washi ngt on, D. C. 20006
Ph. ( 202) 466- 7050 Fax ( 202) 223- 9569
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
I t i s MAP pol i cy t hat al l exhaust , br ake, ABS, st eer i ng and
suspensi on, wheel al i gnment , t i r es and wheel s, dr i vel i ne, engi ne
per f or mance and mai nt enance and heat i ng, vent i l at i on and ai r
condi t i oni ng ser vi ces be of f er ed and per f or med under t he gui del i nes
and pr ocedur es speci f i ed i n t hese sect i ons.
Bef or e any ser vi ce i s per f or med on a vehi cl e, an i nspect i on
of t he appr opr i at e syst emmust be per f or med. The r esul t s of t hi s
i nspect i on must be expl ai ned t o t he cust omer and document ed on an
i nspect i on f or m. The condi t i on of t he vehi cl e and i t s component s wi l l
i ndi cat e what ser vi ces/ par t r epl acement s may be r equi r ed or suggest ed.
I n addi t i on, suggest i ons may be made t o sat i sf y t he needs expr essed by
t he cust omer .
Thi s sect i on l i st s t he var i ous par t s and condi t i ons t hat
i ndi cat e r equi r ed or suggest ed ser vi ce or par t r epl acement . Al t hough
t hi s l i st i s ext ensi ve, i t i s not i ncl usi ve. I n addi t i on t o t hi s l i st ,
a t echni ci an may make a suggest i on. Thi s suggest i on must be based on
subst ant i al and i nf or med exper i ence or t he vehi cl e manuf act ur er ' s
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
r ecommended ser vi ce i nt er val .
Some condi t i ons i ndi cat e t hat ser vi ce or par t r epl acement i s
r equi r ed because t he par t i n quest i on i s no l onger pr ovi di ng t he
f unct i on f or whi ch i t i s i nt ended, does not meet a vehi cl e
manuf act ur er ' s desi gn speci f i cat i on or i s mi ssi ng.
* Exampl e: An exhaust pi pe has cor r oded sever el y and has a hol e
i n i t t hr ough whi ch exhaust gases ar e l eaki ng. Repl acement of
t he exhaust pi pe i n t hi s case i s r equi r ed due t o f unct i onal
f ai l ur e.
* Exampl e: A br ake r ot or has been wor n t o t he poi nt wher e i t
measur es l ess t han t he vehi cl e manuf act ur er ' s speci f i cat i ons.
Repl acement of t he r ot or i s r equi r ed because i t does not meet
desi gn speci f i cat i ons.
Some condi t i ons i ndi cat e t hat a ser vi ce or par t r epl acement
i s suggest ed because t he par t i s cl ose t o t he end of i t s usef ul l i f e
or t o addr ess a cust omer ' s need, conveni ence or r equest . I f a
cust omer ' s vehi cl e has one of t hese condi t i ons, t he pr ocedur e may
onl y be t o suggest ser vi ce.
* Exampl e: An exhaust pi pe i s r ust ed, cor r oded or weak, but no
l eaks ar e pr esent . I n t hi s case, t he exhaust pi pe has not
f ai l ed. However , t her e i s evi dence t hat t he pi pe may need
r epl acement i n t he near f ut ur e. Repl acement of t he pi pe may
be suggest ed f or t he cust omer ' s conveni ence i n avoi di ng a
f ut ur e pr obl em.
* Exampl e: The cust omer desi r es i mpr oved r i de and/ or handl i ng,
but t he vehi cl e' s shocks or st r ut s have not f ai l ed. I n t hi s
case, r epl acement may be suggest ed t o sat i sf y t he cust omer ' s
wi shes. I n t hi s case, r epl acement of t he shocks or st r ut s may
not be sol d as a r equi r ement .
A cust omer , of cour se, has t he choi ce of whet her or not a
shop wi l l ser vi ce hi s or her vehi cl e. He or she may deci de not t o
f ol l ow some of your suggest i ons. When a cust omer decl i nes t o aut hor i ze
a ser vi ce or r epai r i ndi cat ed i n t he MAP Uni f or mI nspect i on Gui del i nes
as " r equi r ed, " a MAP shop may r ef use ser vi ce on t hat syst em, i f
pr oceedi ng wi t h t he wor k coul d cr eat e or cont i nue an unsaf e or
unsat i sf act or y condi t i on.
The f ol l owi ng r easons may be used f or r equi r ed and suggest ed
ser vi ces. These codes ar e shown i n t he " Code" col umn of t he Uni f or m
I nspect i on Gui del i nes t hat f ol l ow.
PART REPLACEMENT CODE IDENTIFICATION
NOTE: Ref er t o t he f ol l owi ng t abl es f or def i ni t i ons of t he codes
l i st ed i n t he condi t i on/ pr ocedur e t abl es f or t he speci f i c
component s t hat may need t o be r epl aced.
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
A - PART NO LONGER PERFORMS I NTENDED PURPOSE

Reasons t o Requi r e Repai r Reasons t o Suggest Repai r


or Repl acement or Repl acement

A - Par t no l onger per f or ms 1 - Par t i s cl ose t o t he end of


i nt ended pur pose i t s usef ul l i f e ( j ust above
di scar d speci f i cat i ons, or
weak; f ai l ur e l i kel y t o
occur soon, et c. )

B - PART DOES NOT MEET DESI GN SPEC. , REGARDLESS OF PERFORMANCE

Reasons t o Requi r e Repai r Reasons t o Suggest Repai r


or Repl acement or Repl acement

B - Par t does not meet a desi gn 2 - To addr ess a cust omer need,
speci f i cat i on ( r egar dl ess conveni ence, or r equest ( t o
of per f or mance) st i f f en r i de, enhance
per f or mance, el i mi nat e noi se
et c. )

C - PART I S MI SSI NG

Reasons t o Requi r e Repai r Reasons t o Suggest Repai r


or Repl acement or Repl acement

C - Par t i s mi ssi ng 3 - To compl y wi t h mai nt enance


r ecommended by t he vehi cl e' s
Or i gi nal Equi pment
Manuf act ur er ( OEM)
4 - Techni ci an' s r ecommendat i on
based on subst ant i al and
i nf or med exper i ence

STEERING & SUSPENSION


SERVICE PROCEDURES REQUIRED & SUGGESTED FOR PROPER
VEHI CLE OPERATI ON
St eer i ng and suspensi on ar e compl ex syst ems made up of a
var i et y of i nt er dependent component s. For pr oper vehi cl e handl i ng,
r i de, and t i r e wear , a t hor ough i nspect i on i s r equi r ed whenever
suspensi on wor k i s bei ng per f or med.
Condi t i ons l i st ed assume t hat t he pr obl emhas been i sol at ed
t o t he speci f i c component by pr oper t est i ng pr ocedur es.
NOTE: When r epl aci ng st eer i ng and/ or suspensi on component s whi ch
may af f ect an al i gnment angl e, you ar e r equi r ed t o check and
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
adj ust al i gnment as needed. Ref er t o t he OEM speci f i cat i ons.
CAUTI ON: DO NOT use r i de hei ght al t er i ng or l oad compensat i ng
component s, such as var i abl e r at e spr i ngs and coi l over
shocks, on vehi cl es wi t h hei ght or l oad sensi ng pr opor t i oni ng
val ve- equi pped br aki ng syst ems, unl ess t hese component s ar e
or i gi nal equi pment .
AIR RIDE SUSPENSION
NOTE: Dependi ng on t he ai r suspensi on desi gn, t her e ar e some
af t er mar ket pr oduct s avai l abl e t o el i mi nat e t he ai r r i de
suspensi on on cer t ai n vehi cl es. I f t he syst emhas been
el i mi nat ed wi t h one of t hese pr oduct s, t hen no ser vi ce i s
suggest ed or r equi r ed.
AIR RIDE SUSPENSION - AIR SHOCKS & AIR STRUTS
NOTE: Thi s sect i on cover s t he ai r spr i ng por t i on of t he ai r shock
or st r ut . For dampeni ng por t i on of shock or st r ut condi t i ons
and pr ocedur es, r ef er t o t he " Shock Absor ber s, St r ut
Car t r i dges, and St r ut Assembl i es" sect i on.
AI R RI DE SUSPENSI ON - AI R SHOCKS & AI R STRUTS

Condi t i on Code Pr ocedur e

I nner f abr i c of ai r bag A Requi r e r epl acement .


damaged

Leaki ng A Requi r e r epai r or r epl acement .

Out er cover i ng of ai r bag A, 1 Suggest r epl acement .


i s cr acked t o t he ext ent
t hat i nner f abr i c of ai r
bag i s vi si bl e

AIR RIDE SUSPENSION - AIR SPRING VALVES


AI R RI DE SUSPENSI ON - AI R SPRI NG VALVES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 6)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bl ocked A Requi r e r epai r or r epl acement .

Connect or bent A Requi r e r epai r or r epl acement .

Connect or br oken A Requi r e r epl acement .

Connect or l oose A Requi r e r epai r or r epl acement .

I noper at i ve A Requi r e r epai r or r epl acement .

Leaki ng A Requi r e r epai r or r epl acement .

Rest r i ct ed A Requi r e r epai r or r epl acement .

AIR RIDE SUSPENSION - AIR SPRINGS


AI R RI DE SUSPENSI ON - AI R SPRI NGS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Col l ar cr acked A Requi r e r epl acement .

End cap cr acked A Requi r e r epl acement .

I nner f abr i c of bag damaged A Requi r e r epl acement .

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 7)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
Leaki ng A Requi r e r epai r or r epl acement .

Out er cover i ng of ai r bag A, 1 Suggest r epl acement .


i s cr acked t o t he ext ent
t hat i nner f abr i c of ai r
bag i s vi si bl e

Pi st on cr acked A Requi r e r epl acement .

AIR RIDE SUSPENSION - COMPRESSORS


AI R RI DE SUSPENSI ON - COMPRESSORS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Connect or bent A Requi r e r epai r or r epl acement .

Connect or br oken A Requi r e r epl acement .

Connect or l oose A Requi r e r epai r or r epl acement .

Does not bui l d pr essur e A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Excessi ve r un t i me B Fur t her i nspect i on r equi r ed.


See not e ( 2) bel ow.

I noper at i ve A Requi r e r epl acement .

Leaki ng A Requi r e r epai r or r epl acement .

Mi ssi ng C Requi r e r epl acement .

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 8)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
NOTE: ( 1) I f f ai l ur e t o bui l d pr essur e i s t r aced t o t he compr essor ,
r equi r e r epl acement .
( 2) I f excessi ve r un t i me i s t r aced t o t he compr essor , r equi r e
r epl acement .

AIR RIDE SUSPENSION - HEIGHT SENSORS


AI R RI DE SUSPENSI ON - HEI GHT SENSORS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t .
i nt egr i t y

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Dust boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 1) .

Dust boot spl i t B, 2 Suggest r epl acement . See not e ( 1) .

Dust boot t or n B, 2 Suggest r epl acement . See not e ( 1) .

Housi ng cr acked A Requi r e r epl acement .

Lead r out i ng i ncor r ect B Requi r e r e- r out i ng accor di ng t o


vehi cl e manuf act ur er ' s specs.

Loose B Requi r e adj ust ment t o vehi cl e


manuf act ur er ' s speci f i cat i ons.

Mi ssi ng C Requi r e r epl acement .

Out put si gnal i ncor r ect A Requi r e r epai r or r epl acement .

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 9)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
Wi r e l ead damaged A Requi r e r epai r or r epl acement .

NOTE: ( 1) Thi s condi t i on can l ead t o damage of t he sl i di ng magnet ,


whi ch, i n t ur n, causes pr emat ur e sensor f ai l ur e.

AIR RIDE SUSPENSION - MODULES


AI R RI DE SUSPENSI ON - MODULES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Housi ng cr acked B, 2 Suggest r epai r or r epl acement .

I noper at i ve A Requi r e r epl acement .

Mi ssi ng C Requi r e r epl acement .

AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)


AI R RI DE SUSPENSI ON - RELAYS ( COMPRESSOR)

Condi t i on Code Pr ocedur e

Housi ng cr acked B, 2 Suggest r epl acement . See not e ( 1) .

I nt er mi t t ent A Requi r e r epl acement .

Mi ssi ng C Requi r e r epl acement .

Out put si gnal i ncor r ect A Requi r e r epl acement .

NOTE: ( 1) I f moi st ur e ent er s t he r el ay, i t can r educe l i f e expect ancy


or i mpai r f unct i on.

AIR RIDE SUSPENSION - SWITCHES (ON/OFF)


AI R RI DE SUSPENSI ON - SWI TCHES ( ON/ OFF)
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 10)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM

Condi t i on Code Pr ocedur e

Br oken A Requi r e r epl acement .

Mi ssi ng C Requi r e r epl acement .

Out put si gnal i ncor r ect A Requi r e r epl acement .

AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)


AI R RI DE SUSPENSI ON - TORSI ON SPRI NGS ( COUNTER BALANCI NG)

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e i ncor r ect A Requi r e r epl acement of i ncor r ect
par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Br oken A Requi r e r epl acement .

Mi ssi ng C Requi r e r epl acement .

AIR RIDE SUSPENSION - TUBING


AI R RI DE SUSPENSI ON - TUBI NG

Condi t i on Code Pr ocedur e

At t achi ng har dwar e i ncor r ect A Requi r e r epl acement of i ncor r ect
par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 11)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

Bl ocked A Requi r e r epai r or r epl acement .

Fi t t i ng i ncor r ect B Requi r e r epl acement .

Leaki ng A Requi r e r epai r or r epl acement .

Li ne t ype i ncor r ect B Requi r e r epl acement .

Mi ssi ng C Requi r e r epl acement .

Rest r i ct ed A Requi r e r epai r or r epl acement .

Rout ed i ncor r ect l y B Requi r e r out i ng cor r ect i on.

AIR RIDE SUSPENSION - WARNING LAMPS


AI R RI DE SUSPENSI ON - WARNI NG LAMPS

Condi t i on Code Pr ocedur e

Bul b bur ned out A Requi r e r epl acement .

War ni ng l i ght does not come


on dur i ng bul b check

War ni ng l i ght f l ashes
Fur t her i nspect i on r equi r ed t o
War ni ng l i ght i s i nt er mi t t ent det er mi ne cause.

War ni ng l i ght st ays on af t er
i ni t i al bul b check

AIR RIDE SUSPENSION - WIRING HARNESSES


AI R RI DE SUSPENSI ON - WI RI NG HARNESSES

Condi t i on Code Pr ocedur e

Connect or bent A

Connect or br oken A

Connect or l oose A Requi r e r epai r or r epl acement .

Damaged ( cut , bur ned, or A


* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 12)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
chaf ed)

Excessi ve r esi st ance B

Fuse bl own A
Requi r e r epl acement .
Fusi bl e l i nk bl own A

Open A
Requi r e r epai r or r epl acement .
Poor gr ound A

Rout ed i ncor r ect l y B Requi r e r e- r out i ng accor di ng t o


vehi cl e manuf act ur er ' s specs.

Shor t ed A

Ter mi nal bent A

Ter mi nal br oken A Requi r e r epai r or r epl acement .

Ter mi nal cor r oded A

Ter mi nal l oose A

BALL JOINTS
Bef or e r equi r i ng or suggest i ng bal l j oi nt r epl acement , t he
appr oved OEM pr ocedur e must be used t o measur e bal l j oi nt wear . The
measur ement ( s) obt ai ned, al ong wi t h t he vehi cl e manuf act ur er ' s
speci f i cat i ons, must be not ed on t he i nspect i on r epor t . Some st at es
r equi r e t hat t hese measur ement s al so appear on t he i nvoi ce.
NOTE: The t er m" per cept i bl e movement , " def i ned as any vi si bl e
movement i n any di r ect i on, has been t he i ndust r y st andar d
f or det er mi ni ng t he need f or r epl acement of f ol l ower bal l
j oi nt s. Some vehi cl e manuf act ur er s ar e now publ i shi ng
speci f i cat i ons f or f ol l ower bal l j oi nt s t hat wer e pr evi ousl y
di agnosed by t he " per cept i bl e movement " st andar d. Bef or e
r equi r i ng or suggest i ng any par t s be r epl aced based on
" per cept i bl e movement , " consul t your r epai r manual t o
det er mi ne i f OEM speci f i cat i ons exi st .
You ar e not r equi r ed t o r epl ace bal l j oi nt s i n axl e set s.
However , when r epl aci ng a bal l j oi nt due t o wear exceedi ng
manuf act ur er ' s speci f i cat i on, you may suggest r epl acement of t he ot her
bal l j oi nt i f i t s measur ement shows i t i s cl ose t o t he end of i t s
usef ul l i f e, f or pr event i ve mai nt enance.
BALL J OI NTS

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 13)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t i f avai l abl e; ot her wi se,
r epl ace bal l j oi nt .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken par t


i f avai l abl e; ot her wi se, r epl ace
bal l j oi nt .

At t achi ng har dwar e cor r oded A Requi r e r epl acement of br oken par t
af f ect i ng st r uct ur al i f avai l abl e; ot her wi se, r epl ace
i nt egr i t y bal l j oi nt .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t i f avai l abl e; ot her wi se,
r epl ace bal l j oi nt .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t i f avai l abl e;
ot her wi se, r epl ace bal l j oi nt .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t i f avai l abl e; ot her wi se,
r epl ace bal l j oi nt .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads i f
avai l abl e; ot her wi se, r epl ace
bal l j oi nt .

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads i f avai l abl e;
ot her wi se, r epl ace bal l j oi nt .

Bi ndi ng A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .

Gr ease f i t t i ng br oken A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng won' t seal A Requi r e r epl acement of gr ease


f i t t i ng.
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 14)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM

Gr easeabl e bal l j oi nt wi l l B, 2 Suggest r epl acement of gr ease


not t ake gr ease f i t t i ng. See not e ( 5) bel ow.

Nut on bal l j oi nt l oose A Requi r e r epai r or r epl acement .


See not e ( 6) bel ow.

Pr e- l oad adj ust ment B Requi r e r epai r or r epl acement .


i ncor r ect

Sei zed A Requi r e r epl acement .

St ud bent B Requi r e r epl acement . See not e ( 7) .

St ud br oken A Requi r e r epl acement . See not e ( 7) .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 7) .


mi ssi ng)

Wear exceeds manuf act ur er ' s B Requi r e r epl acement .


speci f i cat i ons

NOTE: ( 1) I f gr easeabl e, gr ease bal l j oi nt . I f pr obl emper si st s or


j oi nt i s non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er t he
bal l j oi nt and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er t he
bal l j oi nt and wi l l accel er at e wear .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he bal l
j oi nt and wi l l accel er at e wear .
( 5) I f t he gr easeabl e bal l j oi nt st i l l wi l l not t ake gr ease
af t er r epl aci ng t he gr ease f i t t i ng, suggest r epl acement of
bal l j oi nt .
( 6) Check f or bent st ud or damaged t aper hol e.
( 7) Check f or damaged t aper hol e.

BUSHINGS
BUSHI NGS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t i f avai l abl e; ot her wi se,
r epl ace bushi ng.

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken par t


i f avai l abl e; ot her wi se, r epl ace
bushi ng.
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 15)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace bushi ng.

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t i f avai l abl e; ot her wi se,
r epl ace bushi ng.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t i f avai l abl e;
ot her wi se, r epl ace bushi ng.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t i f avai l abl e; ot her wi se,
r epl ace bushi ng.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads i f
avai l abl e; ot her wi se, r epl ace
bushi ng.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads i f avai l abl e;
ot her wi se, r epl ace bushi ng.

Bi ndi ng A Requi r e r epai r or r epl acement .

Det er i or at ed, af f ect i ng A Requi r e r epai r or r epl acement .


per f or mance

Di st or t ed, af f ect i ng A Requi r e r epai r or r epl acement .


per f or mance

Leaki ng ( f l ui d- f i l l ed t ype) A Requi r e r epl acement .

Mi ssi ng A Requi r e r epl acement .

Noi sy B, 2 Fur t her i nspect i on r equi r ed.


See not e ( 1) and caut i on bel ow.

Rubber separ at i ng f r om A Requi r e r epl acement .


i nt er nal met al sl eeve on
bonded bushi ng

Sei zed A Requi r e r epl acement .

Shi f t ed ( out of posi t i on) B Requi r e r epai r or r epl acement .

Spl i t A Requi r e r epl acement .

Sur f ace cr acki ng No ser vi ce suggest ed or r equi r ed.


* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 16)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
( weat her - checked)

NOTE: ( 1) I f noi se i sol at ed t o bushi ng, suggest r epai r or r epl acement .


CAUTI ON: Use onl y appr oved l ubr i cant on r ubber bushi ngs. Pet r ol eum-
based l ubr i cant s may damage r ubber bushi ngs.

CENTER LINKS
CENTER LI NKS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace cent er l i nk.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace cent er l i nk.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace cent er l i nk.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
cent er l i nk.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace cent er l i nk.

Bent B Requi r e r epl acement .

Bi ndi ng A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .

Gr ease f i t t i ng br oken A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease


f i t t i ng.

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 17)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
Gr ease f i t t i ng won' t seal A Requi r e r epl acement of gr ease
f i t t i ng.

Gr ease seal mi ssi ng B, 2 Suggest r epl acement . See not e ( 5) .

Gr ease seal t or n B, 2 Suggest r epl acement . See not e ( 6) .

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 7) .


hor i zont al movement )

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 8)


and ( 9) , caut i on bel ow.

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Sei zed A Requi r e r epl acement .

St ud bent B Requi r e r epl acement . See not e ( 10)

St ud br oken A Requi r e r epl acement . See not e ( 10)

St ud l oose i n t aper hol e A Requi r e r epai r or r epl acement .


See not e ( 10) bel ow.

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 11)

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 10)
mi ssi ng)

Wear exceeds manuf act ur er ' s B Requi r e r epl acement .


speci f i cat i ons

NOTE: ( 1) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt i s


non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he j oi nt
and wi l l accel er at e wear .
( 5) Lack of gr ease seal wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 6) Tor n gr ease seal wi l l al l ow cont ami nant s t o ent er t he j oi nt
and wi l l accel er at e wear .
( 7) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 18)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
such as t he dr y par k check.
( 8) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 9) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
( 10) Check f or damaged t aper hol e.
( 11) Check f or damaged st ud.

CONTROL ARM SHAFTS


CONTROL ARM SHAFTS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace shaf t .
At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of
l oose par t , i f avai l abl e;
ot her wi se, r epl ace shaf t .
At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng
par t , i f avai l abl e; ot her wi se,
r epl ace shaf t .
At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of
damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
shaf t .
At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h
st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace shaf t .
Bent B Requi r e r epl acement .
Shaf t bushi ng sur f ace B Requi r e r epl acement .
under si zed ( wor n)
Thr eads damaged A Requi r e r epai r or r epl acement .
Thr eads st r i pped A Requi r e r epl acement .
( t hr eads mi ssi ng)

CONTROL ARMS
CONTROL ARMS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t , i f avai l abl e;
ot her wi se, r epl ace cont r ol ar m.

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 19)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
r epl ace cont r ol ar m.

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t , i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace cont r ol ar m.

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace cont r ol ar m.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace cont r ol ar m.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace cont r ol ar m.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
cont r ol ar m.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace cont r ol ar m.

Bent B Requi r e r epl acement .

Bushi ng hol e over si zed B Requi r e r epl acement .

Bal l j oi nt hol e over si zed B Fur t her i nspect i on r equi r ed.


( l oose i nt er f er ence or See not e ( 1) bel ow.
pr ess f i t )

Cor r oded, af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y

Hol es di st or t ed A Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

NOTE: ( 1) I f over si zed bal l j oi nt i s avai l abl e, r equi r e r epl acement


of bal l j oi nt . I f over si zed bal l j oi nt i s not avai l abl e,
r equi r e r epl acement of cont r ol ar m.

DRAG LINKS
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 20)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
DRAG LI NKS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace dr ag l i nk.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace dr ag l i nk.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace dr ag l i nk.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
dr ag l i nk.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace dr ag l i nk.

Bent B Requi r e r epl acement .

Bi ndi ng A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .

Gr ease f i t t i ng br oken A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng won' t seal A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease seal mi ssi ng B, 2 Suggest r epl acement . See not e ( 5) .

Gr ease seal t or n B, 2 Suggest r epl acement . See not e ( 4) .

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 6) .


hor i zont al movement )

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 21)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket
movement . Use onl y moder at e hand pr essur e.

Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 6)


and ( 7) , caut i on bel ow.

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Sei zed A Requi r e r epl acement .

St ud bent B Requi r e r epl acement . See not e ( 8) .

St ud br oken A Requi r e r epl acement . See not e ( 8) .

St ud l oose i n t aper hol e A Requi r e r epai r or r epl acement .


See not e ( 8) bel ow.

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 9) .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 8) .


mi ssi ng)

Wear exceeds manuf act ur er ' s B Requi r e r epl acement .


speci f i cat i ons

NOTE: ( 1) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt i s


non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he j oi nt
and wi l l accel er at e wear .
( 5) Mi ssi ng gr ease seal wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 6) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
( 7) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 8) Check f or damaged t aper hol e.
( 9) Check f or damaged st ud.

ELECTRONIC RIDE CONTROL SHOCKS & STRUTS


NOTE: Thi s sect i on cover s t he el ect r oni c dampi ng cont r ol por t i on of
t he el ect r oni c shock or st r ut . For dampeni ng por t i on of shock
or st r ut condi t i ons and pr ocedur es, r ef er t o t he " Shock
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 22)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
Absor ber s, St r ut Car t r i dges, and St r ut Assembl i es" sect i on.
ELECTRONI C RI DE CONTROL SHOCKS & STRUTS

Condi t i on Code Pr ocedur e

Connect or bent A Requi r e r epai r or r epl acement .

Connect or br oken A Requi r e r epai r or r epl acement .

Connect or l oose A Requi r e r epai r or r epl acement .

El ect r oni c val ve cont r ol B, 2 Suggest r epl acement . See not e ( 1) .


i noper at i ve

Ter mi nal bent A Requi r e r epai r or r epl acement .

Ter mi nal br oken A Requi r e r epai r or r epl acement .

Ter mi nal cor r oded A Requi r e r epai r or r epl acement .

Ter mi nal l oose A Requi r e r epai r or r epl acement .

NOTE: ( 1) I t i s accept abl e t o r epl ace wi t h a non- el ect r oni cal l y


cont r ol l ed uni t , wher e avai l abl e.

IDLER ARMS
I DLER ARMS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace i dl er ar m.

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace i dl er ar m.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace i dl er ar m.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace i dl er ar m.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 23)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
i dl er ar m.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace i dl er ar m.

Bi ndi ng A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .

Gr ease f i t t i ng br oken A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng won' t seal A Requi r e r epl acement of seal .

Gr ease seal mi ssi ng B, 2 Suggest r epl acement . See not e ( 5) .

Gr ease seal t or n B, 2 Suggest r epl acement . See not e ( 4) .

Gr easeabl e j oi nt wi l l not B, 2 Suggest r epl acement of gr ease


t ake gr ease f i t t i ng. See not e ( 6) bel ow.

Looseness at f r ame br acket B Requi r e r epai r or r epl acement .


end See not es ( 7) and ( 8) bel ow.

Looseness at l i nk end A, 1 Suggest r epl acement . See not e ( 7) .


( per cept i bl e hor i zont al
movement )

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Looseness at l i nk end t hat B Requi r e r epl acement . See not es ( 7)


i s excessi ve and ( 9) and caut i on bel ow.

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Mount ed out of posi t i on B Requi r e r eposi t i oni ng.


( cent er l i nk not par al l el )

Nut on st ud l oose A Requi r e r epai r or r epl acement .


See not e ( 10) bel ow.

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 24)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
Sei zed A Requi r e r epl acement .

St ud bent B Requi r e r epl acement . See not e ( 11)

St ud br oken A Requi r e r epl acement . See not e ( 11)

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 12)

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 11)
mi ssi ng)

Wear exceeds manuf act ur er ' s B Requi r e r epl acement .


speci f i cat i ons

NOTE: ( 1) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt


i s non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt and
wi l l accel er at e wear .
( 5) Mi ssi ng gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 6) I f gr easeabl e j oi nt wi l l not t ake gr ease af t er r epl aci ng t he
gr ease f i t t i ng, suggest r epl acement of i dl er ar m.
( 7) I f manuf act ur er ' s pr ocedur es and speci f i cat i ons exi st , use
t hose pr ocedur es and speci f i cat i ons; ot her wi se, use an
appr oved i nspect i on met hod such as t he dr y par k check.
( 8) Looseness i s def i ned as movement t hat cr eat es excessi ve t oe
change.
( 9) Excessi ve l ooseness i s def i ned as si gni f i cant enough t o
af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 10) Check f or bent st ud or damaged t aper hol e.
( 11) Check f or damaged t aper hol e.
( 12) Check f or damaged st ud.

KING PINS
You ar e not r equi r ed t o r epl ace ki ng pi ns i n axl e set s.
However , when r epl aci ng a ki ng pi n due t o wear exceedi ng
manuf act ur er ' s speci f i cat i ons, you may suggest r epl acement of t he
ot her ki ng pi n on t he axl e i f i t s measur ement shows i t i s cl ose t o t he
end of i t s usef ul l i f e.
KI NG PI NS

Condi t i on Code Pr ocedur e

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 25)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
Bear i ng bal l s pi t t ed A Requi r e r epl acement .

Bear i ng bal l s wor n A Requi r e r epl acement .

Bear i ng r aces pi t t ed A Requi r e r epl acement .

Bear i ng r aces wor n A Requi r e r epl acement .

Bear i ng r ol l er s pi t t ed A Requi r e r epl acement .

Bear i ng r ol l er s wor n A Requi r e r epl acement .

Bear i ng seal bent B, 2


Suggest r epl acement of seal or
Bear i ng seal mi ssi ng B, 2 bear i ng.

Bear i ng seal t or n B, 2

Bi ndi ng A Requi r e r epai r or r epl acement of


af f ect ed par t s.

End caps mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace ki ng pi n.

End pl ay exceeds B Requi r e r epai r .


speci f i cat i ons

Gr ease f i t t i ng br oken A

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease


f i t t i ng.
Gr ease f i t t i ng won' t seal A

Locat i ng pi ns mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace ki ng pi n.

Looseness exceeds B Requi r e r epl acement of wor n par t s.


manuf act ur er ' s specs

Sei zed A Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

Wi l l not t ake gr ease B, 2 Suggest r epl acement of gr ease


f i t t i ng. See not e ( 1) bel ow.

NOTE: ( 1) I f ki ng pi n wi l l not t ake gr ease af t er r epl acement of gr ease


* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 26)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
f i t t i ng, suggest r epl acement of ki ng pi n.

PITMAN ARMS
PI TMAN ARMS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace pi t man ar m.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace pi t man ar m.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace pi t man ar m.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
pi t man ar m.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace pi t man ar m.

Bent B Requi r e r epl acement .

Bi ndi ng A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .

Gr ease f i t t i ng br oken A
Requi r e r epl acement gr ease
Gr ease f i t t i ng mi ssi ng C f i t t i ng.

Gr ease f i t t i ng won' t seal A

Gr ease seal mi ssi ng B, 2 Suggest r epl acement of seal .


See not e ( 5) bel ow.

Gr ease seal t or n B, 2 Suggest r epl acement of seal .


See not e ( 6) bel ow.
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 27)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 7)


hor i zont al movement )

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 7)


and ( 8) , caut i on bel ow.

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Nut on st ud l oose A Requi r e r epai r or r epl acement .


See not e ( 9) bel ow.

Sei zed A Requi r e r epl acement .

Spl i nes damaged A Requi r e r epai r or r epl acement .

Spl i nes st r i pped ( spl i nes A Requi r e r epl acement .


mi ssi ng)

St ud bent B Requi r e r epl acement . See not e ( 10)

St ud br oken A Requi r e r epl acement . See not e ( 10)

St ud l oose i n t aper hol e A Requi r e r epai r or r epl acement .


See not e ( 10) bel ow.

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 11)

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 10)
mi ssi ng)

NOTE: ( 1) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt


i s non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt and
wi l l accel er at e wear .
( 5) Lack of gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 6) Tor n gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt and
wi l l accel er at e wear .
( 7) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 28)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
( 8) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 9) Check f or bent st ud of damaged t aper hol e.
( 10) Check f or damaged t aper hol e.
( 11) Check f or damaged st ud.

POWER STEERING HOSES


POWER STEERI NG HOSES

Condi t i on Code Pr ocedur e

Bl i st er ed B Requi r e r epl acement .

Bl ocked A Requi r e r epai r or r epl acement .

Fi t t i ng t hr eads damaged A Requi r e r epai r or r epl acement .

Fi t t i ng t hr eads st r i pped A Requi r e r epl acement .


( t hr eads mi ssi ng)

I nner f abr i c ( webbi ng) cut A Requi r e r epl acement .

Leaki ng A Requi r e r epai r or r epl acement .

Mi ssi ng C Requi r e r epl acement .

Out er cover i ng i s cr acked B Requi r e r epl acement .


t o t he ext ent t hat t he
i nner f abr i c of hose i s
vi si bl e

Rest r i ct ed A Requi r e r epai r or r epl acement .

POWER STEERING (HYDRAULIC) PUMPS


I f di agnosi s has det er mi ned t hat compl et e di sassembl y i s
necessar y t o det er mi ne t he ext ent of t he syst emf ai l ur e, t he
suggest i on may be made t o r ebui l d or r epl ace t he power st eer i ng pump.
Repai r or r epl acement of t he f ol l owi ng component s may be r equi r ed i f
per f or med as par t of a power st eer i ng pump over haul or r ebui l d ser vi ce
t o meet a mi ni mumr ebui l d st andar d.
POWER STEERI NG ( HYDRAULI C) PUMPS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 29)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
At t achi ng har dwar e br oken A Requi r e r epl acement of br oken
par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bel t al i gnment i ncor r ect B Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Bel t cr acked A, 1 Suggest r epl acement .

Bel t f r ayed A, 1 Suggest r epl acement .

Bel t mi ssi ng C Requi r e r epl acement .

Bel t noi sy B, 2 Fur t her i nspect i on r equi r ed.


See not e ( 2) bel ow.

Bel t pl i es separ at ed A Requi r e r epl acement .

Bel t t ensi on out of spec B Requi r e adj ust ment or r epl acement .

Bel t wor n beyond adj ust ment B Requi r e r epl acement .


r ange

Bel t wor n so i t cont act s A Requi r e r epl acement .


bot t omof pul l ey

Bi ndi ng A Requi r e r epai r or r epl acement .

Fl ui d at or beyond ser vi ce C, 3 Suggest f l ui d change.


i nt er val

Fl ui d cont ami nat ed B Requi r e f l ushi ng and r ef i l l i ng of


t he syst em. See not e ( 3) bel ow.

Fl ui d l evel i ncor r ect B Requi r e adj ust ment of f l ui d l evel .

I nadequat e assi st A Fur t her i nspect i on r equi r ed.


See not e ( 4) bel ow.

Leaki ng A Requi r e r epai r or r epl acement .

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 30)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
Noi se B, 2 Fur t her i nspect i on r equi r ed.
See not e ( 5) bel ow.

Pul l ey bent A Requi r e r epai r or r epl acement of


pul l ey.

Pul l ey mi ssi ng C? Requi r e r epl acement of pul l ey.

Remot e r eser voi r l eaki ng A Requi r e r epl acement of r eser voi r .

Reser voi r cap br oken A Requi r e r epl acement of cap.

Reser voi r cap mi ssi ng C Requi r e r epl acement of cap.

Sei zed A Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

NOTE: ( 1) Det er mi ne cause of i ncor r ect al i gnment and r equi r e r epai r .


( 2) Det er mi ne cause of noi se and suggest r epai r .
( 3) Det er mi ne and cor r ect sour ce of cont ami nat i on. OEM
speci f i cat i ons must be f ol l owed f or f l ui d t ype.
( 4) I f pump i s sour ce of i nadequat e assi st , r equi r e r epai r or
r epl acement .
( 5) I f noi se i s i sol at ed t o pump, suggest r epai r or r epl acement .

RADIUS ARMS
RADI US ARMS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 31)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bent B Requi r e r epl acement .

Cor r oded, af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y

Hol es di st or t ed A Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

RELAY RODS
RELAY RODS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace r el ay r od.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace r el ay r od.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace r el ay r od.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
r el ay r od.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace r el ay r od.

Bent B Requi r e r epl acement .

Bi ndi ng A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .


* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 32)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM

Gr ease f i t t i ng br oken A

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement gr ease


f i t t i ng.
Gr ease f i t t i ng won' t seal A

Gr ease seal mi ssi ng B, 2 Suggest r epl acement . See not e ( 5) .

Gr ease seal t or n B, 2 Suggest r epl acement . See not e ( 6) .

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 7) .


hor i zont al movement )

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 7)


and ( 8) and caut i on bel ow.

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Sei zed A Requi r e r epl acement .

St ud bent B Requi r e r epl acement . See not e ( 9) .

St ud br oken A Requi r e r epl acement . See not e ( 9) .

St ud l oose i n t aper hol e A Requi r e r epai r or r epl acement .


See not e ( 9) .

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 10)

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 9) .


mi ssi ng)

Wear exceeds manuf act ur er ' s B Requi r e r epl acement .


speci f i cat i ons

NOTE: ( 1) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt


i s non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he j oi nt
and wi l l accel er at e wear .
( 5) Lack of gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 33)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
( 6) Tor n gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt and
wi l l accel er at e wear .
( 7) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
( 8) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 9) Check f or damaged t aper hol e.
( 10) Check f or damaged st ud.

SHOCK ABSORBERS, STRUT CARTRIDGES, & STRUT ASSEMBLIES


You ar e not r equi r ed t o r epl ace shocks or st r ut s i n axl e
set s. However , when r epl aci ng a shock or st r ut due t o t he condi t i ons
t hat f ol l ow, you may suggest r epl acement of t he ot her shock or st r ut
on t he same axl e f or i mpr oved per f or mance and pr event i ve mai nt enance.
* par t i s cl ose t o t he end of i t s usef ul l i f e
* t o ext end t i r e l i f e
* t o bal ance r i de and handl i ng
* t o i mpr ove st oppi ng di st ance
When r epl aci ng st eer i ng and/ or suspensi on component s whi ch
may af f ect an al i gnment angl e, you ar e r equi r ed t o check and adj ust
al i gnment as needed. Ref er t o t he OEM speci f i cat i ons.
Under no ci r cumst ances shoul d a t echni ci an bend st r ut s or
st r ut housi ngs.
A vehi cl e' s l oad- car r yi ng and handl i ng abi l i t i es ar e l i mi t ed
by i t s suspensi on, t i r es, br akes, and dr i vel i ne. I nst al l i ng coi l over
shocks or any ot her l oad assi st devi ce does not i ncr ease t he vehi cl e' s
l oad capaci t y. See t he vehi cl e owner ' s manual f or mor e det ai l s.
NOTE: I f vehi cl e i s equi pped wi t h or i gi nal equi pment coi l over
shocks, appl y t he condi t i ons f or coi l spr i ngs f r omt he
" Spr i ngs: Coi l , Leaf , and Tor si on Bar " sect i on of t he
St eer i ng and Suspensi on gui del i nes. I f t he vehi cl e i s
equi pped wi t h add- on coi l over shocks, you may suggest
r epl aci ng t he shocks wi t h st andar d shocks f or any spr i ng-
r el at ed condi t i on.
SHOCK ABSORBERS, STRUT CARTRI DGES, & STRUT ASSEMBLI ES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t , i f avai l abl e;
ot her wi se, r epl ace shock or st r ut .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace shock or st r ut .
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 34)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t , i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace shock or st r ut .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace shock or st r ut .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace shock or st r ut .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace shock or st r ut .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
shock or st r ut .

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace shock or st r ut .

Bi ndi ng A Requi r e r epl acement .

Body dent ed A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Body punct ur ed A Requi r e r epl acement .

Br ake hose br acket bent B Requi r e r epai r or r epl acement .

Br ake hose br acket mi ssi ng C Requi r e r epl acement .

Br ake hose br acket t hr eads C Requi r e r epai r or r epl acement .


damaged

Br ake hose br acket t hr eads C Requi r e r epl acement .


st r i pped ( t hr eads mi ssi ng)

Compr essi on bumper mi ssi ng C Requi r e r epl acement of compr essi on


bumper .

Compr essi on bumper spl i t A, 1 Suggest r epl acement of compr essi on


bumper .

Dampi ng ( none) A Requi r e r epl acement .

Dust boot ( bel l ows) spl i t B, 2 Suggest r epl acement of boot .


* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 35)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
See not e ( 2) bel ow.

Dust boot ( bel l ows) mi ssi ng B, 2 Suggest r epl acement of boot .


See ( 3) not e bel ow.

Dust boot ( bel l ows) t or n B, 2 Suggest r epl acement of boot .


See not e ( 4) bel ow.

Dust shi el d br oken B, 2 Suggest r epl acement . See not e ( 4) .

Dust shi el d mi ssi ng B, 2 Suggest r epl acement . See not e ( 4) .

Gl and nut ( st r ut housi ng A Requi r e r epl acement of nut and/ or


cap) i s not r emovabl e housi ng. See not e ( 5) bel ow.
usi ng appr opr i at e t ool

Gl and nut ( st r ut housi ng A Requi r e r epai r or r epl acement of


cap) t hr eads damaged nut .

Gl and nut ( st r ut housi ng A Requi r e r epl acement of nut .


cap) t hr eads st r i pped
( t hr eads mi ssi ng)

Housi ng dent ed A Fur t her i nspect i on r equi r ed.


See not e ( 6) bel ow.

Housi ng punct ur ed A Requi r e r epl acement .

J ounce bumper mi ssi ng C Requi r e r epl acement of j ounce


bumper .

J ounce bumper spl i t 1? Suggest r epl acement of j ounce


bumper .

Leaki ng oi l , enough f or A Requi r e r epl acement . See caut i on


f l ui d t o be r unni ng down bel ow.
t he body

CAUTI ON: I f t he st r ut car t r i dge has been r epl aced pr evi ousl y, t he oi l
on t he st r ut housi ng may be f i l l er oi l . The t echni ci an must
i dent i f y t he sour ce of t he oi l .

Noi se B, 2 Fur t her i nspect i on r equi r ed.


See not e ( 7) bel ow.

Pi st on r od bent A Requi r e r epl acement .

Pi st on r od br oken A Requi r e r epl acement .

Pi st on r od has sur f ace B, 2 Suggest r epl acement .


def ect

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 36)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
Pi st on r od t hr eads damaged A Requi r e r epai r or r epl acement .

Pi st on r od t hr eads st r i pped A Requi r e r epl acement .


( t hr eads mi ssi ng)

Sei zed A Requi r e r epl acement .

Shock mi ssi ng C Requi r e r epl acement .

St r ut housi ng bent A Requi r e r epl acement .

St r ut housi ng cap ( gl and A Requi r e r epl acement of nut and/ or


nut ) i s not r emovabl e housi ng. See not e ( 5) bel ow.
usi ng appr opr i at e t ool

St r ut housi ng cap ( gl and A Requi r e r epai r or r epl acement of


nut ) t hr eads damaged nut .

St r ut housi ng cap ( gl and A Requi r e r epl acement of nut .


nut ) t hr eads st r i pped
( t hr eads mi ssi ng)

St r ut housi ng sever el y A Requi r e r epl acement .


cor r oded, af f ect i ng
st r uct ur al i nt egr i t y

St r ut housi ng t hr eads A Requi r e r epai r or r epl acement .


damaged

St r ut housi ng t hr eads A Requi r e r epl acement .


st r i pped ( t hr eads mi ssi ng)

Ti r e cuppi ng A Fur t her i nspect i on r equi r ed.


See not e ( 8) bel ow

NOTE: ( 1) Requi r e r epl acement of uni t s wher e dent s r est r i ct shock or


st r ut pi st on r od movement . I f dent s don' t r est r i ct movement ,
no ser vi ce i s suggest ed or r equi r ed. Especi al l y cr i t i cal on
mono- t ube shocks.
( 2) Thi s condi t i on can l ead t o damage of t he pi st on r od, whi ch,
i n t ur n, causes pr emat ur e pi st on r od seal wear .
( 3) Thi s condi t i on can l ead t o damage of t he pi st on r od, whi ch
causes pi st on r od seal wear .
( 4) Thi s condi t i on can l ead t o damage of t he pi st on r od, whi ch,
i n t ur n, causes pr emat ur e pi st on r od seal wear .
( 5) Onl y r equi r ed i f r epl aci ng car t r i dge.
( 6) Requi r e r epl acement of uni t s wher e dent s r est r i ct shock or
st r ut pi st on r od movement . I f dent s don' t r est r i ct movement ,
no ser vi ce i s suggest ed or r equi r ed. Especi al l y cr i t i cal on
mono- t ube shocks.
( 7) I f noi se i s i sol at ed t o shock or st r ut , suggest r epl acement .
( 8) Al t hough shocks or st r ut s may have cont r i but ed t o t i r e
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 37)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
cuppi ng, an i nspect i on i s needed of t he ent i r e suspensi on
syst em. I f t he shock or st r ut i s f ound t o be cont r i but i ng
t o t he t i r e cuppi ng, r equi r e r epl acement .

SPINDLES
SPI NDLES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken par t

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bent B Requi r e r epl acement .

Br oken A Requi r e r epl acement .

Race seat ar ea under si zed B Requi r e r epl acement .

Scor ed A Requi r e r epai r or r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

SPRINGS: COIL, LEAF, & TORSION BAR


When spr i ngs ar e r epl aced, i t i s suggest ed, but not r equi r ed,
t hat bot h spr i ngs on an axl e be r epl aced t o mai nt ai n equal hei ght f r om
si de t o si de and t o pr ovi de a bal anced r i de and pr oper handl i ng.
When var i abl e r at e spr i ngs ar e i nst al l ed i n pl ace of
convent i onal coi l spr i ngs, t hey must be i nst al l ed i n axl e set s t o
ensur e pr oper handl i ng, uni f or mr i de, and pr oper chassi s hei ght .
Er r oneous hei ght measur ement s may r esul t f r om: i mpr oper t i r e
i nf l at i on, non- st andar d t i r e or wheel si ze, and heavy l oad i n vehi cl e
or t r unk.
SPRI NGS: COI L, LEAF, & TORSI ON BAR
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 38)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t .
i nt egr i t y

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Br oken ( al l spr i ngs except A Requi r e r epl acement .


secondar y l eave( s) on
mul t i - l eaf spr i ngs)

Coi l cl ash Requi r e r i de hei ght check.


See not e ( 1) bel ow.

Coi l spr i ng i nsul at or B, 2 Suggest r epl acement of i nsul at or .


det er i or at ed

Coi l spr i ng i nsul at or B, 2 Suggest r epl acement of i nsul at or .


mi ssi ng

Coi l spr i ng i nsul at or spl i t B, 2 Suggest r epl acement of i nsul at or .

Coi l spr i ng pl ast i c coat i ng A Ref er t o manuf act ur er ' s ser vi ce


det er i or at ed - r ust r equi r ement s. See not e ( 2) bel ow.
pr esent

Composi t e spr i ng damaged A Fur t her i nspect i on r equi r ed.


See not e ( 3) bel ow.

Cr acked ( al l spr i ngs except A Requi r e r epl acement .


composi t e l eaf and
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 39)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
secondar y l eave( s) on
mul t i - l eaf spr i ngs)

I nst al l ed i ncor r ect l y B Requi r e r epai r .

Leaf spr i ng i nsul at or s B, 2 Suggest r epl acement of i nsul at or s.


mi ssi ng

Secondar y l eaf on mul t i - A, 1 Suggest r epai r or r epl acement


l eaf spr i ng br oken

Secondar y l eaf on mul t i - A, 1 Suggest r epai r or r epl acement


l eaf spr i ng cr acked

Tor si on bar adj ust er bent A Requi r e r epai r or r epl acement of


adj ust er . See not e ( 4) bel ow.

Tor si on bar adj ust er sei zed A Requi r e r epai r or r epl acement of
adj ust er . See not e ( 4) bel ow.

Tor si on bar adj ust er A Requi r e r epai r or r epl acement of


t hr eads damaged par t wi t h damaged t hr eads.
See not e ( 4) bel ow.

Tor si on bar adj ust er A Requi r e r epl acement of par t wi t h


t hr eads st r i pped ( t hr eads st r i pped t hr eads.
mi ssi ng)

Vehi cl e suspensi on hei ght B Requi r e adj ust ment or r epl acement .
not wi t hi n OEM specs

NOTE: ( 1) I f vehi cl e i s wi t hi n manuf act ur er ' s hei ght speci f i cat i ons,
no ser vi ce i s suggest ed or r equi r ed.
( 2) Some manuf act ur er s r equi r e r epl acement under t hese
condi t i ons.
( 3) Check vehi cl e r i de hei ght . I f r i de hei ght i s OK, no ser vi ce
i s suggest ed or r equi r ed.
( 4) Onl y r equi r ed i f r i de hei ght needs t o be adj ust ed.

STEEL POWER STEERING LINES


CAUTI ON: When r epl aci ng st eel power st eer i ng l i nes, be sur e t o use
a r epl acement pr oduct t hat meet s or exceeds OEM desi gn
speci f i cat i ons.
STEEL POWER STEERI NG LI NES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 40)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bl ocked A Requi r e r epai r or r epl acement .

Fi t t i ng i ncor r ect ( such as B Requi r e r epl acement .


compr essi on f i t t i ng)

Fl ar e t ype i ncor r ect B Requi r ed r epl acement .

Leaki ng A Requi r e t i ght eni ng or r epl acement .

Li ne t ype i ncor r ect B Requi r e r epl acement .

Rest r i ct ed A Requi r e r epl acement .

Rout ed i ncor r ect l y B Requi r e r out i ng cor r ect i on.

Rust - pi t t ed A, 1 Suggest r epl acement .

Rust pi t t ed af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y

STEERING ARMS
STEERI NG ARMS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t .

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 41)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of
l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bent B Requi r e r epl acement .

Br oken A Requi r e r epl acement .

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 1) .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

NOTE: ( 1) Check f or damaged st ud.

STEERING DAMPERS
The f ol l owi ng pr ocedur es ar e onl y r equi r ed i f t he vehi cl e was
or i gi nal l y equi pped f r omt he f act or y wi t h a st eer i ng damper . I f t he
st eer i ng damper i s an add- on uni t , t hen t he uni t may be r emoved
i nst ead of r epai r i ng or r epl aci ng.
STEERI NG DAMPERS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t , i f avai l abl e;
ot her wi se, r epl ace st eer i ng
damper .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace st eer i ng damper .

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t , i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace st eer i ng damper .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 42)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
r epl ace st eer i ng damper .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace st eer i ng
damper .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace st eer i ng damper .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
st eer i ng damper .

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace st eer i ng
damper .

Bi ndi ng A Requi r e r epl acement .

Damper body dent ed A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Damper body punct ur ed A Requi r e r epl acement .

Dampi ng ( none) A Requi r e r epl acement .

Dust boot ( bel l ows) mi ssi ng B, 2 Suggest r epl acement of boot .


See not e ( 2) bel ow.

Dust boot ( bel l ows) spl i t B, 2 Suggest r epl acement of boot .


See not e ( 2) bel ow.

Dust shi el d br oken B, 2 Suggest r epl acement . See not e ( 2) .

Dust shi el d mi ssi ng B, 2 Suggest r epl acement . See not e ( 2) .

Leaki ng oi l , enough f or A Requi r e r epl acement .


f l ui d t o be r unni ng down
t he body

Loose A Requi r e r epai r or r epl acement .

Mi ssi ng C Requi r e r epl acement .

Noi se B, 2 Fur t her i nspect i on r equi r ed.


See not e ( 3) bel ow.

Pi st on r od bent A Requi r e r epl acement .


* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 43)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM

Pi st on r od br oken A Requi r e r epl acement .

Pi st on r od has sur f ace B, 2 Suggest r epl acement .


def ect

Pi st on r od t hr eads st r i pped A Requi r e r epl acement .


( t hr eads mi ssi ng)

Pi st on r od t hr eads damaged A Requi r e r epai r or r epl acement .

Sei zed A Requi r e r epl acement .

NOTE: ( 1) Requi r e r epl acement of uni t s wher e dent s r est r i ct damper


pi st on r od movement . I f dent s don' t r est r i ct movement , no
ser vi ce i s suggest ed or r equi r ed. Especi al l y cr i t i cal on
mono- t ube damper s.
( 2) Thi s condi t i on can l ead t o damage of t he pi st on r od, whi ch,
i n t ur n, causes pr emat ur e pi st on r od seal wear .
( 3) I f noi se i s i sol at ed t o damper , suggest r epl acement .

STEERING GEARS (EXCEPT RACK & PINION)


I f di agnosi s has det er mi ned t hat compl et e di sassembl y i s
necessar y t o det er mi ne t he ext ent of t he syst emf ai l ur e, t he
suggest i on may be made t o r ebui l d or r epl ace t he power st eer i ng pump.
Repai r or r epl acement of t he f ol l owi ng component s may be r equi r ed, i f
per f or med as par t of a power st eer i ng pump over haul or r ebui l d ser vi ce
t o meet a mi ni mumr ebui l d st andar d.
STEERI NG GEARS ( EXCEPT RACK & PI NI ON)

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bi ndi ng A Requi r e r epai r or r epl acement

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 44)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:57PM
Fl ex coupl er bi ndi ng A Requi r e r epai r or r epl acement of
coupl er .

Fl ex coupl er l oose A Requi r e r epai r or r epl acement of


coupl er .

Fl ex coupl er mi ssi ng par t s A Requi r e r epai r or r epl acement of


coupl er .

Fl ex coupl er sof t / spongy A Requi r e r epl acement of coupl er .

Fl ex coupl er t or n A Requi r e r epl acement of coupl er .

Fl ui d cont ami nat ed B Requi r e f l ushi ng and r ef i l l i ng


of t he syst em. See not e ( 1) bel ow.

Gasket l eaki ng A Requi r e r epai r or r epl acement of


gasket .

Housi ng l eaki ng A Requi r e r epl acement .

Hydr aul i c f i t t i ngs l eaki ng A Requi r e r epai r or r epl acement of


f i t t i ngs.

I nadequat e power assi st A Fur t her i nspect i on r equi r ed.


See not e ( 2) bel ow.

Lash exceeds manuf act ur er ' s B Requi r e r epai r or r epl acement .


speci f i cat i ons

Seal l eaki ng A Requi r e r epai r or r epl acement of


seal and/ or mat i ng par t .

Spl i nes damaged A Requi r e r epai r or r epl acement of


spl i nes.

Spl i nes st r i pped A Requi r e r epl acement of spl i nes.

St eer i ng coupl er shi el d B, 2 Suggest r epl acement .


cr acked

St eer i ng coupl er shi el d C Requi r e r epl acement .


mi ssi ng

Thr eads damaged A Requi r e r epai r or r epl acement of


par t wi t h damaged t hr eads.

Thr eads st r i pped ( t hr eads A Requi r e r epl acement of par t wi t h


mi ssi ng) st r i pped t hr eads.

U- j oi nt bi ndi ng A Requi r e r epai r or r epl acement of


j oi nt .
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 45)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM

U- j oi nt l oose A Requi r e r epai r or r epl acement of


j oi nt .

Unequal power assi st A Requi r e r epai r or r epl acement .

NOTE: ( 1) Det er mi ne and cor r ect sour ce of cont ami nat i on.
OEM speci f i cat i ons must be f ol l owed f or f l ui d t ype.
( 2) I f st eer i ng gear i s sour ce of i nadequat e assi st , r equi r e
r epai r or r epl acement .

STEERING GEARS: RACK & PINION


I f di agnosi s has det er mi ned t hat compl et e di sassembl y i s
necessar y t o det er mi ne t he ext ent of t he syst emf ai l ur e, t he
suggest i on may be made t o r ebui l d or r epl ace t he power st eer i ng pump.
Repai r or r epl acement of t he f ol l owi ng component s may be r equi r ed, i f
per f or med as par t of a power st eer i ng pump over haul or r ebui l d ser vi ce
t o meet a mi ni mumr ebui l d st andar d.
STEERI NG GEARS: RACK & PI NI ON

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bal ance t ube bl ocked A Requi r e r epai r or r epl acement of


bal ance t ube.

Bal ance t ube mi ssi ng C Requi r e r epl acement of bal ance


t ube.

Bal ance t ube r est r i ct ed A Requi r e r epai r or r epl acement of


bal ance t ube.

Bel l ows boot cl amp mi ssi ng C Requi r e r epl acement of cl amp.

Bel l ows boot cr acked ( not B, 2 Suggest r epl acement of bel l ows
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 46)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
t hr ough) boot .

Bel l ows boot mi ssi ng C Requi r e r epl acement of bel l ows


boot .

Bel l ows boot not seal i ng A Requi r e r epai r or r epl acement of


bel l ows boot .

Bel l ows boot t or n A Requi r e r epl acement of bel l ows


boot .

Bel l ows boot t wi st ed ( f r om B Requi r e r epai r .


t oe adj ust ment )

Fi t t i ng l eaki ng A Requi r e r epai r or r epl acement .

Fi t t i ng mi ssi ng A Requi r e r epl acement of f i t t i ng.

Fi t t i ng t hr eads damaged A Requi r e r epai r or r epl acement of


par t wi t h damaged t hr eads.

Fi t t i ng t hr eads st r i pped A Requi r e r epl acement of par t wi t h


( t hr eads mi ssi ng) st r i pped t hr eads.

Fl ex coupl er bi ndi ng A Requi r e r epai r or r epl acement of


coupl er .

Fl ex coupl er l oose A Requi r e r epai r or r epl acement of


coupl er .

Fl ex coupl er mi ssi ng par t s A Requi r e r epai r or r epl acement of


coupl er .

Fl ex coupl er sof t / spongy A Requi r e r epl acement of coupl er .

Fl ex coupl er t or n A Requi r e r epl acement of coupl er .

Fl ui d cont ami nat ed B Requi r e f l ushi ng and r ef i l l i ng of


t he syst em. See not e ( 1) bel ow.

Gasket l eaki ng A Requi r e r epai r or r epl acement .

Har d st eer i ng on col d A, 1 Suggest r epai r or r epl acement .


st ar t - up See not e ( 2) bel ow.

Housi ng cr acked, af f ect i ng B Requi r e r epl acement .


st r uct ur al i nt egr i t y

Housi ng l eaki ng A Requi r e r epl acement .

I nadequat e power assi st A Fur t her i nspect i on r equi r ed.


See not e ( 3) bel ow.
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 47)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM

Lash exceeds manuf act ur er ' s B Requi r e r epai r or r epl acement .


speci f i cat i ons

Seal l eaki ng A Requi r e r epai r or r epl acement .

Spl i nes damaged A Requi r e r epai r or r epl acement .

Spl i nes st r i pped ( spl i nes A Requi r e r epl acement .


mi ssi ng)

St eel l i ne bl ocked A Requi r e r epai r or r epl acement of


l i ne.
St eel l i ne l eaki ng A

St eel l i ne mi ssi ng C Requi r e r epl acement of l i ne.

St eel l i ne r est r i ct ed A Requi r e r epai r or r epl acement of


l i ne.

St eer i ng coupl er shi el d B, 2 Suggest r epl acement .


cr acked

St eer i ng coupl er shi el d C Requi r e r epl acement .


mi ssi ng

St eer i ng coupl er shi el d B, 2 Suggest r epl acement .


t or n

Thr eads damaged A Requi r e r epai r or r epl acement of


par t wi t h damaged t hr eads.

Thr eads st r i pped ( t hr eads A Requi r e r epl acement of par t wi t h


mi ssi ng) st r i pped t hr eads.

U- j oi nt bi ndi ng A Requi r e r epai r or r epl acement of


j oi nt .

U- j oi nt l oose A Requi r e r epai r or r epl acement of


j oi nt .

Unequal power assi st A Requi r e r epai r or r epl acement .

NOTE: ( 1) Det er mi ne and cor r ect sour ce of cont ami nat i on.
Fol l ow OE speci f i cat i ons f or f l ui d t ype.
( 2) I ndi cat es i nt er nal wear .
( 3) I f st eer i ng gear i s sour ce of i nadequat e assi st , r equi r e
r epai r or r epl acement .

STEERING KNUCKLES
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 48)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
STEERI NG KNUCKLES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bent B Requi r e r epl acement .

Br oken A Requi r e r epl acement .

Pi nch bol t i ncor r ect B Requi r e r epl acement wi t h bol t t hat


meet s OE desi gn.

Pi nch bol t l oose B Requi r e r epai r .

Pi nch bol t mi ssi ng B Requi r e r epl acement .

Pi nch bol t t abs def or med B Requi r e r epl acement .


( pi nched t oget her ) , . 032" See not e ( 1) bel ow.
or mor e bef or e cl ampi ng

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 2) .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epai r or r epl acement .


mi ssi ng)

NOTE: ( 1) St eer i ng knuckl e def or mat i on can cause pi nch bol t br eakage.
( 2) Check f or damaged st ud.

STRIKE OUT BUMPERS


* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 49)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
STRI KE OUT BUMPERS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t .
i nt egr i t y

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Mi ssi ng C Requi r e r epl acement .

Spl i t A, 1 Suggest r epl acement .

STRUT RODS
STRUT RODS

Condi t i on Code Pr ocedur e

Adj ust i ng nut sei zed A Requi r e r epai r or r epl acement .


See not e ( 1) bel ow.

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t , i f avai l abl e;
ot her wi se, r epl ace st r ut r od.

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace st r ut r od.

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace st r ut r od.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 50)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
ot her wi se, r epl ace st r ut r od.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace st r ut r od.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
st r ut r od.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace st r ut r od.

At t achi ng ( mat i ng) hol e A Requi r e r epai r or r epl acement of


over si zed f r ame.

At t achi ng poi nt on f r ame A Requi r e r epai r of f r ame.


cor r oded, af f ect i ng
st r uct ur al i nt egr i t y

Bent A Requi r e r epl acement .

Mat i ng ( at t achi ng) hol e A Requi r e r epai r or r epl acement of


over si zed f r ame.

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

NOTE: ( 1) Onl y r equi r ed i f an al i gnment i s bei ng per f or med.

STRUT UPPER BEARING PLATE ASSEMBLIES


NOTE: When t he f ol l owi ng gui del i nes i ndi cat e r epl acement of
bear i ng, onl y t he bear i ng shoul d be r epl aced i f i t i s
avai l abl e separ at el y; ot her wi se, r epl ace t he bear i ng
pl at e assembl y.
STRUT UPPER BEARI NG PLATE ASSEMBLI ES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace bear i ng pl at e assembl y.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 51)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
ot her wi se, r epl ace bear i ng pl at e
assembl y.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace bear i ng pl at e assembl y.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
bear i ng pl at e assembl y.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace bear i ng pl at e
assembl y.

Bear i ng axi al or r adi al B Requi r e r epl acement of bear i ng.


movement exceeds vehi cl e
manuf act ur er ' s specs

Bear i ng bi ndi ng A Requi r e r epl acement of bear i ng.

Bear i ng mi ssi ng C Requi r e r epl acement of bear i ng.

Bear i ng sei zed A Requi r e r epl acement of bear i ng.

Bent B Requi r e r epl acement .

Hol es di st or t ed A Requi r e r epl acement .

Mi ssi ng C Requi r e r epl acement .

Sever el y cor r oded, A Requi r e r epl acement .


af f ect i ng st r uct ur al
i nt egr i t y

SWAY BAR LINKS


SWAY BAR LI NKS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace l i nk.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace l i nk.

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 52)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng
par t , i f avai l abl e; ot her wi se,
r epl ace l i nk.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
l i nk.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace l i nk.

Bal l and socket has A, 1 Suggest r epl acement . See not e ( 1) .


l ooseness ( per cept i bl e
ver t i cal movement )

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Bal l and socket has B Requi r e r epl acement . See not es ( 1)


l ooseness t hat i s and ( 2) and caut i on.
excessi ve

Bent B Requi r e r epl acement .

Br oken A Requi r e r epl acement .

Cor r oded, af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 4) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 5) .

Mi ssi ng C Requi r e r epl acement .

Nut on st ud l oose A Requi r e r epai r . See not e ( 6) .

St ud bent B Requi r e r epl acement . See not e ( 7) .

St ud br oken A Requi r e r epl acement . See not e ( 7) .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 7) .


mi ssi ng)

NOTE: ( 1) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose


pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 53)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
such as t he dr y par k check.
( 2) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 3) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 4) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 5) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he j oi nt
and wi l l accel er at e wear .
( 6) Check f or bent st ud or damaged t aper hol e.
( 7) Check f or damaged t aper hol e.

SWAY BARS
SWAY BARS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace sway bar .

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t , i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace sway bar .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace sway bar .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace sway bar .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace sway
bar .

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace sway bar .

Bent B Requi r e r epl acement .

Br oken A Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 54)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM

TIE ROD ENDS (INNER & OUTER)


TI E ROD ENDS ( I NNER & OUTER)

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace t i e r od end.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace t i e r od end.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace t i e r od end.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace t i e
r od end.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace t i e r od end.

Adj ust i ng sl eeve bent B Requi r e r epl acement of sl eeve or


t i e r od end.

Adj ust i ng sl eeve cl amps B Requi r e r epai r .


out of posi t i on

Adj ust i ng sl eeve cor r oded, A Requi r e r epl acement of sl eeve or


af f ect i ng st r uct ur al t i e r od end.
i nt egr i t y

Adj ust i ng sl eeve mi ssi ng C Requi r e r epl acement of sl eeve or


t i e r od end.

Adj ust i ng sl eeve sei zed A Requi r e r epai r or r epl acement .


See not e ( 1) bel ow.

Adj ust i ng sl eeve t hr eads A Requi r e r epai r or r epl acement of


damaged sl eeve or t i e r od end.

Adj ust i ng sl eeve t hr eads A Requi r e r epl acement of sl eeve or


st r i pped ( t hr eads mi ssi ng) t i e r od end.

Bi ndi ng A Fur t her i nspect i on r equi r ed.


* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 55)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
See not e ( 2) bel ow.

Gr ease boot cr acked Suggest r epl acement . See not e ( 3) .

Gr ease boot mi ssi ng Suggest r epl acement . See not e ( 4) .

Gr ease boot t or n Suggest r epl acement . See not e ( 5) .

Gr ease f i t t i ng br oken A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng won' t seal A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease seal mi ssi ng B, 2 Suggest r epl acement of seal .


See not e ( 4) bel ow.

Gr ease seal t or n B, 2 Suggest r epl acement of seal .


See not e ( 5) bel ow.

Gr easeabl e t i e r od end B, 2 Suggest r epl acement of gr ease


wi l l not t ake gr ease f i t t i ng. See not e ( 6) bel ow.

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 7) .


hor i zont al movement )

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Looseness exceeds B Requi r e r epl acement .


manuf act ur er ' s specs

Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 7)


and ( 8) , caut i on.

Nut on st ud l oose A Requi r e r epai r or r epl acement of


nut . See not e ( 9) bel ow.

Sei zed A Requi r e r epl acement

St ud bent B Requi r e r epl acement . See not e ( 10)

St ud br oken A Requi r e r epl acement . See not e ( 10)

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 10)
mi ssi ng)

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 56)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
NOTE: ( 1) Onl y r equi r ed i f t oe needs t o be adj ust ed.
( 2) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt
i s non- gr easeabl e, r equi r e r epl acement .
( 3) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 4) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 5) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 6) I f gr easeabl e t i e r od end wi l l not t ake gr ease af t er
r epl aci ng t he gr ease f i t t i ng, suggest r epl acement of
t i e r od end.
( 7) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
( 8) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 9) Check f or bent st ud or damaged t aper hol e.
( 10) Check f or damaged t aper hol e.

TRACK BARS
TRACK BARS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace t r ack bar .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace t r ack bar .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace t r ack bar .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
t r ack bar .

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace t r ack bar .

Bent B Requi r e r epl acement .

Cor r oded, af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 57)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 1) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 3) .

Hol es di st or t ed A Requi r e r epl acement .

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 4)


hor i zont al movement ) bel ow.

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 4)


and ( 5) , caut i on.

Nut on st ud l oose A Requi r e r epai r or r epl acement of


nut . See not e ( 6) bel ow.

Sei zed A Requi r e r epl acement .

St ud bent B Requi r e r epl acement . See not e ( 7) .

St ud br oken A Requi r e r epl acement . See not e ( 7) .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 7) .


mi ssi ng)

Wear exceeds manuf act ur er ' s B Requi r e r epl acement .


speci f i cat i ons

NOTE: ( 1) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt


and wi l l accel er at e wear .
( 2) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 3) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt and
wi l l accel er at e wear .
( 4) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
( 5) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 6) Check f or bent st ud or damaged t aper hol e.
( 7) Check f or damaged t aper hol e.

TRAILING ARMS
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 58)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
TRAI LI NG ARMS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace t r ai l i ng ar m.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace t r ai l i ng ar m.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace t r ai l i ng ar m.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
t r ai l i ng ar m.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace t r ai l i ng ar m.

Bent B Requi r e r epl acement .

Bushi ng hol e over si zed B Requi r e r epl acement .

Cor r oded, af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y

Hol es di st or t ed A Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

WHEEL ALIGNMENT
WHEEL ALIGNMENT
Wheel al i gnment i s def i ned as t he measur ement , anal ysi s, and
adj ust ment of st eer i ng and suspensi on angl es t o conf or mt o OEM
speci f i cat i ons. These angl es usual l y i ncl ude, but ar e not l i mi t ed t o:
cast er , camber , t oe, and t hr ust angl e. Wher e t hese angl es ar e not
adj ust abl e and not i n speci f i cat i on, component r epl acement or
cor r ect i on ki t s may be r equi r ed. Er r or s i n set - back and st eer i ng axi s
i ncl i nat i on ( SAI ) ar e of t en at t r i but abl e t o f ai l ed or damaged
component s and must be cor r ect ed pr i or t o per f or mi ng an al i gnment .
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 59)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
Fai l ur e t o r epl ace or cor r ect suggest ed or r equi r ed par t s or
ser vi ce may pr event a pr oper al i gnment .
Bef or e per f or mi ng an al i gnment check, i nspect and ver i f y t he
f ol l owi ng:
* Ti r e pr essur e and si ze
* Vehi cl e l oadi ng
* Ri de hei ght
* St eer i ng and suspensi on par t s
Onl y i f t he i nspect i on r eveal s t hat al l t he above ar e wi t hi n
publ i shed speci f i cat i ons, shoul d a wheel al i gnment check and an
al i gnment , i f needed, be per f or med.
CAUTI ON: Under no ci r cumst ances shoul d a t echni ci an bend or heat any
st eer i ng or suspensi on component , unl ess speci f i ed by t he
vehi cl e manuf act ur er , f or exampl e, For d f or ged t wi n " I " beam
axl es. Al l measur ement s and suggest i ons must be not ed on t he
i nspect i on r epor t .
WHEEL ALI GNMENT

Condi t i on Code Pr ocedur e

Dog t r acki ng, shown t o be B, 2 Suggest r epai r .


caused by f aul t y al i gnment

Lead, shown t o be caused B Requi r e al i gnment .


by f aul t y al i gnment

Par t has been changed t hat B Requi r e al i gnment check.


may af f ect al i gnment

Pul l , shown t o be caused B Requi r e al i gnment .


by f aul t y al i gnment

St eer i ng wheel of f - cent er B, 2 Suggest al i gnment .

Ti r e wear , shown t o be B Requi r e al i gnment .


caused by f aul t y al i gnment

Wander , shown t o be caused B Requi r e al i gnment .


by f aul t y al i gnment

WHEEL BEARINGS, RACES, & SEALS


NOTE: When r epl aci ng or r epacki ng wheel bear i ngs, gr ease seal
r epl acement i s r equi r ed. You ar e not r equi r ed t o r epl ace
t hese component s i n axl e set s. Det er mi ne t he need t o r epl ace
based upon t he i ndi vi dual component condi t i ons t hat f ol l ow.
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 60)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
WHEEL BEARI NGS, RACES, & SEALS

Condi t i on Code Pr ocedur e

Rear axl e seal on r ear - A Requi r e r epl acement of seal and


wheel dr i ve l eaki ng i nspect i on of axl e, bear i ng,
housi ng, and vent t ube

Seal bent A, 1 Suggest r epl acement .

Seal l eaki ng A Requi r e r epl acement of seal and


i nspect i on of bear i ngs.

Seal mi ssi ng C Requi r e r epl acement .

Seal t or n A Requi r e r epl acement .

Wheel bear i ng assembl y A Requi r e r epl acement of bear i ng


f eel s r ough when r ot at ed assembl y.

Wheel bear i ng bal l s ar e A Requi r e r epl acement of bear i ng


pi t t ed assembl y.

Wheel bear i ng bal l s ar e A Requi r e r epl acement of bear i ng


wor n assembl y.

Wheel bear i ng end- pl ay A Requi r e adj ust ment of bear i ng, i f


exceeds vehi cl e possi bl e. I f pr oper adj ust ment
manuf act ur er ' s specs cannot be obt ai ned, r equi r e r epai r
or r epl acement of wor n component .

Wheel bear i ng r ace i s l oose A Requi r e r epl acement of hub


i n t he hub bor e assembl y and wheel bear i ngs.

Wheel bear i ng r aces ar e A Requi r e r epl acement of bear i ng


pi t t ed assembl y.

Wheel bear i ng r aces ar e A Requi r e r epl acement of bear i ng


wor n assembl y.

Wheel bear i ng r ol l er s ar e A Requi r e r epl acement of bear i ng


pi t t ed assembl y.

Wheel bear i ng r ol l er s ar e A Requi r e r epl acement of bear i ng


wor n assembl y.

WHEELS & TIRES


TIRES
WARNI NG: These gui del i nes do not appl y t o spl i t r i ms.
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 61)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
Some vehi cl e manuf act ur er s r est r i ct r epl acement of t i r es t o
speci f i c br ands, t ypes, or si zes.
Hi gh pr essur e t empor ar y compact spar e t i r es shoul d not be
used wi t h any ot her r i ms or wheel s, nor shoul d st andar d t i r es, snow
t i r es, wheel cover s, or t r i mr i ngs be used wi t h hi gh pr essur e compact
spar e r i ms or wheel s.
At t empt i ng t o mount a t i r e of one di amet er on a wheel of a
di f f er ent di amet er or f l ange t ype may r esul t i n ser i ous i nj ur y or
deat h.
Onl y speci al l y t r ai ned per sons shoul d de- mount or mount
t i r es. Expl osi ons of t i r e and wheel assembl y can r esul t f r omi mpr oper
mount i ng, possi bl y causi ng ser i ous i nj ur y or deat h.
Consul t t he vehi cl e owner ' s manual or vehi cl e pl acar d f or
cor r ect si ze, speed r at i ng, desi gnat i on, and col d i nf l at i on pr essur e
of t he or i gi nal t i r es. DO NOT exceed t he maxi muml oad or i nf l at i on
capaci t y of t he t i r e speci f i ed by t he Ti r e and Ri mAssoci at i on
When r epl aci ng t i r es, i t i s suggest ed t hat t he r epl acement
t i r es mat ch or exceed t he OEM speed r at i ng desi gnat i on. I f t i r es of
di f f er ent speed r at i ng desi gnat i ons ar e mi xed on t he same vehi cl e, t he
t i r es may var y i n handl i ng char act er i st i cs. DO NOT mi x di f f er ent speed
r at i ng desi gnat i ons on t he same axl e.
DO NOT mi x r adi al s wi t h non- r adi al t i r es on t he same axl e, as
t hi s may af f ect vehi cl e handl i ng and st abi l i t y. I f r adi al t i r es and
bi as or bi as- bel t ed pl y t i r es ar e mi xed on t he same vehi cl e, t he
r adi al s must be on t he r ear . Hi gh- pr essur e t empor ar y compact spar e
t i r es ar e exempt f r omt hi s r ul e.
DO NOT mi x si ze or t ype ( al l season, per f or mance, mud and
snow) of t i r es on t he same axl e.
TI RES

Condi t i on Code Pr ocedur e

Ai r pr essur e i ncor r ect B Requi r e r epai r

Bead br oken A Requi r e r epl acement .

Bead l eaki ng, caused by t i r e A Requi r e r epai r or r epl acement .

Bead wi r e/ cor d exposed A Requi r e r epl acement .

Cor d or bel t mat er i al exposed A Requi r e r epl acement .

Cor d pl y separ at i ons A Requi r e r epl acement .

Di r ect i onal / asymmet r i cal t i r es B Requi r e r emount i ng and/ or


mount ed i ncor r ect l y r eposi t i oni ng.

I r r egul ar t r ead wear , A Suggest r epl acement .


af f ect i ng per f or mance See not e ( 1) bel ow.

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 62)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
Load r at i ngs l ess t han OEM B Requi r e r epl acement .
speci f i cat i ons

Mi xed t i r e si ze desi gnat i ons A Requi r e r ot at i on or


on same axl e r epl acement .

Mi xed t r ead t ypes ( al l season, A Requi r e r ot at i on or


per f or mance, mud and snow) r epl acement .
on same axl e

Number of punct ur es exceeds B Requi r e r epl acement .


manuf act ur er ' s l i mi t

Out of bal ance B Requi r e r ebal ance of t i r e/ wheel


assembl y.

Pl y separ at i on A Requi r e r epl acement .

Pul l or l ead, caused by t i r e A Requi r e r ot at i on or


r epl acement .

Radi al and bi as or bi as- bel t ed B Requi r e r ot at i on or


pl y t i r es on same axl e r epl acement .

Radi al s ar e on t he f r ont and B Requi r e r ot at i on or


not on t he r ear r epl acement . See not e ( 2) .

Run f l at damage A Requi r e r epl acement .

Shoul der cut A Requi r e r epl acement .

Shoul der punct ur e A Requi r e r epl acement .

Shoul der wi t h pl ug A Requi r e r epl acement .

Si dewal l bul ge A Requi r e r epl acement .

Si dewal l cut A Requi r e r epl acement .

Si dewal l i ndent at i on No ser vi ce r equi r ed/ suggest ed.

Si dewal l punct ur e A Requi r e r epl acement .

Si dewal l wi t h pl ug A Requi r e r epl acement .

Speed r at i ng desi gnat i ons B Suggest r ot at i on or


di f f er ent on same axl e r epl acement .

Ti r e and wheel assembl y has B Requi r e r epai r or r epl acement


excessi ve r un- out of appr opr i at e par t . See not e
( 3) bel ow.

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 63)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
Ti r es wi t h mor e t han 1/ 4" B Requi r e r epl acement .
di amet er di f f er ence on a
f our - wheel dr i ve vehi cl e

Tr ead ar ea punct ur e l ar ger i n B Requi r e r epl acement .


di amet er t han t i r e
manuf act ur er ' s speci f i cat i ons

Tr ead mi ssi ng pi eces A Requi r e r epl acement .


( chunki ng) , exposi ng cor d

Tr ead mi ssi ng pi eces A Suggest r epl acement .


( chunki ng) , not exposi ng cor d

Tr ead separ at i ons A Requi r e r epl acement .

Tube i n t ubel ess t i r e C, 3 Suggest r emoval of t ube.


See not e ( 4) bel ow.

Weat her - checki ng No ser vi ce r equi r ed/ suggest ed.

Wor n t o t r ead wear i ndi cat or s B Requi r e r epl acement .

NOTE: ( 1) Det er mi ne and cor r ect cause of i r r egul ar t i r e wear .


( 2) I f r adi al s and bi as or bi as- bel t ed pl y t i r es ar e on t he same
vehi cl e, t he r adi al s must be on t he r ear axl e, except f or
hi gh- pr essur e t empor ar y spar es.
( 3) Excessi ve i s def i ned as enough t o cont r i but e t o per f or mance
pr obl ems. Mat ch mount i ng may cor r ect r un- out . I f not ,
r equi r e r epl acement of appr opr i at e par t . Ref er t o
manuf act ur er ' s speci f i cat i ons.
( 4) Most manuf act ur er s do not r ecommend t ubes i n t ubel ess t i r es.
I nspect t i r e and wheel assembl y t o det er mi ne t he r eason f or
a t ube i n t ubel ess t i r e. Recommendat i on f or r epai r or
r epl acement shoul d be based upon condi t i on of t i r es and/ or
wheel l i st ed i n t hese gui del i nes.

VALVE STEMS
VALVE STEMS

Condi t i on Code Pr ocedur e

Bent A, 1 Suggest r epl acement .

Br oken A Requi r e r epl acement .

Cut , but not l eaki ng A, 1 Suggest r epl acement .

Det er i or at ed ( cr acki ng, dr y r ot ) A, 1 Suggest r epl acement .

* SUSPENSION UNIFORM INSPECTION GUIDELINES *


Article Text (p. 64)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
Leaki ng A Requi r e r epai r / r epl acement .

Mi ssi ng C Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r / r epl acement .

Thr eads st r i pped ( t hr eads mi ssi ng) A Requi r e r epl acement .

Val ve cap mi ssi ng C Requi r e r epl acement of cap.

Weat her - checki ng A, 1 Suggest r epl acement .

Won' t t ake ai r A Requi r e r epai r / r epl acement .

WHEEL ATTACHMENT HARDWARE


For condi t i ons not ed bel ow, al so check condi t i ons of wheel
st ud hol es.
CAUTI ON: Pr oper l ug nut t or que i s essent i al . Fol l ow manuf act ur er ' s
t or que speci f i cat i ons and t i ght eni ng sequence. DO NOT
l ubr i cat e t hr eads unl ess speci f i ed by t he vehi cl e
manuf act ur er .
WHEEL ATTACHMENT HARDWARE

Condi t i on Code Pr ocedur e

Bent A Requi r e r epl acement .

Br oken A Requi r e r epl acement .


See not e ( 1) bel ow.

Loose B Requi r e r epai r or r epl acement


of af f ect ed component .

Lug nut i nst al l ed backwar d B Requi r e r epai r .

Lug nut mat i ng t ype i ncor r ect B Requi r e r epl acement of nut .

Lug nut mat i ng sur f ace di shed A Requi r e r epl acement of nut .

Lug nut f l at s r ounded A Requi r e r epl acement of nut .


See not e ( 2) bel ow.

Lug nut sei zed A Requi r e r epl acement of nut


and/ or st ud. See not e ( 2) bel ow.

St ud i ncor r ect B Requi r e r epl acement of st ud.

Thr eads damaged A Requi r e r epai r or r epl acement of


* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 65)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM
component wi t h damaged t hr eads.

Thr eads st r i pped ( t hr eads A Requi r e r epl acement of


mi ssi ng) component wi t h st r i pped t hr eads.

NOTE: ( 1) Some manuf act ur er s r equi r e r epl acement of al l st uds on t hat


wheel i f t wo or mor e st uds or nut s on t he same wheel ar e
br oken or mi ssi ng.
( 2) Onl y r equi r ed i f r emovi ng wheel .

WHEELS
WARNI NG: Mount i ng a r egul ar t i r e on a hi gh- pr essur e compact spar e
wheel i s not per mi t t ed. At t empt i ng t o mount a t i r e of one
di amet er on a wheel of a di f f er ent di amet er or f l ange t ype
may r esul t i n ser i ous i nj ur y or deat h. I f t he wheel
i dent i f i cat i on st amp i s not l egi bl e, or cannot be f ound,
DO NOT use t he wheel unt i l t he si ze and t ype have been
pr oper l y i dent i f i ed. Wheel s of di f f er ent di amet er , of f set ,
or wi dt h cannot be mi xed on t he same axl e. Bead seat t aper s
cannot be i nt er changed.
WHEELS

Condi t i on Code Pr ocedur e

Bead l eaki ng, caused by A Requi r e r epai r or r epl acement .


wheel r i mf l ange See caut i on bel ow.

CAUTI ON: DO NOT at t empt t o cor r ect a bent wheel r i m.

Bent wheel hub mount i ng A Requi r e r epl acement .


sur f ace

Bent wheel r i m, causi ng B, 2 Suggest r epl acement .


vi br at i on See caut i on above.

Br oken A Requi r e r epl acement .

Cast wheel por ous, causi ng A Requi r e r epai r or r epl acement .


a l eak

Cl i p- on bal ance wei ght i s B, 2 Suggest r epl acement .


i ncor r ect t ype f or wheel
r i mf l ange

Cor r osi on, af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y

Cor r osi on bui l d- up on wheel A Requi r e r epai r .


hub mount i ng sur f ace
* SUSPENSION UNIFORM INSPECTION GUIDELINES *
Article Text (p. 66)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:58PM

Cr acked A Requi r e r epl acement .

Di r ect i onal / asymmet r i cal B Requi r e r emount i ng and/ or


wheel s mount ed i ncor r ect l y r eposi t i oni ng.

Load capaci t y l ess t han B Requi r e r epl acement .


OEM speci f i cat i ons

Of f set mi smat ched on same B Requi r e r epl acement .


axl e

Ri vet s l eaki ng A Requi r e r epl acement .

Run- out beyond OEM specs B Requi r e r epl acement .

St ud hol es el ongat ed A Requi r e r epl acement . See not e ( 1)

Wel ded or br azed r epai r B, 2 Suggest r epl acement .

Wel ds l eaki ng A Requi r e r epl acement .

Wheel hub cent er i ng ( pi l ot ) B Requi r e r epl acement .


hol e i ncor r ect

NOTE: ( 1) I nspect wheel at t achi ng har dwar e f or damage.

END OF ARTICLE
STEERING SYSTEM - POWER RACK & PINION
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
ARTICLE BEGINNING
1995- 96 STEERI NG
Vol kswagen - Power Rack & Pi ni on
Gol f I I I
DESCRIPTION & OPERATION
Syst emconsi st s of a vane pump, r ack and pi ni on st eer i ng
gear , and an oi l r eser voi r . Vane pump dr aws f l ui d f r omr eser voi r and
suppl i es i t t o f l ow cont r ol val ve. Cont r ol val ve di r ect s f l ui d t o
appr opr i at e si de of r ack pi st on.
LUBRICATION
CAPACITY
Fl ui d capaci t y i s about 1 qt . ( . 95L) .
FLUID TYPE
Recommended f l ui d t ype i s VWHydr aul i c Oi l No. G 002 000.
FLUID LEVEL CHECK
Remove r eser voi r cover . St ar t engi ne and l et i t i dl e. Fl ui d
l evel shoul d be bet ween MI N and MAX mar ks on r eser voi r .
HYDRAULIC SYSTEM BLEEDING
1) St ar t engi ne and l et i t i dl e. Fi l l f l ui d r eser voi r t o MAX
mar k. Tur n st eer i ng wheel l ef t and r i ght sever al t i mes t o br i ng f l ui d
t o nor mal oper at i ng t emper at ur e.
CAUTI ON: DO NOT hol d st eer i ng wheel t o l ef t or r i ght l ock f or l onger
t han 5 seconds, or oi l pump damage may occur .
2) Add f l ui d t o MAX mar k as needed dur i ng bl eedi ng pr ocedur e.
Tur n st eer i ng wheel f r oml ock t o l ock. Repeat pr ocedur e unt i l ai r
bubbl es ar e no l onger pr esent i n f l ui d and f l ui d l evel st abi l i zes.
Shut of f engi ne.
ADJUSTMENTS
POWER STEERING PUMP BELT
NOTE: VR6 engi nes ar e equi pped wi t h a ser pent i ne bel t whi ch i s
aut omat i cal l y adj ust ed by t ensi oner .
4- Cyl i nder
STEERING SYSTEM - POWER RACK & PINION
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
Loosen nut s on pump mount i ng br acket . Tur n adj ust er bol t
unt i l bel t def l ect i on i s 62 I NCH l bs. ( 7 N. m) on new bel t , or 35 I NCH
l bs. ( 4 N. m) on used bel t .
TESTING
HYDRAULIC SYSTEM INSPECTION
Ensur e f l ui d l evel i s okay. See FLUI D LEVEL CHECK under
LUBRI CATI ON. Check power st eer i ng pump bel t condi t i on and adj ust ment .
See POWER STEERI NG PUMP BELT under ADJ USTMENTS. Ensur e hoses ar e not
ki nked or l eaki ng.
PUMP PRESSURE TEST
1) I nst al l Pr essur e Gauge ( US 1074 B) bet ween pr essur e hose
and pr essur e l i ne of val ve housi ng. See Fi g. 1. St ar t engi ne and l et
i t i dl e.
2) Cl ose pr essur e gauge val ve. Leave val ve cl osed f or no
l onger t han 5 seconds. Pr essur e shoul d be 85- 95 bar ( 1232- 1378 psi ) .
I f pump pr essur e i s not wi t hi n speci f i cat i on, r epl ace pump.
Fi g. 1: I dent i f yi ng Power Rack & Pi ni on Component s ( Typi cal )
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
STEERING GEAR INSPECTION
Remove r ack and pi ni on assembl y. See POWER RACK & PI NI ON
under REMOVAL & I NSTALLATI ON. Loosen l ock nut . Tur n adj ust er bol t
unt i l pi ni on shaf t can be t ur ned by hand wi t hout bi ndi ng. Hol d
adj ust er bol t i n posi t i on whi l e t i ght eni ng l ock nut .
STEERING SYSTEM - POWER RACK & PINION
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
REMOVAL & INSTALLATION
POWER STEERING PUMP
Removal
Remove gener at or and pump bel t s. Di sconnect hydr aul i c l i nes
f r ompump. Cap l i nes t o pr event cont ami nat i on. Remove br acket bol t s.
Remove pump. See Fi g. 2.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Adj ust bel t t ensi on.
See POWER STEERI NG PUMP BELT under ADJ USTMENTS. Ti ght en nut s and bol t s
t o speci f i cat i on. See TORQUE SPECI FI CATI ONS. Fi l l and bl eed hydr aul i c
syst em. See HYDRAULI C SYSTEM BLEEDI NG under LUBRI CATI ON. St ar t engi ne
and check f or l eaks.
Fi g. 2: I dent i f yi ng Power St eer i ng Pump Component s ( Typi cal )
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
POWER RACK & PINION
NOTE: Ref er t o i l l ust r at i on f or expl oded vi ew of power r ack and
pi ni on component s. See Fi g. 1.
Removal
1) Di sconnect r et ur n l i ne f r ompump. Dr ai n f l ui d f r ompump
and l i ne. Di sconnect t i e r od ends f r omst eer i ng knuckl es.
2) Suppor t engi ne and t r ansmi ssi on wi t h Engi ne Suppor t ( 10-
222A and 10- 222A/ 1 on 4- cyl i nder engi ne, or 10- 222A and 10- 222A/ 3 on
VR6 engi ne) . Remove st eer i ng gear boot . Remove t r ansmi ssi on mount
bol t s.
3) Di sconnect hydr aul i c l i nes f r omst eer i ng gear . Pl ug
openi ngs. Remove st eer i ng gear nut s. Remove st eer i ng gear . Lower
STEERING SYSTEM - POWER RACK & PINION
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:56PM
engi ne/ t r ansmi ssi on suf f i ci ent l y t o separ at e st eer i ng shaf t hal ves.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ti ght en nut s and bol t s
t o speci f i cat i on. See TORQUE SPECI FI CATI ONS. Fi l l and bl eed hydr aul i c
syst em. See HYDRAULI C SYSTEM BLEEDI NG. Check wheel al i gnment . See
WHEEL ALI GNMENT SPECI FI CATI ONS & PROCEDURES ar t i cl e i n WHEEL ALI GNMENT
sect i on.
OVERHAUL
Manuf act ur er r ecommends t hat power st eer i ng pump and st eer i ng
gear be r epl aced, r at her t han be r epai r ed.
TORQUE SPECIFICATIONS
TORQUE SPECI FI CATI ONS TABLE

Appl i cat i on Ft . Lbs. ( N. m)


Lower Val ve Body Nut
4- Cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ( 40)
Power St eer i ng Pump
Banj o Bol t
4- Cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ( 35)
VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
Mount i ng Bol t
4- Cyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ( 20)
VR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Pr essur e Li ne Fi t t i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
St eer i ng Gear
Adj ust i ng Pl ug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Br acket / Bushi ng Cl amp Nut . . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
Ti e Rod Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 ( 55)
Ti e Rod- To- St eer i ng Ar mNut . . . . . . . . . . . . . . . . . . . . . . 52 ( 70)

END OF ARTICLE
STEERING COLUMN
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
ARTICLE BEGINNING
1995- 96 STEERI NG
Vol kswagen - St eer i ng Col umns
Gol f I I I
WARNI NG: Al l model s ar e equi pped wi t h a Suppl ement al Rest r ai nt Syst em
( SRS) t hat i ncl udes an ai r bag l ocat ed i n st eer i ng wheel .
Use caut i on when wor ki ng ar ound st eer i ng col umn. Ensur e
bat t er y i s di sconnect ed bef or e at t empt i ng any r epai r . DO NOT
appl y el ect r i cal power t o any component on st eer i ng col umn
wi t hout di sconnect i ng ai r bag modul e ( ai r bag coul d depl oy) .
NOTE: For i nf or mat i on on ai r bag DI AGNOSI S & TESTI NG or DI SPOSAL
PROCEDURES, see appr opr i at e AI R BAG RESTRAI NT SYSTEM ar t i cl e
i n ACCESSORI ES/ SAFETY EQUI PMENT sect i on:
* AI R BAG RESTRAI NT SYSTEM - 1995
* AI R BAG RESTRAI NT SYSTEM - 1996
DESCRIPTION
St eer i ng col umn shaf t i s hel d t oget her by a nyl on but t on.
Dur i ng an acci dent , t he nyl on but t on shear s and upper par t of shaf t
sl i des down over l ower par t of shaf t . Thi s al l ows SRS t o mai nt ai n
pr oper al i gnment dur i ng i nf l at i on whi l e absor bi ng i mpact of col l i si on.
DISABLING & ACTIVATING AIR BAG SYSTEM
To di sabl e ai r bag syst em, di sconnect and i sol at e negat i ve
bat t er y cabl e. No wai t i ng t i me i s necessar y bef or e wor ki ng on vehi cl e.
To act i vat e syst em, t ur n i gni t i on swi t ch t o ON posi t i on and exi t
vehi cl e. Reconnect negat i ve bat t er y cabl e. Per f or ma syst em
oper at i onal check t o ensur e pr oper syst emoper at i on. See
SYSTEM OPERATI ON CHECK.
SERVICE PRECAUTIONS
Obser ve t hese pr ecaut i ons when wor ki ng wi t h ai r bag syst ems:
* Di sabl e ai r bag syst embef or e ser vi ci ng any ai r bag syst emor
st eer i ng col umn component . See DI SABLI NG & ACTI VATI NG AI R BAG
SYSTEM.
* Because of cr i t i cal oper at i ng r equi r ement s of syst em, DO NOT
at t empt t o ser vi ce any ai r bag syst emcomponent .
* Ai r bag par t s shoul d not be l ef t unat t ended. They shoul d be
i nst al l ed i n vehi cl e i mmedi at el y af t er r emovi ng t hemf r om
t hei r packagi ng.
* Ai r bag component s whi ch have been dr opped ont o a har d
sur f ace shoul d not be used.
STEERING COLUMN
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
* Chemi cal cl eaner s, oi l and gr ease shoul d not cont act vi nyl
cover i ng on ai r bag modul e.
* Al ways di sabl e ai r bag syst embef or e per f or mi ng el ect r i c
wel di ng on vehi cl e.
* Ai r bag syst emcan onl y be t est ed usi ng Di agnost i c Test er
( VAG 1551) . Never use t est l i ght on ai r bag syst em.
SYSTEM OPERATION CHECK
An ai r bag l i ght i s l ocat ed on l ef t si de of i nst r ument
cl ust er . Ai r bag l i ght i s used t o i ndi cat e r eadi ness of syst em. Li ght
gl ows when i gni t i on swi t ch i s on or engi ne i s st ar t ed. Li ght shoul d
st ay on about 3 seconds whi l e ai r bag cont r ol uni t per f or ms an
el ect r oni c t est of syst em.
I f ai r bag l i ght does not gl ow when i gni t i on i s on or does
not go out af t er 3 seconds, a f aul t pr obabl y exi st s i n syst em. I f a
f aul t occur s whi l e i gni t i on i s on, i t i s st or ed i n f aul t memor y.
War ni ng l i ght wi l l t hen gl ow and ai r bag syst emwi l l be swi t ched of f .
I f war ni ng l i ght gl ows or f l i cker s whi l e dr i vi ng, ai r bag syst em
shoul d be t est ed. See DI AGNOSI S & TESTI NG i n appr opr i at e AI R BAG
RESTRAI NT SYSTEM ar t i cl e i n ACCESSORI ES/ SAFETY EQUI PMENT sect i on.
* AI R BAG RESTRAI NT SYSTEM - 1995
* AI R BAG RESTRAI NT SYSTEM - 1996
ADJUSTMENTS
AIR BAG SPIRAL SPRING
To cent er spi r al spr i ng assembl y, t ur n spr i ng assembl y 3
t ur ns f r omst op i n ei t her di r ect i on.
REMOVAL & INSTALLATION
WARNI NG: Fai l ur e t o f ol l ow ai r bag ser vi ce pr ecaut i ons may r esul t i n
ai r bag depl oyment and per sonal i nj ur y. See SERVI CE
PRECAUTI ONS. Af t er component r epl acement , per f or ma syst em
oper at i onal check t o ensur e pr oper syst emoper at i on. See
SYSTEM OPERATI ON CHECK.
AIR BAG MODULE
Removal
1) Bef or e pr oceedi ng, f ol l ow ai r bag ser vi ce pr ecaut i ons. See
SERVI CE PRECAUTI ONS. Di sabl e ai r bag syst em. See DI SABLI NG &
ACTI VATI NG AI R BAG SYSTEM.
2) Ai r bag modul e i s l ocat ed i n st eer i ng wheel . See Fi g. 1.
Remove ai r bag modul e Tor x head scr ews f r omr ear of st eer i ng wheel .
Li f t of f ai r bag modul e f r omst eer i ng wheel , and t i l t ai r bag modul e
downwar d. Di sconnect ai r bag modul e connect or .
STEERING COLUMN
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ti ght en ai r bag modul e
r et ai ni ng scr ews t o speci f i cat i on. See TORQUE SPECI FI CATI ONS.
React i vat e ai r bag syst em. See DI SABLI NG & ACTI VATI NG AI R BAG SYSTEM.
Check ai r bag i ndi cat or l i ght s t o ensur e syst emi s f unct i oni ng
pr oper l y. See SYSTEM OPERATI ON CHECK.
Fi g. 1: Expl oded Vi ew Of SRS Component s
Cour t esy of Vol kswagen of Uni t ed St at es, I nc.
IGNITION SWITCH
Removal & I nst al l at i on
1) Remove st eer i ng wheel . See STEERI NG WHEEL. Remove l ower
cover f r omst eer i ng col umn.
2) Remove t ur n si gnal and wi ndshi el d wi per swi t ches. See TURN
SI GNAL SWI TCH and WI NDSHI ELD WI PER SWI TCH. Remove l ock washer , spr i ng
and hor n cont act r i ng. Remove st eer i ng col umn t ube- t o- st eer i ng col umn
housi ng bol t .
3) Di sconnect i gni t i on swi t ch connect or . Unl ock st eer i ng wi t h
i gni t i on key. Remove st eer i ng col umn housi ng, i gni t i on l ock and upper
hal f of st eer i ng col umn swi t ch cover . Remove and i gni t i on swi t ch scr ew
and i gni t i on swi t ch. To i nst al l i gni t i on swi t ch, r ever se r emoval
pr ocedur e.
SPIRAL SPRING
Removal
1) Bef or e pr oceedi ng, f ol l ow ai r bag ser vi ce pr ecaut i ons. See
SERVI CE PRECAUTI ONS. Di sabl e ai r bag syst em. See DI SABLI NG &
ACTI VATI NG AI R BAG SYSTEM.
2) Remove ai r bag modul e. See AI R BAG MODULE. Remove st eer i ng
STEERING COLUMN
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
wheel . See STEERI NG WHEEL. Remove knee bar panel and st eer i ng col umn
l ower t r i m. Di sconnect 2- pi n connect or at base of st eer i ng col umn.
Remove 3 spi r al spr i ng scr ews, and r emove spi r al spr i ng. See Fi g. 2.
Fi g. 2: I nst al l i ng Spi r al Spr i ng
Cour t esy of Vol kswagen of Uni t ed St at es, I nc.
I nst al l at i on
1) New spi r al spr i ng assembl i es have a cabl e t i e whi ch l ocks
assembl y i n i t s cent er ed posi t i on. Cabl e t i e must be r emoved bef or e
i nst al l i ng new spr i ng assembl y.
2) I f a spi r al spr i ng assembl y i s r ei nst al l ed, i t must be
cent er ed. To cent er , t ur n spr i ng assembl y 4 t ur ns f r omst op, i n ei t her
di r ect i on.
3) To i nst al l spi r al spr i ng assembl y, r ever se r emoval
pr ocedur e. React i vat e ai r bag syst em. See DI SABLI NG & ACTI VATI NG AI R
BAG SYSTEM. Check ai r bag i ndi cat or l i ght s t o ensur e syst emi s
f unct i oni ng pr oper l y. See SYSTEM OPERATI ON CHECK.
STEERING COLUMN
WARNI NG: Remove ai r bag f r omvehi cl e bef or e wor ki ng on st eer i ng
col umn. See AI R BAG MODULE. Fai l ur e t o r emove ai r bag may
r esul t i n per sonal i nj ur y.
NOTE: Ref er t o appr opr i at e i l l ust r at i on f or expl oded vi ew of
st eer i ng col umn. See Fi g. 3 or 4.
STEERING COLUMN
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
Removal
1) Di sconnect negat i ve bat t er y cabl e. Remove st eer i ng wheel .
See STEERI NG WHEEL. Remove bol t and scr ew f r omswi t ch housi ng r ecess.
Ti l t swi t ch uni t t owar d i nst r ument panel . Pr y spacer sl eeve f r om
col umn.
2) Pul l up combi nat i on swi t ch t o di sconnect connect or . Remove
combi nat i on swi t ch. Di sconnect st eer i ng shaf t f r om" U" j oi nt shaf t .
Di sconnect br ake pedal push r od.
3) Di sconnect cl ut ch cabl e f r omcl ut ch pedal ( i f equi pped) .
Remove st eer i ng col umn bol t s under i nst r ument panel . Dr i l l out shear
bol t s. Remove col umn assembl y f r omvehi cl e.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Pl ace wheel s i n
st r ai ght - ahead posi t i on. Ti ght en pi nch bol t . I nst al l spacer . I nst al l
combi nat i on swi t ch and st eer i ng wheel . Adj ust br ake pedal and cl ut ch
pedal hei ght .
STEERING WHEEL
CAUTI ON: Appl yi ng excessi ve pr essur e or causi ng i mpact t o mai nshaf t
dur i ng ser vi ce may cause t he col umn t o di sengage.
Removal
1) Bef or e pr oceedi ng, f ol l ow ai r bag ser vi ce pr ecaut i ons. See
SERVI CE PRECAUTI ONS. Di sabl e ai r bag syst em. See DI SABLI NG &
ACTI VATI NG AI R BAG SYSTEM.
2) Tur n f r ont wheel s t o st r ai ght - ahead posi t i on. Remove ai r
bag modul e. See AI R BAG MODULE. Remove st eer i ng wheel nut and spr i ng
washer . Mar k st eer i ng wheel and shaf t f or r eassembl y r ef er ence. Remove
st eer i ng wheel .
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Ti ght en st eer i ng wheel
nut t o speci f i cat i on. See TORQUE SPECI FI CATI ONS. React i vat e ai r bag
syst em. See DI SABLI NG & ACTI VATI NG AI R BAG SYSTEM. Check ai r bag
i ndi cat or l i ght s t o ensur e syst emi s f unct i oni ng pr oper l y. See SYSTEM
OPERATI ON CHECK.
TURN SIGNAL SWITCH
Removal & I nst al l at i on
Remove st eer i ng wheel . See STEERI NG WHEEL. Di sconnect t ur n
si gnal swi t ch connect or . Remove t ur n si gnal swi t ch. To i nst al l ,
r ever se r emoval pr ocedur e.
WINDSHIELD WIPER SWITCH
Removal & I nst al l at i on
Remove st eer i ng wheel . See STEERI NG WHEEL. Remove t ur n si gnal
swi t ch. See TURN SI GNAL SWI TCH. Di sconnect wi ndshi el d wi per swi t ch
STEERING COLUMN
Article Text (p. 6)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
connect or . Remove wi ndshi el d wi per swi t ch. To i nst al l , r ever se r emoval
pr ocedur e.
OVERHAUL
STEERING COLUMN
NOTE: Ref er t o appr opr i at e i l l ust r at i on f or expl oded vi ew of
st eer i ng col umn. See Fi g. 3.
Fi g. 3: Expl oded Vi ew Of St eer i ng Col umn
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
Di sassembl y
Pr ess st eer i ng shaf t ( col umn) f r omcol umn t ube. Remove
bear i ngs f r omst eer i ng shaf t .
I nspect i on
Check upper br acket f or damage and upper bear i ng f or smoot h
r ot at i on. Check shaf t s f or si gns of bendi ng, damaged spl i nes, or
damaged " U" j oi nt s. Check col umn t ube f or bendi ng or ot her damage.
Repai r or r epl ace component s as necessar y.
Reassembl y
Pr ess i n st eer i ng shaf t and new bear i ngs. DO NOT use mor e
t han 200 l bs. ( 90 kg) f or ce t o pr ess shaf t and bear i ngs i nt o col umn
t ube.
"U" JOINT SHAFT
Di sassembl y
1) Remove l ower " U" j oi nt shaf t - t o- st eer i ng gear pi ni on shaf t
pi nch bol t . Separ at e manual gear shi f t l i nkage f r omst eer i ng box ( i f
equi pped) . Remove st eer i ng gear nut s.
STEERING COLUMN
Article Text (p. 7)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
2) Pul l box down t o separ at e f r oml ower " U" j oi nt . Remove
r ubber boot f r oml ower " U" j oi nt . Remove upper " U" j oi nt pi nch bol t .
Pul l down j oi nt and r emove shaf t wi t h " U" j oi nt s.
I nspect i on
I nspect " U" j oi nt s f or wear or excessi ve pl ay. I f abnor mal
wear or pl ay exi st s, r epl ace as necessar y.
Reassembl y
1) Fi t " U" j oi nt t o st eer i ng shaf t . Al i gn st eer i ng shaf t
not ch wi t h l ower " U" j oi nt sl ot . I nst al l boot and dampi ng gr ommet . Fi t
st eer i ng box t o f r ame whi l e gui di ng pi ni on shaf t i nt o l ower " U" j oi nt .
2) Hand- t i ght en st eer i ng gear r et ai ni ng nut s. Pl ace wheel s i n
st r ai ght - ahead posi t i on. Al i gn st eer i ng shaf t ( col umn) and " U" j oi nt .
Ti ght en pi nch bol t . Ti ght en st eer i ng gear nut s. Connect gear shi f t
l i nkage. Check l i nkage f or smoot h oper at i on.
TORQUE SPECIFICATIONS
TORQUE SPECI FI CATI ONS TABLE

Appl i cat i on Ft . Lbs. ( N. m)


Pi nch Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
Shear Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
St eer i ng Col umn- To- I nst r ument Panel Bol t . . . . . . . . . 16 ( 22)
St eer i ng Gear Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
St eer i ng Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
I NCH Lbs. ( N. m)
Ai r Bag Modul e- To- St eer i ng Wheel Scr ews . . . . . . . . . 57 ( 6. 5)
( 1) - Ti ght en unt i l bol t head snaps of f .

END OF ARTICLE
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
ARTICLE BEGINNING
GENERAL I NFORMATI ON
St eer i ng & Suspensi on Syst ems - ( I ncl udi ng Wheel s & Ti r es)
Al l Makes & Model s
Updat ed: J anuar y, 1997
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Mot or i st Assur ance Pr ogr am( MAP) i s t he consumer out r each
ef f or t of t he Aut omot i ve Mai nt enance and Repai r Associ at i on, I nc.
( AMRA) . Par t i ci pat i on i n t he Mot or i st Assur ance Pr ogr ami s dr awn f r om
r et ai l er s, suppl i er s, i ndependent r epai r f aci l i t i es, vehi cl e
manuf act ur er s and i ndust r y associ at i ons.
The Mot or i st Assur ance Pr ogr amwas est abl i shed as an
i ndust r y- wi de ef f or t t o addr ess concer ns r ai sed by r egul at or s, t he
medi a and consumer s quest i oni ng our et hi cs and met hods of doi ng
busi ness. The aut omot i ve r epai r i ndust r y had been bombar ded by mont hs
of negat i ve st or i es i n t he medi a and scr ut i ny f r omst at e and f eder al
r egul at or s who f ocused on how t he need f or r epai r s i s det er mi ned. MAP
was f or med as an i ndust r y r esponse t o t hi s i ssue.
Our mi ssi on i s t o st r engt hen t he r el at i onshi p bet ween t he
consumer and t he aut o r epai r i ndust r y. We pr oduce mat er i al s t hat gi ve
mot or i st s t he i nf or mat i on and encour agement t o t ake r esponsi bi l i t y f or
t hei r vehi cl es - t hr ough pr oper , manuf act ur er - r ecommended,
mai nt enance. We encour age par t i ci pat i nf ser vi ce and r epai r shops
( i ncl udi ng f r anchi sees and deal er s) t o adopt a Pl edge t o t hei r
Cust omer s and t he Mot or i st Assur ance Pr ogr amdevel oped St andar ds of
Ser vi ce. Al l par t i ci pat i ng ser vi ce pr ovi der s have agr eed t o subscr i be
t o t hi s Pl edge and t o adher e t o t he pr omul gat ed St andar ds of Ser vi ce
whi ch demonst r at es t o t hei r cust omer s t hat t hey ar e ser i ous about
cust omer sat i sf act i on.
These St andar ds of Ser vi ce r equi r e t hat an i nspect i on of t he
vehi cl e' s ( pr obl em) syst embe made accor di ng t o i ndust r y gui del i nes.
Af t er l ear ni ng t hat nei t her t he car manuf act ur er s nor any ot her sour ce
had compl et e gui del i nes, l eadi ng i ndust r y or gani zat i ons, al ong wi t h
ot her i ndust r y par t i ci pant s banded t oget her t o addr ess t hi s
chal l engi ng t ask. Dur i ng t he past t wo and a hal f year s, t hey
successf ul l y devel oped i ndust r y i nspect i on gui del i nes f or t he
f ol l owi ng syst ems: Exhaust , Br akes, ABS, St eer i ng and Suspensi on,
Engi ne Mai nt enance and Per f or mance, HVAC, and El ect r i cal syst ems.
Gui del i nes f or Dr i ve Tr ai n and Tr ansmi si on ar e cur r ent l y bei ng
pr omul gat ed. Revi si ons t o t he i nspect i on gui del i nes f or Exhaust ,
Br akes/ ABS and St eer i ng and Suspensi on Syst ems, whi ch wer e i ssued t wo
year s ago, ar e now bei ng publ i shed f or i mpl ement at i on begi nni ng spr i ng
1997. Par t i ci pat i ng shops ut i l i ze t hese Uni f or mI nspect i on Gui del i nes
as par t of t he i nspect i on pr ocess and f or communi cat i ng t hei r f i ndi ngs
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
t o t hei r cust omer s.
The Mot or i st Assur ance Pr ogr amcont i nues t o wor k
cooper at i vel y and pr oact i vel y wi t h gover nment agenci es and consumer
gr oups t owar d sol ut i ons t hat bot h benef i t t he cust omer and ar e
mut ual l y accept abl e t o bot h r egul at or s and i ndust r y. We mai nt ai n t he
bel i ef t hat i ndust r y must r et ai n cont r ol over how we conduct our
busi ness, and we must be vi ewed as par t of t he sol ut i on and not par t
of t he pr obl em. Meet i ngs wi t h st at e and ot her gover nment of f i ci al s
concer ned wi t h aut o r epai r and/ or consumer pr ot ect i on ar e conduct ed.
Feedback f r omt hese r epr esent at i ves ar e br ought back t o member s, and
t he pr ogr amadj ust ed as needed.
To assur e aut o r epai r cust omer s r ecour se i f t hey wer e not
sat i sf i ed wi t h a r epai r t r ansact i on, t he Mot or i st Assur ance Pr ogr am
of f er s ar bi t r at i on t hr ough MAP/ BBB- CARE i n cooper at i on wi t h t he
Counci l of Bet t er Busi ness Bur eaus and i ndi vi dual par t i ci pat i ng
Bur eaus. MAP " pi l ot ed" i n I ndi anapol i s and Pi t t sbur gh dur i ng spr i ng,
1996 - and publ i ci zed " r ol l - out s" i n New J er sey, Det r oi t ( MI ) , Chi cago
( I L) and Ri chmond ( VA) wer e conduct ed. To put some " t eet h" i n t he
pr ogr am, and accr edi t at i on r equi r ement f or shops was i ni t i at ed. The
r equi r ement s ar e st r i ngent and a sel f - pol i ci ng met hod has been
i ncor por at ed whi ch i ncl udes t he " myst er y shoppi ng" of out l et s. I n
addi t i on, a commi t t ee of ser vi ce pr ovi der s had been wor ki ng di l i gent l y
devel opi ng st andar ds f or newspaper , t el evi si on and I nt er net
adver t i si ng.
We wel come you t o j oi n us as we cont i nue our out r each . . .
wi t h your suppor t , bot h t he aut omot i ve r epai r i ndust r y and your
cust omer s wi l l r eap t he benef i t s. Pl ease vi si t MAP at our I nt er net
si t e: www. hunt er . com/ map. ht mor cont act us at :
808 17t h St r eet , NW Sui t e 200
Washi ngt on, D. C. 20006
Ph. ( 202) 466- 7050 Fax ( 202) 223- 9569
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
I t i s MAP pol i cy t hat al l exhaust , br ake, ABS, st eer i ng and
suspensi on, wheel al i gnment , t i r es and wheel s, dr i vel i ne, engi ne
per f or mance and mai nt enance and heat i ng, vent i l at i on and ai r
condi t i oni ng ser vi ces be of f er ed and per f or med under t he gui del i nes
and pr ocedur es speci f i ed i n t hese sect i ons.
Bef or e any ser vi ce i s per f or med on a vehi cl e, an i nspect i on
of t he appr opr i at e syst emmust be per f or med. The r esul t s of t hi s
i nspect i on must be expl ai ned t o t he cust omer and document ed on an
i nspect i on f or m. The condi t i on of t he vehi cl e and i t s component s wi l l
i ndi cat e what ser vi ces/ par t r epl acement s may be r equi r ed or suggest ed.
I n addi t i on, suggest i ons may be made t o sat i sf y t he needs expr essed by
t he cust omer .
Thi s sect i on l i st s t he var i ous par t s and condi t i ons t hat
i ndi cat e r equi r ed or suggest ed ser vi ce or par t r epl acement . Al t hough
t hi s l i st i s ext ensi ve, i t i s not i ncl usi ve. I n addi t i on t o t hi s l i st ,
a t echni ci an may make a suggest i on. Thi s suggest i on must be based on
subst ant i al and i nf or med exper i ence or t he vehi cl e manuf act ur er ' s
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
r ecommended ser vi ce i nt er val .
Some condi t i ons i ndi cat e t hat ser vi ce or par t r epl acement i s
r equi r ed because t he par t i n quest i on i s no l onger pr ovi di ng t he
f unct i on f or whi ch i t i s i nt ended, does not meet a vehi cl e
manuf act ur er ' s desi gn speci f i cat i on or i s mi ssi ng.
* Exampl e: An exhaust pi pe has cor r oded sever el y and has a hol e
i n i t t hr ough whi ch exhaust gases ar e l eaki ng. Repl acement of
t he exhaust pi pe i n t hi s case i s r equi r ed due t o f unct i onal
f ai l ur e.
* Exampl e: A br ake r ot or has been wor n t o t he poi nt wher e i t
measur es l ess t han t he vehi cl e manuf act ur er ' s speci f i cat i ons.
Repl acement of t he r ot or i s r equi r ed because i t does not meet
desi gn speci f i cat i ons.
Some condi t i ons i ndi cat e t hat a ser vi ce or par t r epl acement
i s suggest ed because t he par t i s cl ose t o t he end of i t s usef ul l i f e
or t o addr ess a cust omer ' s need, conveni ence or r equest . I f a
cust omer ' s vehi cl e has one of t hese condi t i ons, t he pr ocedur e may
onl y be t o suggest ser vi ce.
* Exampl e: An exhaust pi pe i s r ust ed, cor r oded or weak, but no
l eaks ar e pr esent . I n t hi s case, t he exhaust pi pe has not
f ai l ed. However , t her e i s evi dence t hat t he pi pe may need
r epl acement i n t he near f ut ur e. Repl acement of t he pi pe may
be suggest ed f or t he cust omer ' s conveni ence i n avoi di ng a
f ut ur e pr obl em.
* Exampl e: The cust omer desi r es i mpr oved r i de and/ or handl i ng,
but t he vehi cl e' s shocks or st r ut s have not f ai l ed. I n t hi s
case, r epl acement may be suggest ed t o sat i sf y t he cust omer ' s
wi shes. I n t hi s case, r epl acement of t he shocks or st r ut s may
not be sol d as a r equi r ement .
A cust omer , of cour se, has t he choi ce of whet her or not a
shop wi l l ser vi ce hi s or her vehi cl e. He or she may deci de not t o
f ol l ow some of your suggest i ons. When a cust omer decl i nes t o aut hor i ze
a ser vi ce or r epai r i ndi cat ed i n t he MAP Uni f or mI nspect i on Gui del i nes
as " r equi r ed, " a MAP shop may r ef use ser vi ce on t hat syst em, i f
pr oceedi ng wi t h t he wor k coul d cr eat e or cont i nue an unsaf e or
unsat i sf act or y condi t i on.
The f ol l owi ng r easons may be used f or r equi r ed and suggest ed
ser vi ces. These codes ar e shown i n t he " Code" col umn of t he Uni f or m
I nspect i on Gui del i nes t hat f ol l ow.
PART REPLACEMENT CODE IDENTIFICATION
NOTE: Ref er t o t he f ol l owi ng t abl es f or def i ni t i ons of t he codes
l i st ed i n t he condi t i on/ pr ocedur e t abl es f or t he speci f i c
component s t hat may need t o be r epl aced.
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
A - PART NO LONGER PERFORMS I NTENDED PURPOSE

Reasons t o Requi r e Repai r Reasons t o Suggest Repai r


or Repl acement or Repl acement

A - Par t no l onger per f or ms 1 - Par t i s cl ose t o t he end of


i nt ended pur pose i t s usef ul l i f e ( j ust above
di scar d speci f i cat i ons, or
weak; f ai l ur e l i kel y t o
occur soon, et c. )

B - PART DOES NOT MEET DESI GN SPEC. , REGARDLESS OF PERFORMANCE

Reasons t o Requi r e Repai r Reasons t o Suggest Repai r


or Repl acement or Repl acement

B - Par t does not meet a desi gn 2 - To addr ess a cust omer need,
speci f i cat i on ( r egar dl ess conveni ence, or r equest ( t o
of per f or mance) st i f f en r i de, enhance
per f or mance, el i mi nat e noi se
et c. )

C - PART I S MI SSI NG

Reasons t o Requi r e Repai r Reasons t o Suggest Repai r


or Repl acement or Repl acement

C - Par t i s mi ssi ng 3 - To compl y wi t h mai nt enance


r ecommended by t he vehi cl e' s
Or i gi nal Equi pment
Manuf act ur er ( OEM)
4 - Techni ci an' s r ecommendat i on
based on subst ant i al and
i nf or med exper i ence

STEERING & SUSPENSION


SERVICE PROCEDURES REQUIRED & SUGGESTED FOR PROPER
VEHI CLE OPERATI ON
St eer i ng and suspensi on ar e compl ex syst ems made up of a
var i et y of i nt er dependent component s. For pr oper vehi cl e handl i ng,
r i de, and t i r e wear , a t hor ough i nspect i on i s r equi r ed whenever
suspensi on wor k i s bei ng per f or med.
Condi t i ons l i st ed assume t hat t he pr obl emhas been i sol at ed
t o t he speci f i c component by pr oper t est i ng pr ocedur es.
NOTE: When r epl aci ng st eer i ng and/ or suspensi on component s whi ch
may af f ect an al i gnment angl e, you ar e r equi r ed t o check and
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
adj ust al i gnment as needed. Ref er t o t he OEM speci f i cat i ons.
CAUTI ON: DO NOT use r i de hei ght al t er i ng or l oad compensat i ng
component s, such as var i abl e r at e spr i ngs and coi l over
shocks, on vehi cl es wi t h hei ght or l oad sensi ng pr opor t i oni ng
val ve- equi pped br aki ng syst ems, unl ess t hese component s ar e
or i gi nal equi pment .
AIR RIDE SUSPENSION
NOTE: Dependi ng on t he ai r suspensi on desi gn, t her e ar e some
af t er mar ket pr oduct s avai l abl e t o el i mi nat e t he ai r r i de
suspensi on on cer t ai n vehi cl es. I f t he syst emhas been
el i mi nat ed wi t h one of t hese pr oduct s, t hen no ser vi ce i s
suggest ed or r equi r ed.
AIR RIDE SUSPENSION - AIR SHOCKS & AIR STRUTS
NOTE: Thi s sect i on cover s t he ai r spr i ng por t i on of t he ai r shock
or st r ut . For dampeni ng por t i on of shock or st r ut condi t i ons
and pr ocedur es, r ef er t o t he " Shock Absor ber s, St r ut
Car t r i dges, and St r ut Assembl i es" sect i on.
AI R RI DE SUSPENSI ON - AI R SHOCKS & AI R STRUTS

Condi t i on Code Pr ocedur e

I nner f abr i c of ai r bag A Requi r e r epl acement .


damaged

Leaki ng A Requi r e r epai r or r epl acement .

Out er cover i ng of ai r bag A, 1 Suggest r epl acement .


i s cr acked t o t he ext ent
t hat i nner f abr i c of ai r
bag i s vi si bl e

AIR RIDE SUSPENSION - AIR SPRING VALVES


AI R RI DE SUSPENSI ON - AI R SPRI NG VALVES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 6)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bl ocked A Requi r e r epai r or r epl acement .

Connect or bent A Requi r e r epai r or r epl acement .

Connect or br oken A Requi r e r epl acement .

Connect or l oose A Requi r e r epai r or r epl acement .

I noper at i ve A Requi r e r epai r or r epl acement .

Leaki ng A Requi r e r epai r or r epl acement .

Rest r i ct ed A Requi r e r epai r or r epl acement .

AIR RIDE SUSPENSION - AIR SPRINGS


AI R RI DE SUSPENSI ON - AI R SPRI NGS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Col l ar cr acked A Requi r e r epl acement .

End cap cr acked A Requi r e r epl acement .

I nner f abr i c of bag damaged A Requi r e r epl acement .

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 7)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
Leaki ng A Requi r e r epai r or r epl acement .

Out er cover i ng of ai r bag A, 1 Suggest r epl acement .


i s cr acked t o t he ext ent
t hat i nner f abr i c of ai r
bag i s vi si bl e

Pi st on cr acked A Requi r e r epl acement .

AIR RIDE SUSPENSION - COMPRESSORS


AI R RI DE SUSPENSI ON - COMPRESSORS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Connect or bent A Requi r e r epai r or r epl acement .

Connect or br oken A Requi r e r epl acement .

Connect or l oose A Requi r e r epai r or r epl acement .

Does not bui l d pr essur e A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Excessi ve r un t i me B Fur t her i nspect i on r equi r ed.


See not e ( 2) bel ow.

I noper at i ve A Requi r e r epl acement .

Leaki ng A Requi r e r epai r or r epl acement .

Mi ssi ng C Requi r e r epl acement .

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 8)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
NOTE: ( 1) I f f ai l ur e t o bui l d pr essur e i s t r aced t o t he compr essor ,
r equi r e r epl acement .
( 2) I f excessi ve r un t i me i s t r aced t o t he compr essor , r equi r e
r epl acement .

AIR RIDE SUSPENSION - HEIGHT SENSORS


AI R RI DE SUSPENSI ON - HEI GHT SENSORS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t .
i nt egr i t y

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Dust boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 1) .

Dust boot spl i t B, 2 Suggest r epl acement . See not e ( 1) .

Dust boot t or n B, 2 Suggest r epl acement . See not e ( 1) .

Housi ng cr acked A Requi r e r epl acement .

Lead r out i ng i ncor r ect B Requi r e r e- r out i ng accor di ng t o


vehi cl e manuf act ur er ' s specs.

Loose B Requi r e adj ust ment t o vehi cl e


manuf act ur er ' s speci f i cat i ons.

Mi ssi ng C Requi r e r epl acement .

Out put si gnal i ncor r ect A Requi r e r epai r or r epl acement .

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 9)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
Wi r e l ead damaged A Requi r e r epai r or r epl acement .

NOTE: ( 1) Thi s condi t i on can l ead t o damage of t he sl i di ng magnet ,


whi ch, i n t ur n, causes pr emat ur e sensor f ai l ur e.

AIR RIDE SUSPENSION - MODULES


AI R RI DE SUSPENSI ON - MODULES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Housi ng cr acked B, 2 Suggest r epai r or r epl acement .

I noper at i ve A Requi r e r epl acement .

Mi ssi ng C Requi r e r epl acement .

AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)


AI R RI DE SUSPENSI ON - RELAYS ( COMPRESSOR)

Condi t i on Code Pr ocedur e

Housi ng cr acked B, 2 Suggest r epl acement . See not e ( 1) .

I nt er mi t t ent A Requi r e r epl acement .

Mi ssi ng C Requi r e r epl acement .

Out put si gnal i ncor r ect A Requi r e r epl acement .

NOTE: ( 1) I f moi st ur e ent er s t he r el ay, i t can r educe l i f e expect ancy


or i mpai r f unct i on.

AIR RIDE SUSPENSION - SWITCHES (ON/OFF)


AI R RI DE SUSPENSI ON - SWI TCHES ( ON/ OFF)
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 10)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM

Condi t i on Code Pr ocedur e

Br oken A Requi r e r epl acement .

Mi ssi ng C Requi r e r epl acement .

Out put si gnal i ncor r ect A Requi r e r epl acement .

AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)


AI R RI DE SUSPENSI ON - TORSI ON SPRI NGS ( COUNTER BALANCI NG)

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e i ncor r ect A Requi r e r epl acement of i ncor r ect
par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Br oken A Requi r e r epl acement .

Mi ssi ng C Requi r e r epl acement .

AIR RIDE SUSPENSION - TUBING


AI R RI DE SUSPENSI ON - TUBI NG

Condi t i on Code Pr ocedur e

At t achi ng har dwar e i ncor r ect A Requi r e r epl acement of i ncor r ect
par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 11)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

Bl ocked A Requi r e r epai r or r epl acement .

Fi t t i ng i ncor r ect B Requi r e r epl acement .

Leaki ng A Requi r e r epai r or r epl acement .

Li ne t ype i ncor r ect B Requi r e r epl acement .

Mi ssi ng C Requi r e r epl acement .

Rest r i ct ed A Requi r e r epai r or r epl acement .

Rout ed i ncor r ect l y B Requi r e r out i ng cor r ect i on.

AIR RIDE SUSPENSION - WARNING LAMPS


AI R RI DE SUSPENSI ON - WARNI NG LAMPS

Condi t i on Code Pr ocedur e

Bul b bur ned out A Requi r e r epl acement .

War ni ng l i ght does not come


on dur i ng bul b check

War ni ng l i ght f l ashes
Fur t her i nspect i on r equi r ed t o
War ni ng l i ght i s i nt er mi t t ent det er mi ne cause.

War ni ng l i ght st ays on af t er
i ni t i al bul b check

AIR RIDE SUSPENSION - WIRING HARNESSES


AI R RI DE SUSPENSI ON - WI RI NG HARNESSES

Condi t i on Code Pr ocedur e

Connect or bent A

Connect or br oken A

Connect or l oose A Requi r e r epai r or r epl acement .

Damaged ( cut , bur ned, or A


* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 12)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
chaf ed)

Excessi ve r esi st ance B

Fuse bl own A
Requi r e r epl acement .
Fusi bl e l i nk bl own A

Open A
Requi r e r epai r or r epl acement .
Poor gr ound A

Rout ed i ncor r ect l y B Requi r e r e- r out i ng accor di ng t o


vehi cl e manuf act ur er ' s specs.

Shor t ed A

Ter mi nal bent A

Ter mi nal br oken A Requi r e r epai r or r epl acement .

Ter mi nal cor r oded A

Ter mi nal l oose A

BALL JOINTS
Bef or e r equi r i ng or suggest i ng bal l j oi nt r epl acement , t he
appr oved OEM pr ocedur e must be used t o measur e bal l j oi nt wear . The
measur ement ( s) obt ai ned, al ong wi t h t he vehi cl e manuf act ur er ' s
speci f i cat i ons, must be not ed on t he i nspect i on r epor t . Some st at es
r equi r e t hat t hese measur ement s al so appear on t he i nvoi ce.
NOTE: The t er m" per cept i bl e movement , " def i ned as any vi si bl e
movement i n any di r ect i on, has been t he i ndust r y st andar d
f or det er mi ni ng t he need f or r epl acement of f ol l ower bal l
j oi nt s. Some vehi cl e manuf act ur er s ar e now publ i shi ng
speci f i cat i ons f or f ol l ower bal l j oi nt s t hat wer e pr evi ousl y
di agnosed by t he " per cept i bl e movement " st andar d. Bef or e
r equi r i ng or suggest i ng any par t s be r epl aced based on
" per cept i bl e movement , " consul t your r epai r manual t o
det er mi ne i f OEM speci f i cat i ons exi st .
You ar e not r equi r ed t o r epl ace bal l j oi nt s i n axl e set s.
However , when r epl aci ng a bal l j oi nt due t o wear exceedi ng
manuf act ur er ' s speci f i cat i on, you may suggest r epl acement of t he ot her
bal l j oi nt i f i t s measur ement shows i t i s cl ose t o t he end of i t s
usef ul l i f e, f or pr event i ve mai nt enance.
BALL J OI NTS

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 13)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t i f avai l abl e; ot her wi se,
r epl ace bal l j oi nt .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken par t


i f avai l abl e; ot her wi se, r epl ace
bal l j oi nt .

At t achi ng har dwar e cor r oded A Requi r e r epl acement of br oken par t
af f ect i ng st r uct ur al i f avai l abl e; ot her wi se, r epl ace
i nt egr i t y bal l j oi nt .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t i f avai l abl e; ot her wi se,
r epl ace bal l j oi nt .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t i f avai l abl e;
ot her wi se, r epl ace bal l j oi nt .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t i f avai l abl e; ot her wi se,
r epl ace bal l j oi nt .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads i f
avai l abl e; ot her wi se, r epl ace
bal l j oi nt .

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads i f avai l abl e;
ot her wi se, r epl ace bal l j oi nt .

Bi ndi ng A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .

Gr ease f i t t i ng br oken A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng won' t seal A Requi r e r epl acement of gr ease


f i t t i ng.
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 14)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM

Gr easeabl e bal l j oi nt wi l l B, 2 Suggest r epl acement of gr ease


not t ake gr ease f i t t i ng. See not e ( 5) bel ow.

Nut on bal l j oi nt l oose A Requi r e r epai r or r epl acement .


See not e ( 6) bel ow.

Pr e- l oad adj ust ment B Requi r e r epai r or r epl acement .


i ncor r ect

Sei zed A Requi r e r epl acement .

St ud bent B Requi r e r epl acement . See not e ( 7) .

St ud br oken A Requi r e r epl acement . See not e ( 7) .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 7) .


mi ssi ng)

Wear exceeds manuf act ur er ' s B Requi r e r epl acement .


speci f i cat i ons

NOTE: ( 1) I f gr easeabl e, gr ease bal l j oi nt . I f pr obl emper si st s or


j oi nt i s non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er t he
bal l j oi nt and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er t he
bal l j oi nt and wi l l accel er at e wear .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he bal l
j oi nt and wi l l accel er at e wear .
( 5) I f t he gr easeabl e bal l j oi nt st i l l wi l l not t ake gr ease
af t er r epl aci ng t he gr ease f i t t i ng, suggest r epl acement of
bal l j oi nt .
( 6) Check f or bent st ud or damaged t aper hol e.
( 7) Check f or damaged t aper hol e.

BUSHINGS
BUSHI NGS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t i f avai l abl e; ot her wi se,
r epl ace bushi ng.

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken par t


i f avai l abl e; ot her wi se, r epl ace
bushi ng.
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 15)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace bushi ng.

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t i f avai l abl e; ot her wi se,
r epl ace bushi ng.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t i f avai l abl e;
ot her wi se, r epl ace bushi ng.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t i f avai l abl e; ot her wi se,
r epl ace bushi ng.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads i f
avai l abl e; ot her wi se, r epl ace
bushi ng.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads i f avai l abl e;
ot her wi se, r epl ace bushi ng.

Bi ndi ng A Requi r e r epai r or r epl acement .

Det er i or at ed, af f ect i ng A Requi r e r epai r or r epl acement .


per f or mance

Di st or t ed, af f ect i ng A Requi r e r epai r or r epl acement .


per f or mance

Leaki ng ( f l ui d- f i l l ed t ype) A Requi r e r epl acement .

Mi ssi ng A Requi r e r epl acement .

Noi sy B, 2 Fur t her i nspect i on r equi r ed.


See not e ( 1) and caut i on bel ow.

Rubber separ at i ng f r om A Requi r e r epl acement .


i nt er nal met al sl eeve on
bonded bushi ng

Sei zed A Requi r e r epl acement .

Shi f t ed ( out of posi t i on) B Requi r e r epai r or r epl acement .

Spl i t A Requi r e r epl acement .

Sur f ace cr acki ng No ser vi ce suggest ed or r equi r ed.


* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 16)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
( weat her - checked)

NOTE: ( 1) I f noi se i sol at ed t o bushi ng, suggest r epai r or r epl acement .


CAUTI ON: Use onl y appr oved l ubr i cant on r ubber bushi ngs. Pet r ol eum-
based l ubr i cant s may damage r ubber bushi ngs.

CENTER LINKS
CENTER LI NKS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace cent er l i nk.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace cent er l i nk.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace cent er l i nk.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
cent er l i nk.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace cent er l i nk.

Bent B Requi r e r epl acement .

Bi ndi ng A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .

Gr ease f i t t i ng br oken A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease


f i t t i ng.

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 17)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:53PM
Gr ease f i t t i ng won' t seal A Requi r e r epl acement of gr ease
f i t t i ng.

Gr ease seal mi ssi ng B, 2 Suggest r epl acement . See not e ( 5) .

Gr ease seal t or n B, 2 Suggest r epl acement . See not e ( 6) .

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 7) .


hor i zont al movement )

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 8)


and ( 9) , caut i on bel ow.

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Sei zed A Requi r e r epl acement .

St ud bent B Requi r e r epl acement . See not e ( 10)

St ud br oken A Requi r e r epl acement . See not e ( 10)

St ud l oose i n t aper hol e A Requi r e r epai r or r epl acement .


See not e ( 10) bel ow.

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 11)

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 10)
mi ssi ng)

Wear exceeds manuf act ur er ' s B Requi r e r epl acement .


speci f i cat i ons

NOTE: ( 1) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt i s


non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he j oi nt
and wi l l accel er at e wear .
( 5) Lack of gr ease seal wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 6) Tor n gr ease seal wi l l al l ow cont ami nant s t o ent er t he j oi nt
and wi l l accel er at e wear .
( 7) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 18)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
such as t he dr y par k check.
( 8) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 9) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
( 10) Check f or damaged t aper hol e.
( 11) Check f or damaged st ud.

CONTROL ARM SHAFTS


CONTROL ARM SHAFTS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace shaf t .
At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of
l oose par t , i f avai l abl e;
ot her wi se, r epl ace shaf t .
At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng
par t , i f avai l abl e; ot her wi se,
r epl ace shaf t .
At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of
damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
shaf t .
At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h
st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace shaf t .
Bent B Requi r e r epl acement .
Shaf t bushi ng sur f ace B Requi r e r epl acement .
under si zed ( wor n)
Thr eads damaged A Requi r e r epai r or r epl acement .
Thr eads st r i pped A Requi r e r epl acement .
( t hr eads mi ssi ng)

CONTROL ARMS
CONTROL ARMS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t , i f avai l abl e;
ot her wi se, r epl ace cont r ol ar m.

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 19)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
r epl ace cont r ol ar m.

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t , i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace cont r ol ar m.

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace cont r ol ar m.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace cont r ol ar m.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace cont r ol ar m.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
cont r ol ar m.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace cont r ol ar m.

Bent B Requi r e r epl acement .

Bushi ng hol e over si zed B Requi r e r epl acement .

Bal l j oi nt hol e over si zed B Fur t her i nspect i on r equi r ed.


( l oose i nt er f er ence or See not e ( 1) bel ow.
pr ess f i t )

Cor r oded, af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y

Hol es di st or t ed A Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

NOTE: ( 1) I f over si zed bal l j oi nt i s avai l abl e, r equi r e r epl acement


of bal l j oi nt . I f over si zed bal l j oi nt i s not avai l abl e,
r equi r e r epl acement of cont r ol ar m.

DRAG LINKS
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 20)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
DRAG LI NKS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace dr ag l i nk.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace dr ag l i nk.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace dr ag l i nk.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
dr ag l i nk.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace dr ag l i nk.

Bent B Requi r e r epl acement .

Bi ndi ng A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .

Gr ease f i t t i ng br oken A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng won' t seal A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease seal mi ssi ng B, 2 Suggest r epl acement . See not e ( 5) .

Gr ease seal t or n B, 2 Suggest r epl acement . See not e ( 4) .

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 6) .


hor i zont al movement )

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 21)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket
movement . Use onl y moder at e hand pr essur e.

Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 6)


and ( 7) , caut i on bel ow.

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Sei zed A Requi r e r epl acement .

St ud bent B Requi r e r epl acement . See not e ( 8) .

St ud br oken A Requi r e r epl acement . See not e ( 8) .

St ud l oose i n t aper hol e A Requi r e r epai r or r epl acement .


See not e ( 8) bel ow.

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 9) .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 8) .


mi ssi ng)

Wear exceeds manuf act ur er ' s B Requi r e r epl acement .


speci f i cat i ons

NOTE: ( 1) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt i s


non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he j oi nt
and wi l l accel er at e wear .
( 5) Mi ssi ng gr ease seal wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 6) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
( 7) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 8) Check f or damaged t aper hol e.
( 9) Check f or damaged st ud.

ELECTRONIC RIDE CONTROL SHOCKS & STRUTS


NOTE: Thi s sect i on cover s t he el ect r oni c dampi ng cont r ol por t i on of
t he el ect r oni c shock or st r ut . For dampeni ng por t i on of shock
or st r ut condi t i ons and pr ocedur es, r ef er t o t he " Shock
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 22)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
Absor ber s, St r ut Car t r i dges, and St r ut Assembl i es" sect i on.
ELECTRONI C RI DE CONTROL SHOCKS & STRUTS

Condi t i on Code Pr ocedur e

Connect or bent A Requi r e r epai r or r epl acement .

Connect or br oken A Requi r e r epai r or r epl acement .

Connect or l oose A Requi r e r epai r or r epl acement .

El ect r oni c val ve cont r ol B, 2 Suggest r epl acement . See not e ( 1) .


i noper at i ve

Ter mi nal bent A Requi r e r epai r or r epl acement .

Ter mi nal br oken A Requi r e r epai r or r epl acement .

Ter mi nal cor r oded A Requi r e r epai r or r epl acement .

Ter mi nal l oose A Requi r e r epai r or r epl acement .

NOTE: ( 1) I t i s accept abl e t o r epl ace wi t h a non- el ect r oni cal l y


cont r ol l ed uni t , wher e avai l abl e.

IDLER ARMS
I DLER ARMS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace i dl er ar m.

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace i dl er ar m.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace i dl er ar m.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace i dl er ar m.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 23)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
i dl er ar m.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace i dl er ar m.

Bi ndi ng A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .

Gr ease f i t t i ng br oken A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng won' t seal A Requi r e r epl acement of seal .

Gr ease seal mi ssi ng B, 2 Suggest r epl acement . See not e ( 5) .

Gr ease seal t or n B, 2 Suggest r epl acement . See not e ( 4) .

Gr easeabl e j oi nt wi l l not B, 2 Suggest r epl acement of gr ease


t ake gr ease f i t t i ng. See not e ( 6) bel ow.

Looseness at f r ame br acket B Requi r e r epai r or r epl acement .


end See not es ( 7) and ( 8) bel ow.

Looseness at l i nk end A, 1 Suggest r epl acement . See not e ( 7) .


( per cept i bl e hor i zont al
movement )

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Looseness at l i nk end t hat B Requi r e r epl acement . See not es ( 7)


i s excessi ve and ( 9) and caut i on bel ow.

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Mount ed out of posi t i on B Requi r e r eposi t i oni ng.


( cent er l i nk not par al l el )

Nut on st ud l oose A Requi r e r epai r or r epl acement .


See not e ( 10) bel ow.

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 24)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
Sei zed A Requi r e r epl acement .

St ud bent B Requi r e r epl acement . See not e ( 11)

St ud br oken A Requi r e r epl acement . See not e ( 11)

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 12)

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 11)
mi ssi ng)

Wear exceeds manuf act ur er ' s B Requi r e r epl acement .


speci f i cat i ons

NOTE: ( 1) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt


i s non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt and
wi l l accel er at e wear .
( 5) Mi ssi ng gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 6) I f gr easeabl e j oi nt wi l l not t ake gr ease af t er r epl aci ng t he
gr ease f i t t i ng, suggest r epl acement of i dl er ar m.
( 7) I f manuf act ur er ' s pr ocedur es and speci f i cat i ons exi st , use
t hose pr ocedur es and speci f i cat i ons; ot her wi se, use an
appr oved i nspect i on met hod such as t he dr y par k check.
( 8) Looseness i s def i ned as movement t hat cr eat es excessi ve t oe
change.
( 9) Excessi ve l ooseness i s def i ned as si gni f i cant enough t o
af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 10) Check f or bent st ud or damaged t aper hol e.
( 11) Check f or damaged t aper hol e.
( 12) Check f or damaged st ud.

KING PINS
You ar e not r equi r ed t o r epl ace ki ng pi ns i n axl e set s.
However , when r epl aci ng a ki ng pi n due t o wear exceedi ng
manuf act ur er ' s speci f i cat i ons, you may suggest r epl acement of t he
ot her ki ng pi n on t he axl e i f i t s measur ement shows i t i s cl ose t o t he
end of i t s usef ul l i f e.
KI NG PI NS

Condi t i on Code Pr ocedur e

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 25)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
Bear i ng bal l s pi t t ed A Requi r e r epl acement .

Bear i ng bal l s wor n A Requi r e r epl acement .

Bear i ng r aces pi t t ed A Requi r e r epl acement .

Bear i ng r aces wor n A Requi r e r epl acement .

Bear i ng r ol l er s pi t t ed A Requi r e r epl acement .

Bear i ng r ol l er s wor n A Requi r e r epl acement .

Bear i ng seal bent B, 2


Suggest r epl acement of seal or
Bear i ng seal mi ssi ng B, 2 bear i ng.

Bear i ng seal t or n B, 2

Bi ndi ng A Requi r e r epai r or r epl acement of


af f ect ed par t s.

End caps mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace ki ng pi n.

End pl ay exceeds B Requi r e r epai r .


speci f i cat i ons

Gr ease f i t t i ng br oken A

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease


f i t t i ng.
Gr ease f i t t i ng won' t seal A

Locat i ng pi ns mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace ki ng pi n.

Looseness exceeds B Requi r e r epl acement of wor n par t s.


manuf act ur er ' s specs

Sei zed A Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

Wi l l not t ake gr ease B, 2 Suggest r epl acement of gr ease


f i t t i ng. See not e ( 1) bel ow.

NOTE: ( 1) I f ki ng pi n wi l l not t ake gr ease af t er r epl acement of gr ease


* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 26)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
f i t t i ng, suggest r epl acement of ki ng pi n.

PITMAN ARMS
PI TMAN ARMS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace pi t man ar m.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace pi t man ar m.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace pi t man ar m.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
pi t man ar m.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace pi t man ar m.

Bent B Requi r e r epl acement .

Bi ndi ng A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .

Gr ease f i t t i ng br oken A
Requi r e r epl acement gr ease
Gr ease f i t t i ng mi ssi ng C f i t t i ng.

Gr ease f i t t i ng won' t seal A

Gr ease seal mi ssi ng B, 2 Suggest r epl acement of seal .


See not e ( 5) bel ow.

Gr ease seal t or n B, 2 Suggest r epl acement of seal .


See not e ( 6) bel ow.
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 27)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 7)


hor i zont al movement )

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 7)


and ( 8) , caut i on bel ow.

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Nut on st ud l oose A Requi r e r epai r or r epl acement .


See not e ( 9) bel ow.

Sei zed A Requi r e r epl acement .

Spl i nes damaged A Requi r e r epai r or r epl acement .

Spl i nes st r i pped ( spl i nes A Requi r e r epl acement .


mi ssi ng)

St ud bent B Requi r e r epl acement . See not e ( 10)

St ud br oken A Requi r e r epl acement . See not e ( 10)

St ud l oose i n t aper hol e A Requi r e r epai r or r epl acement .


See not e ( 10) bel ow.

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 11)

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 10)
mi ssi ng)

NOTE: ( 1) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt


i s non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt and
wi l l accel er at e wear .
( 5) Lack of gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 6) Tor n gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt and
wi l l accel er at e wear .
( 7) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 28)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
( 8) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 9) Check f or bent st ud of damaged t aper hol e.
( 10) Check f or damaged t aper hol e.
( 11) Check f or damaged st ud.

POWER STEERING HOSES


POWER STEERI NG HOSES

Condi t i on Code Pr ocedur e

Bl i st er ed B Requi r e r epl acement .

Bl ocked A Requi r e r epai r or r epl acement .

Fi t t i ng t hr eads damaged A Requi r e r epai r or r epl acement .

Fi t t i ng t hr eads st r i pped A Requi r e r epl acement .


( t hr eads mi ssi ng)

I nner f abr i c ( webbi ng) cut A Requi r e r epl acement .

Leaki ng A Requi r e r epai r or r epl acement .

Mi ssi ng C Requi r e r epl acement .

Out er cover i ng i s cr acked B Requi r e r epl acement .


t o t he ext ent t hat t he
i nner f abr i c of hose i s
vi si bl e

Rest r i ct ed A Requi r e r epai r or r epl acement .

POWER STEERING (HYDRAULIC) PUMPS


I f di agnosi s has det er mi ned t hat compl et e di sassembl y i s
necessar y t o det er mi ne t he ext ent of t he syst emf ai l ur e, t he
suggest i on may be made t o r ebui l d or r epl ace t he power st eer i ng pump.
Repai r or r epl acement of t he f ol l owi ng component s may be r equi r ed i f
per f or med as par t of a power st eer i ng pump over haul or r ebui l d ser vi ce
t o meet a mi ni mumr ebui l d st andar d.
POWER STEERI NG ( HYDRAULI C) PUMPS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 29)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
At t achi ng har dwar e br oken A Requi r e r epl acement of br oken
par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bel t al i gnment i ncor r ect B Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Bel t cr acked A, 1 Suggest r epl acement .

Bel t f r ayed A, 1 Suggest r epl acement .

Bel t mi ssi ng C Requi r e r epl acement .

Bel t noi sy B, 2 Fur t her i nspect i on r equi r ed.


See not e ( 2) bel ow.

Bel t pl i es separ at ed A Requi r e r epl acement .

Bel t t ensi on out of spec B Requi r e adj ust ment or r epl acement .

Bel t wor n beyond adj ust ment B Requi r e r epl acement .


r ange

Bel t wor n so i t cont act s A Requi r e r epl acement .


bot t omof pul l ey

Bi ndi ng A Requi r e r epai r or r epl acement .

Fl ui d at or beyond ser vi ce C, 3 Suggest f l ui d change.


i nt er val

Fl ui d cont ami nat ed B Requi r e f l ushi ng and r ef i l l i ng of


t he syst em. See not e ( 3) bel ow.

Fl ui d l evel i ncor r ect B Requi r e adj ust ment of f l ui d l evel .

I nadequat e assi st A Fur t her i nspect i on r equi r ed.


See not e ( 4) bel ow.

Leaki ng A Requi r e r epai r or r epl acement .

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 30)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
Noi se B, 2 Fur t her i nspect i on r equi r ed.
See not e ( 5) bel ow.

Pul l ey bent A Requi r e r epai r or r epl acement of


pul l ey.

Pul l ey mi ssi ng C? Requi r e r epl acement of pul l ey.

Remot e r eser voi r l eaki ng A Requi r e r epl acement of r eser voi r .

Reser voi r cap br oken A Requi r e r epl acement of cap.

Reser voi r cap mi ssi ng C Requi r e r epl acement of cap.

Sei zed A Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

NOTE: ( 1) Det er mi ne cause of i ncor r ect al i gnment and r equi r e r epai r .


( 2) Det er mi ne cause of noi se and suggest r epai r .
( 3) Det er mi ne and cor r ect sour ce of cont ami nat i on. OEM
speci f i cat i ons must be f ol l owed f or f l ui d t ype.
( 4) I f pump i s sour ce of i nadequat e assi st , r equi r e r epai r or
r epl acement .
( 5) I f noi se i s i sol at ed t o pump, suggest r epai r or r epl acement .

RADIUS ARMS
RADI US ARMS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 31)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bent B Requi r e r epl acement .

Cor r oded, af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y

Hol es di st or t ed A Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

RELAY RODS
RELAY RODS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace r el ay r od.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace r el ay r od.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace r el ay r od.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
r el ay r od.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace r el ay r od.

Bent B Requi r e r epl acement .

Bi ndi ng A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 4) .


* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 32)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM

Gr ease f i t t i ng br oken A

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement gr ease


f i t t i ng.
Gr ease f i t t i ng won' t seal A

Gr ease seal mi ssi ng B, 2 Suggest r epl acement . See not e ( 5) .

Gr ease seal t or n B, 2 Suggest r epl acement . See not e ( 6) .

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 7) .


hor i zont al movement )

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 7)


and ( 8) and caut i on bel ow.

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Sei zed A Requi r e r epl acement .

St ud bent B Requi r e r epl acement . See not e ( 9) .

St ud br oken A Requi r e r epl acement . See not e ( 9) .

St ud l oose i n t aper hol e A Requi r e r epai r or r epl acement .


See not e ( 9) .

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 10)

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 9) .


mi ssi ng)

Wear exceeds manuf act ur er ' s B Requi r e r epl acement .


speci f i cat i ons

NOTE: ( 1) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt


i s non- gr easeabl e, r equi r e r epl acement .
( 2) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 3) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 4) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he j oi nt
and wi l l accel er at e wear .
( 5) Lack of gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 33)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
( 6) Tor n gr ease seal wi l l al l ow cont ami nant s t o ent er j oi nt and
wi l l accel er at e wear .
( 7) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
( 8) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 9) Check f or damaged t aper hol e.
( 10) Check f or damaged st ud.

SHOCK ABSORBERS, STRUT CARTRIDGES, & STRUT ASSEMBLIES


You ar e not r equi r ed t o r epl ace shocks or st r ut s i n axl e
set s. However , when r epl aci ng a shock or st r ut due t o t he condi t i ons
t hat f ol l ow, you may suggest r epl acement of t he ot her shock or st r ut
on t he same axl e f or i mpr oved per f or mance and pr event i ve mai nt enance.
* par t i s cl ose t o t he end of i t s usef ul l i f e
* t o ext end t i r e l i f e
* t o bal ance r i de and handl i ng
* t o i mpr ove st oppi ng di st ance
When r epl aci ng st eer i ng and/ or suspensi on component s whi ch
may af f ect an al i gnment angl e, you ar e r equi r ed t o check and adj ust
al i gnment as needed. Ref er t o t he OEM speci f i cat i ons.
Under no ci r cumst ances shoul d a t echni ci an bend st r ut s or
st r ut housi ngs.
A vehi cl e' s l oad- car r yi ng and handl i ng abi l i t i es ar e l i mi t ed
by i t s suspensi on, t i r es, br akes, and dr i vel i ne. I nst al l i ng coi l over
shocks or any ot her l oad assi st devi ce does not i ncr ease t he vehi cl e' s
l oad capaci t y. See t he vehi cl e owner ' s manual f or mor e det ai l s.
NOTE: I f vehi cl e i s equi pped wi t h or i gi nal equi pment coi l over
shocks, appl y t he condi t i ons f or coi l spr i ngs f r omt he
" Spr i ngs: Coi l , Leaf , and Tor si on Bar " sect i on of t he
St eer i ng and Suspensi on gui del i nes. I f t he vehi cl e i s
equi pped wi t h add- on coi l over shocks, you may suggest
r epl aci ng t he shocks wi t h st andar d shocks f or any spr i ng-
r el at ed condi t i on.
SHOCK ABSORBERS, STRUT CARTRI DGES, & STRUT ASSEMBLI ES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t , i f avai l abl e;
ot her wi se, r epl ace shock or st r ut .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace shock or st r ut .
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 34)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t , i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace shock or st r ut .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace shock or st r ut .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace shock or st r ut .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace shock or st r ut .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
shock or st r ut .

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace shock or st r ut .

Bi ndi ng A Requi r e r epl acement .

Body dent ed A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Body punct ur ed A Requi r e r epl acement .

Br ake hose br acket bent B Requi r e r epai r or r epl acement .

Br ake hose br acket mi ssi ng C Requi r e r epl acement .

Br ake hose br acket t hr eads C Requi r e r epai r or r epl acement .


damaged

Br ake hose br acket t hr eads C Requi r e r epl acement .


st r i pped ( t hr eads mi ssi ng)

Compr essi on bumper mi ssi ng C Requi r e r epl acement of compr essi on


bumper .

Compr essi on bumper spl i t A, 1 Suggest r epl acement of compr essi on


bumper .

Dampi ng ( none) A Requi r e r epl acement .

Dust boot ( bel l ows) spl i t B, 2 Suggest r epl acement of boot .


* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 35)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
See not e ( 2) bel ow.

Dust boot ( bel l ows) mi ssi ng B, 2 Suggest r epl acement of boot .


See ( 3) not e bel ow.

Dust boot ( bel l ows) t or n B, 2 Suggest r epl acement of boot .


See not e ( 4) bel ow.

Dust shi el d br oken B, 2 Suggest r epl acement . See not e ( 4) .

Dust shi el d mi ssi ng B, 2 Suggest r epl acement . See not e ( 4) .

Gl and nut ( st r ut housi ng A Requi r e r epl acement of nut and/ or


cap) i s not r emovabl e housi ng. See not e ( 5) bel ow.
usi ng appr opr i at e t ool

Gl and nut ( st r ut housi ng A Requi r e r epai r or r epl acement of


cap) t hr eads damaged nut .

Gl and nut ( st r ut housi ng A Requi r e r epl acement of nut .


cap) t hr eads st r i pped
( t hr eads mi ssi ng)

Housi ng dent ed A Fur t her i nspect i on r equi r ed.


See not e ( 6) bel ow.

Housi ng punct ur ed A Requi r e r epl acement .

J ounce bumper mi ssi ng C Requi r e r epl acement of j ounce


bumper .

J ounce bumper spl i t 1? Suggest r epl acement of j ounce


bumper .

Leaki ng oi l , enough f or A Requi r e r epl acement . See caut i on


f l ui d t o be r unni ng down bel ow.
t he body

CAUTI ON: I f t he st r ut car t r i dge has been r epl aced pr evi ousl y, t he oi l
on t he st r ut housi ng may be f i l l er oi l . The t echni ci an must
i dent i f y t he sour ce of t he oi l .

Noi se B, 2 Fur t her i nspect i on r equi r ed.


See not e ( 7) bel ow.

Pi st on r od bent A Requi r e r epl acement .

Pi st on r od br oken A Requi r e r epl acement .

Pi st on r od has sur f ace B, 2 Suggest r epl acement .


def ect

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 36)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
Pi st on r od t hr eads damaged A Requi r e r epai r or r epl acement .

Pi st on r od t hr eads st r i pped A Requi r e r epl acement .


( t hr eads mi ssi ng)

Sei zed A Requi r e r epl acement .

Shock mi ssi ng C Requi r e r epl acement .

St r ut housi ng bent A Requi r e r epl acement .

St r ut housi ng cap ( gl and A Requi r e r epl acement of nut and/ or


nut ) i s not r emovabl e housi ng. See not e ( 5) bel ow.
usi ng appr opr i at e t ool

St r ut housi ng cap ( gl and A Requi r e r epai r or r epl acement of


nut ) t hr eads damaged nut .

St r ut housi ng cap ( gl and A Requi r e r epl acement of nut .


nut ) t hr eads st r i pped
( t hr eads mi ssi ng)

St r ut housi ng sever el y A Requi r e r epl acement .


cor r oded, af f ect i ng
st r uct ur al i nt egr i t y

St r ut housi ng t hr eads A Requi r e r epai r or r epl acement .


damaged

St r ut housi ng t hr eads A Requi r e r epl acement .


st r i pped ( t hr eads mi ssi ng)

Ti r e cuppi ng A Fur t her i nspect i on r equi r ed.


See not e ( 8) bel ow

NOTE: ( 1) Requi r e r epl acement of uni t s wher e dent s r est r i ct shock or


st r ut pi st on r od movement . I f dent s don' t r est r i ct movement ,
no ser vi ce i s suggest ed or r equi r ed. Especi al l y cr i t i cal on
mono- t ube shocks.
( 2) Thi s condi t i on can l ead t o damage of t he pi st on r od, whi ch,
i n t ur n, causes pr emat ur e pi st on r od seal wear .
( 3) Thi s condi t i on can l ead t o damage of t he pi st on r od, whi ch
causes pi st on r od seal wear .
( 4) Thi s condi t i on can l ead t o damage of t he pi st on r od, whi ch,
i n t ur n, causes pr emat ur e pi st on r od seal wear .
( 5) Onl y r equi r ed i f r epl aci ng car t r i dge.
( 6) Requi r e r epl acement of uni t s wher e dent s r est r i ct shock or
st r ut pi st on r od movement . I f dent s don' t r est r i ct movement ,
no ser vi ce i s suggest ed or r equi r ed. Especi al l y cr i t i cal on
mono- t ube shocks.
( 7) I f noi se i s i sol at ed t o shock or st r ut , suggest r epl acement .
( 8) Al t hough shocks or st r ut s may have cont r i but ed t o t i r e
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 37)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
cuppi ng, an i nspect i on i s needed of t he ent i r e suspensi on
syst em. I f t he shock or st r ut i s f ound t o be cont r i but i ng
t o t he t i r e cuppi ng, r equi r e r epl acement .

SPINDLES
SPI NDLES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken par t

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bent B Requi r e r epl acement .

Br oken A Requi r e r epl acement .

Race seat ar ea under si zed B Requi r e r epl acement .

Scor ed A Requi r e r epai r or r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

SPRINGS: COIL, LEAF, & TORSION BAR


When spr i ngs ar e r epl aced, i t i s suggest ed, but not r equi r ed,
t hat bot h spr i ngs on an axl e be r epl aced t o mai nt ai n equal hei ght f r om
si de t o si de and t o pr ovi de a bal anced r i de and pr oper handl i ng.
When var i abl e r at e spr i ngs ar e i nst al l ed i n pl ace of
convent i onal coi l spr i ngs, t hey must be i nst al l ed i n axl e set s t o
ensur e pr oper handl i ng, uni f or mr i de, and pr oper chassi s hei ght .
Er r oneous hei ght measur ement s may r esul t f r om: i mpr oper t i r e
i nf l at i on, non- st andar d t i r e or wheel si ze, and heavy l oad i n vehi cl e
or t r unk.
SPRI NGS: COI L, LEAF, & TORSI ON BAR
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 38)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t .
i nt egr i t y

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Br oken ( al l spr i ngs except A Requi r e r epl acement .


secondar y l eave( s) on
mul t i - l eaf spr i ngs)

Coi l cl ash Requi r e r i de hei ght check.


See not e ( 1) bel ow.

Coi l spr i ng i nsul at or B, 2 Suggest r epl acement of i nsul at or .


det er i or at ed

Coi l spr i ng i nsul at or B, 2 Suggest r epl acement of i nsul at or .


mi ssi ng

Coi l spr i ng i nsul at or spl i t B, 2 Suggest r epl acement of i nsul at or .

Coi l spr i ng pl ast i c coat i ng A Ref er t o manuf act ur er ' s ser vi ce


det er i or at ed - r ust r equi r ement s. See not e ( 2) bel ow.
pr esent

Composi t e spr i ng damaged A Fur t her i nspect i on r equi r ed.


See not e ( 3) bel ow.

Cr acked ( al l spr i ngs except A Requi r e r epl acement .


composi t e l eaf and
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 39)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
secondar y l eave( s) on
mul t i - l eaf spr i ngs)

I nst al l ed i ncor r ect l y B Requi r e r epai r .

Leaf spr i ng i nsul at or s B, 2 Suggest r epl acement of i nsul at or s.


mi ssi ng

Secondar y l eaf on mul t i - A, 1 Suggest r epai r or r epl acement


l eaf spr i ng br oken

Secondar y l eaf on mul t i - A, 1 Suggest r epai r or r epl acement


l eaf spr i ng cr acked

Tor si on bar adj ust er bent A Requi r e r epai r or r epl acement of


adj ust er . See not e ( 4) bel ow.

Tor si on bar adj ust er sei zed A Requi r e r epai r or r epl acement of
adj ust er . See not e ( 4) bel ow.

Tor si on bar adj ust er A Requi r e r epai r or r epl acement of


t hr eads damaged par t wi t h damaged t hr eads.
See not e ( 4) bel ow.

Tor si on bar adj ust er A Requi r e r epl acement of par t wi t h


t hr eads st r i pped ( t hr eads st r i pped t hr eads.
mi ssi ng)

Vehi cl e suspensi on hei ght B Requi r e adj ust ment or r epl acement .
not wi t hi n OEM specs

NOTE: ( 1) I f vehi cl e i s wi t hi n manuf act ur er ' s hei ght speci f i cat i ons,
no ser vi ce i s suggest ed or r equi r ed.
( 2) Some manuf act ur er s r equi r e r epl acement under t hese
condi t i ons.
( 3) Check vehi cl e r i de hei ght . I f r i de hei ght i s OK, no ser vi ce
i s suggest ed or r equi r ed.
( 4) Onl y r equi r ed i f r i de hei ght needs t o be adj ust ed.

STEEL POWER STEERING LINES


CAUTI ON: When r epl aci ng st eel power st eer i ng l i nes, be sur e t o use
a r epl acement pr oduct t hat meet s or exceeds OEM desi gn
speci f i cat i ons.
STEEL POWER STEERI NG LI NES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 40)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bl ocked A Requi r e r epai r or r epl acement .

Fi t t i ng i ncor r ect ( such as B Requi r e r epl acement .


compr essi on f i t t i ng)

Fl ar e t ype i ncor r ect B Requi r ed r epl acement .

Leaki ng A Requi r e t i ght eni ng or r epl acement .

Li ne t ype i ncor r ect B Requi r e r epl acement .

Rest r i ct ed A Requi r e r epl acement .

Rout ed i ncor r ect l y B Requi r e r out i ng cor r ect i on.

Rust - pi t t ed A, 1 Suggest r epl acement .

Rust pi t t ed af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y

STEERING ARMS
STEERI NG ARMS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t .

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 41)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of
l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bent B Requi r e r epl acement .

Br oken A Requi r e r epl acement .

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 1) .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

NOTE: ( 1) Check f or damaged st ud.

STEERING DAMPERS
The f ol l owi ng pr ocedur es ar e onl y r equi r ed i f t he vehi cl e was
or i gi nal l y equi pped f r omt he f act or y wi t h a st eer i ng damper . I f t he
st eer i ng damper i s an add- on uni t , t hen t he uni t may be r emoved
i nst ead of r epai r i ng or r epl aci ng.
STEERI NG DAMPERS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t , i f avai l abl e;
ot her wi se, r epl ace st eer i ng
damper .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace st eer i ng damper .

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t , i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace st eer i ng damper .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 42)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
r epl ace st eer i ng damper .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace st eer i ng
damper .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace st eer i ng damper .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
st eer i ng damper .

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace st eer i ng
damper .

Bi ndi ng A Requi r e r epl acement .

Damper body dent ed A Fur t her i nspect i on r equi r ed.


See not e ( 1) bel ow.

Damper body punct ur ed A Requi r e r epl acement .

Dampi ng ( none) A Requi r e r epl acement .

Dust boot ( bel l ows) mi ssi ng B, 2 Suggest r epl acement of boot .


See not e ( 2) bel ow.

Dust boot ( bel l ows) spl i t B, 2 Suggest r epl acement of boot .


See not e ( 2) bel ow.

Dust shi el d br oken B, 2 Suggest r epl acement . See not e ( 2) .

Dust shi el d mi ssi ng B, 2 Suggest r epl acement . See not e ( 2) .

Leaki ng oi l , enough f or A Requi r e r epl acement .


f l ui d t o be r unni ng down
t he body

Loose A Requi r e r epai r or r epl acement .

Mi ssi ng C Requi r e r epl acement .

Noi se B, 2 Fur t her i nspect i on r equi r ed.


See not e ( 3) bel ow.

Pi st on r od bent A Requi r e r epl acement .


* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 43)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM

Pi st on r od br oken A Requi r e r epl acement .

Pi st on r od has sur f ace B, 2 Suggest r epl acement .


def ect

Pi st on r od t hr eads st r i pped A Requi r e r epl acement .


( t hr eads mi ssi ng)

Pi st on r od t hr eads damaged A Requi r e r epai r or r epl acement .

Sei zed A Requi r e r epl acement .

NOTE: ( 1) Requi r e r epl acement of uni t s wher e dent s r est r i ct damper


pi st on r od movement . I f dent s don' t r est r i ct movement , no
ser vi ce i s suggest ed or r equi r ed. Especi al l y cr i t i cal on
mono- t ube damper s.
( 2) Thi s condi t i on can l ead t o damage of t he pi st on r od, whi ch,
i n t ur n, causes pr emat ur e pi st on r od seal wear .
( 3) I f noi se i s i sol at ed t o damper , suggest r epl acement .

STEERING GEARS (EXCEPT RACK & PINION)


I f di agnosi s has det er mi ned t hat compl et e di sassembl y i s
necessar y t o det er mi ne t he ext ent of t he syst emf ai l ur e, t he
suggest i on may be made t o r ebui l d or r epl ace t he power st eer i ng pump.
Repai r or r epl acement of t he f ol l owi ng component s may be r equi r ed, i f
per f or med as par t of a power st eer i ng pump over haul or r ebui l d ser vi ce
t o meet a mi ni mumr ebui l d st andar d.
STEERI NG GEARS ( EXCEPT RACK & PI NI ON)

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bi ndi ng A Requi r e r epai r or r epl acement

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 44)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
Fl ex coupl er bi ndi ng A Requi r e r epai r or r epl acement of
coupl er .

Fl ex coupl er l oose A Requi r e r epai r or r epl acement of


coupl er .

Fl ex coupl er mi ssi ng par t s A Requi r e r epai r or r epl acement of


coupl er .

Fl ex coupl er sof t / spongy A Requi r e r epl acement of coupl er .

Fl ex coupl er t or n A Requi r e r epl acement of coupl er .

Fl ui d cont ami nat ed B Requi r e f l ushi ng and r ef i l l i ng


of t he syst em. See not e ( 1) bel ow.

Gasket l eaki ng A Requi r e r epai r or r epl acement of


gasket .

Housi ng l eaki ng A Requi r e r epl acement .

Hydr aul i c f i t t i ngs l eaki ng A Requi r e r epai r or r epl acement of


f i t t i ngs.

I nadequat e power assi st A Fur t her i nspect i on r equi r ed.


See not e ( 2) bel ow.

Lash exceeds manuf act ur er ' s B Requi r e r epai r or r epl acement .


speci f i cat i ons

Seal l eaki ng A Requi r e r epai r or r epl acement of


seal and/ or mat i ng par t .

Spl i nes damaged A Requi r e r epai r or r epl acement of


spl i nes.

Spl i nes st r i pped A Requi r e r epl acement of spl i nes.

St eer i ng coupl er shi el d B, 2 Suggest r epl acement .


cr acked

St eer i ng coupl er shi el d C Requi r e r epl acement .


mi ssi ng

Thr eads damaged A Requi r e r epai r or r epl acement of


par t wi t h damaged t hr eads.

Thr eads st r i pped ( t hr eads A Requi r e r epl acement of par t wi t h


mi ssi ng) st r i pped t hr eads.

U- j oi nt bi ndi ng A Requi r e r epai r or r epl acement of


j oi nt .
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 45)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM

U- j oi nt l oose A Requi r e r epai r or r epl acement of


j oi nt .

Unequal power assi st A Requi r e r epai r or r epl acement .

NOTE: ( 1) Det er mi ne and cor r ect sour ce of cont ami nat i on.
OEM speci f i cat i ons must be f ol l owed f or f l ui d t ype.
( 2) I f st eer i ng gear i s sour ce of i nadequat e assi st , r equi r e
r epai r or r epl acement .

STEERING GEARS: RACK & PINION


I f di agnosi s has det er mi ned t hat compl et e di sassembl y i s
necessar y t o det er mi ne t he ext ent of t he syst emf ai l ur e, t he
suggest i on may be made t o r ebui l d or r epl ace t he power st eer i ng pump.
Repai r or r epl acement of t he f ol l owi ng component s may be r equi r ed, i f
per f or med as par t of a power st eer i ng pump over haul or r ebui l d ser vi ce
t o meet a mi ni mumr ebui l d st andar d.
STEERI NG GEARS: RACK & PI NI ON

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bal ance t ube bl ocked A Requi r e r epai r or r epl acement of


bal ance t ube.

Bal ance t ube mi ssi ng C Requi r e r epl acement of bal ance


t ube.

Bal ance t ube r est r i ct ed A Requi r e r epai r or r epl acement of


bal ance t ube.

Bel l ows boot cl amp mi ssi ng C Requi r e r epl acement of cl amp.

Bel l ows boot cr acked ( not B, 2 Suggest r epl acement of bel l ows
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 46)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM
t hr ough) boot .

Bel l ows boot mi ssi ng C Requi r e r epl acement of bel l ows


boot .

Bel l ows boot not seal i ng A Requi r e r epai r or r epl acement of


bel l ows boot .

Bel l ows boot t or n A Requi r e r epl acement of bel l ows


boot .

Bel l ows boot t wi st ed ( f r om B Requi r e r epai r .


t oe adj ust ment )

Fi t t i ng l eaki ng A Requi r e r epai r or r epl acement .

Fi t t i ng mi ssi ng A Requi r e r epl acement of f i t t i ng.

Fi t t i ng t hr eads damaged A Requi r e r epai r or r epl acement of


par t wi t h damaged t hr eads.

Fi t t i ng t hr eads st r i pped A Requi r e r epl acement of par t wi t h


( t hr eads mi ssi ng) st r i pped t hr eads.

Fl ex coupl er bi ndi ng A Requi r e r epai r or r epl acement of


coupl er .

Fl ex coupl er l oose A Requi r e r epai r or r epl acement of


coupl er .

Fl ex coupl er mi ssi ng par t s A Requi r e r epai r or r epl acement of


coupl er .

Fl ex coupl er sof t / spongy A Requi r e r epl acement of coupl er .

Fl ex coupl er t or n A Requi r e r epl acement of coupl er .

Fl ui d cont ami nat ed B Requi r e f l ushi ng and r ef i l l i ng of


t he syst em. See not e ( 1) bel ow.

Gasket l eaki ng A Requi r e r epai r or r epl acement .

Har d st eer i ng on col d A, 1 Suggest r epai r or r epl acement .


st ar t - up See not e ( 2) bel ow.

Housi ng cr acked, af f ect i ng B Requi r e r epl acement .


st r uct ur al i nt egr i t y

Housi ng l eaki ng A Requi r e r epl acement .

I nadequat e power assi st A Fur t her i nspect i on r equi r ed.


See not e ( 3) bel ow.
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 47)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:54PM

Lash exceeds manuf act ur er ' s B Requi r e r epai r or r epl acement .


speci f i cat i ons

Seal l eaki ng A Requi r e r epai r or r epl acement .

Spl i nes damaged A Requi r e r epai r or r epl acement .

Spl i nes st r i pped ( spl i nes A Requi r e r epl acement .


mi ssi ng)

St eel l i ne bl ocked A Requi r e r epai r or r epl acement of


l i ne.
St eel l i ne l eaki ng A

St eel l i ne mi ssi ng C Requi r e r epl acement of l i ne.

St eel l i ne r est r i ct ed A Requi r e r epai r or r epl acement of


l i ne.

St eer i ng coupl er shi el d B, 2 Suggest r epl acement .


cr acked

St eer i ng coupl er shi el d C Requi r e r epl acement .


mi ssi ng

St eer i ng coupl er shi el d B, 2 Suggest r epl acement .


t or n

Thr eads damaged A Requi r e r epai r or r epl acement of


par t wi t h damaged t hr eads.

Thr eads st r i pped ( t hr eads A Requi r e r epl acement of par t wi t h


mi ssi ng) st r i pped t hr eads.

U- j oi nt bi ndi ng A Requi r e r epai r or r epl acement of


j oi nt .

U- j oi nt l oose A Requi r e r epai r or r epl acement of


j oi nt .

Unequal power assi st A Requi r e r epai r or r epl acement .

NOTE: ( 1) Det er mi ne and cor r ect sour ce of cont ami nat i on.
Fol l ow OE speci f i cat i ons f or f l ui d t ype.
( 2) I ndi cat es i nt er nal wear .
( 3) I f st eer i ng gear i s sour ce of i nadequat e assi st , r equi r e
r epai r or r epl acement .

STEERING KNUCKLES
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 48)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
STEERI NG KNUCKLES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t .

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Bent B Requi r e r epl acement .

Br oken A Requi r e r epl acement .

Pi nch bol t i ncor r ect B Requi r e r epl acement wi t h bol t t hat


meet s OE desi gn.

Pi nch bol t l oose B Requi r e r epai r .

Pi nch bol t mi ssi ng B Requi r e r epl acement .

Pi nch bol t t abs def or med B Requi r e r epl acement .


( pi nched t oget her ) , . 032" See not e ( 1) bel ow.
or mor e bef or e cl ampi ng

Taper hol e el ongat ed A Requi r e r epl acement . See not e ( 2) .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epai r or r epl acement .


mi ssi ng)

NOTE: ( 1) St eer i ng knuckl e def or mat i on can cause pi nch bol t br eakage.
( 2) Check f or damaged st ud.

STRIKE OUT BUMPERS


* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 49)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
STRI KE OUT BUMPERS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t .

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t .
i nt egr i t y

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads.

Mi ssi ng C Requi r e r epl acement .

Spl i t A, 1 Suggest r epl acement .

STRUT RODS
STRUT RODS

Condi t i on Code Pr ocedur e

Adj ust i ng nut sei zed A Requi r e r epai r or r epl acement .


See not e ( 1) bel ow.

At t achi ng har dwar e bent B Requi r e r epai r or r epl acement of


bent par t , i f avai l abl e;
ot her wi se, r epl ace st r ut r od.

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace st r ut r od.

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace st r ut r od.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 50)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
ot her wi se, r epl ace st r ut r od.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace st r ut r od.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
st r ut r od.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace st r ut r od.

At t achi ng ( mat i ng) hol e A Requi r e r epai r or r epl acement of


over si zed f r ame.

At t achi ng poi nt on f r ame A Requi r e r epai r of f r ame.


cor r oded, af f ect i ng
st r uct ur al i nt egr i t y

Bent A Requi r e r epl acement .

Mat i ng ( at t achi ng) hol e A Requi r e r epai r or r epl acement of


over si zed f r ame.

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

NOTE: ( 1) Onl y r equi r ed i f an al i gnment i s bei ng per f or med.

STRUT UPPER BEARING PLATE ASSEMBLIES


NOTE: When t he f ol l owi ng gui del i nes i ndi cat e r epl acement of
bear i ng, onl y t he bear i ng shoul d be r epl aced i f i t i s
avai l abl e separ at el y; ot her wi se, r epl ace t he bear i ng
pl at e assembl y.
STRUT UPPER BEARI NG PLATE ASSEMBLI ES

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace bear i ng pl at e assembl y.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 51)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
ot her wi se, r epl ace bear i ng pl at e
assembl y.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace bear i ng pl at e assembl y.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
bear i ng pl at e assembl y.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace bear i ng pl at e
assembl y.

Bear i ng axi al or r adi al B Requi r e r epl acement of bear i ng.


movement exceeds vehi cl e
manuf act ur er ' s specs

Bear i ng bi ndi ng A Requi r e r epl acement of bear i ng.

Bear i ng mi ssi ng C Requi r e r epl acement of bear i ng.

Bear i ng sei zed A Requi r e r epl acement of bear i ng.

Bent B Requi r e r epl acement .

Hol es di st or t ed A Requi r e r epl acement .

Mi ssi ng C Requi r e r epl acement .

Sever el y cor r oded, A Requi r e r epl acement .


af f ect i ng st r uct ur al
i nt egr i t y

SWAY BAR LINKS


SWAY BAR LI NKS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace l i nk.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace l i nk.

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 52)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng
par t , i f avai l abl e; ot her wi se,
r epl ace l i nk.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
l i nk.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace l i nk.

Bal l and socket has A, 1 Suggest r epl acement . See not e ( 1) .


l ooseness ( per cept i bl e
ver t i cal movement )

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Bal l and socket has B Requi r e r epl acement . See not es ( 1)


l ooseness t hat i s and ( 2) and caut i on.
excessi ve

Bent B Requi r e r epl acement .

Br oken A Requi r e r epl acement .

Cor r oded, af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 3) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 4) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 5) .

Mi ssi ng C Requi r e r epl acement .

Nut on st ud l oose A Requi r e r epai r . See not e ( 6) .

St ud bent B Requi r e r epl acement . See not e ( 7) .

St ud br oken A Requi r e r epl acement . See not e ( 7) .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 7) .


mi ssi ng)

NOTE: ( 1) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose


pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 53)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
such as t he dr y par k check.
( 2) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 3) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 4) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er t he
j oi nt and wi l l accel er at e wear .
( 5) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er t he j oi nt
and wi l l accel er at e wear .
( 6) Check f or bent st ud or damaged t aper hol e.
( 7) Check f or damaged t aper hol e.

SWAY BARS
SWAY BARS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace sway bar .

At t achi ng har dwar e cor r oded A Requi r e r epl acement of cor r oded
af f ect i ng st r uct ur al par t , i f avai l abl e; ot her wi se,
i nt egr i t y r epl ace sway bar .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace sway bar .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace sway bar .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace sway
bar .

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace sway bar .

Bent B Requi r e r epl acement .

Br oken A Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 54)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM

TIE ROD ENDS (INNER & OUTER)


TI E ROD ENDS ( I NNER & OUTER)

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace t i e r od end.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace t i e r od end.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace t i e r od end.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace t i e
r od end.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace t i e r od end.

Adj ust i ng sl eeve bent B Requi r e r epl acement of sl eeve or


t i e r od end.

Adj ust i ng sl eeve cl amps B Requi r e r epai r .


out of posi t i on

Adj ust i ng sl eeve cor r oded, A Requi r e r epl acement of sl eeve or


af f ect i ng st r uct ur al t i e r od end.
i nt egr i t y

Adj ust i ng sl eeve mi ssi ng C Requi r e r epl acement of sl eeve or


t i e r od end.

Adj ust i ng sl eeve sei zed A Requi r e r epai r or r epl acement .


See not e ( 1) bel ow.

Adj ust i ng sl eeve t hr eads A Requi r e r epai r or r epl acement of


damaged sl eeve or t i e r od end.

Adj ust i ng sl eeve t hr eads A Requi r e r epl acement of sl eeve or


st r i pped ( t hr eads mi ssi ng) t i e r od end.

Bi ndi ng A Fur t her i nspect i on r equi r ed.


* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 55)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
See not e ( 2) bel ow.

Gr ease boot cr acked Suggest r epl acement . See not e ( 3) .

Gr ease boot mi ssi ng Suggest r epl acement . See not e ( 4) .

Gr ease boot t or n Suggest r epl acement . See not e ( 5) .

Gr ease f i t t i ng br oken A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng mi ssi ng C Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease f i t t i ng won' t seal A Requi r e r epl acement of gr ease


f i t t i ng.

Gr ease seal mi ssi ng B, 2 Suggest r epl acement of seal .


See not e ( 4) bel ow.

Gr ease seal t or n B, 2 Suggest r epl acement of seal .


See not e ( 5) bel ow.

Gr easeabl e t i e r od end B, 2 Suggest r epl acement of gr ease


wi l l not t ake gr ease f i t t i ng. See not e ( 6) bel ow.

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 7) .


hor i zont al movement )

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Looseness exceeds B Requi r e r epl acement .


manuf act ur er ' s specs

Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 7)


and ( 8) , caut i on.

Nut on st ud l oose A Requi r e r epai r or r epl acement of


nut . See not e ( 9) bel ow.

Sei zed A Requi r e r epl acement

St ud bent B Requi r e r epl acement . See not e ( 10)

St ud br oken A Requi r e r epl acement . See not e ( 10)

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 10)
mi ssi ng)

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 56)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
NOTE: ( 1) Onl y r equi r ed i f t oe needs t o be adj ust ed.
( 2) I f gr easeabl e, gr ease j oi nt . I f pr obl emper si st s or j oi nt
i s non- gr easeabl e, r equi r e r epl acement .
( 3) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 4) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 5) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 6) I f gr easeabl e t i e r od end wi l l not t ake gr ease af t er
r epl aci ng t he gr ease f i t t i ng, suggest r epl acement of
t i e r od end.
( 7) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
( 8) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 9) Check f or bent st ud or damaged t aper hol e.
( 10) Check f or damaged t aper hol e.

TRACK BARS
TRACK BARS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e A Requi r e r epl acement of i ncor r ect


i ncor r ect par t , i f avai l abl e; ot her wi se,
r epl ace t r ack bar .

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace t r ack bar .

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace t r ack bar .

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
t r ack bar .

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace t r ack bar .

Bent B Requi r e r epl acement .

Cor r oded, af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 57)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM

Gr ease boot cr acked B, 2 Suggest r epl acement . See not e ( 1) .

Gr ease boot mi ssi ng B, 2 Suggest r epl acement . See not e ( 2) .

Gr ease boot t or n B, 2 Suggest r epl acement . See not e ( 3) .

Hol es di st or t ed A Requi r e r epl acement .

Looseness ( per cept i bl e A, 1 Suggest r epl acement . See not e ( 4)


hor i zont al movement ) bel ow.

CAUTI ON: DO NOT use pl i er s or pr y bar t o check bal l and socket


movement . Use onl y moder at e hand pr essur e.

Looseness t hat i s excessi ve B Requi r e r epl acement . See not es ( 4)


and ( 5) , caut i on.

Nut on st ud l oose A Requi r e r epai r or r epl acement of


nut . See not e ( 6) bel ow.

Sei zed A Requi r e r epl acement .

St ud bent B Requi r e r epl acement . See not e ( 7) .

St ud br oken A Requi r e r epl acement . See not e ( 7) .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement . See not e ( 7) .


mi ssi ng)

Wear exceeds manuf act ur er ' s B Requi r e r epl acement .


speci f i cat i ons

NOTE: ( 1) Cr acked gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt


and wi l l accel er at e wear .
( 2) Lack of gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt
and wi l l accel er at e wear .
( 3) Tor n gr ease boot wi l l al l ow cont ami nant s t o ent er j oi nt and
wi l l accel er at e wear .
( 4) I f manuf act ur er ' s pr ocedur es f or i nspect i on exi st , use t hose
pr ocedur es; ot her wi se, use an appr oved i nspect i on met hod
such as t he dr y par k check.
( 5) Excessi ve l ooseness i s def i ned as bei ng si gni f i cant enough
t o af f ect vehi cl e handl i ng or st r uct ur al i nt egr i t y.
( 6) Check f or bent st ud or damaged t aper hol e.
( 7) Check f or damaged t aper hol e.

TRAILING ARMS
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 58)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
TRAI LI NG ARMS

Condi t i on Code Pr ocedur e

At t achi ng har dwar e br oken A Requi r e r epl acement of br oken


par t , i f avai l abl e; ot her wi se,
r epl ace t r ai l i ng ar m.

At t achi ng har dwar e l oose A Requi r e r epai r or r epl acement of


l oose par t , i f avai l abl e;
ot her wi se, r epl ace t r ai l i ng ar m.

At t achi ng har dwar e mi ssi ng C Requi r e r epl acement of mi ssi ng


par t , i f avai l abl e; ot her wi se,
r epl ace t r ai l i ng ar m.

At t achi ng har dwar e t hr eads A Requi r e r epai r or r epl acement of


damaged par t wi t h damaged t hr eads, i f
avai l abl e; ot her wi se, r epl ace
t r ai l i ng ar m.

At t achi ng har dwar e t hr eads A Requi r e r epl acement of par t wi t h


st r i pped ( t hr eads mi ssi ng) st r i pped t hr eads, i f avai l abl e;
ot her wi se, r epl ace t r ai l i ng ar m.

Bent B Requi r e r epl acement .

Bushi ng hol e over si zed B Requi r e r epl acement .

Cor r oded, af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y

Hol es di st or t ed A Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r or r epl acement .

Thr eads st r i pped ( t hr eads A Requi r e r epl acement .


mi ssi ng)

WHEEL ALIGNMENT
WHEEL ALIGNMENT
Wheel al i gnment i s def i ned as t he measur ement , anal ysi s, and
adj ust ment of st eer i ng and suspensi on angl es t o conf or mt o OEM
speci f i cat i ons. These angl es usual l y i ncl ude, but ar e not l i mi t ed t o:
cast er , camber , t oe, and t hr ust angl e. Wher e t hese angl es ar e not
adj ust abl e and not i n speci f i cat i on, component r epl acement or
cor r ect i on ki t s may be r equi r ed. Er r or s i n set - back and st eer i ng axi s
i ncl i nat i on ( SAI ) ar e of t en at t r i but abl e t o f ai l ed or damaged
component s and must be cor r ect ed pr i or t o per f or mi ng an al i gnment .
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 59)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
Fai l ur e t o r epl ace or cor r ect suggest ed or r equi r ed par t s or
ser vi ce may pr event a pr oper al i gnment .
Bef or e per f or mi ng an al i gnment check, i nspect and ver i f y t he
f ol l owi ng:
* Ti r e pr essur e and si ze
* Vehi cl e l oadi ng
* Ri de hei ght
* St eer i ng and suspensi on par t s
Onl y i f t he i nspect i on r eveal s t hat al l t he above ar e wi t hi n
publ i shed speci f i cat i ons, shoul d a wheel al i gnment check and an
al i gnment , i f needed, be per f or med.
CAUTI ON: Under no ci r cumst ances shoul d a t echni ci an bend or heat any
st eer i ng or suspensi on component , unl ess speci f i ed by t he
vehi cl e manuf act ur er , f or exampl e, For d f or ged t wi n " I " beam
axl es. Al l measur ement s and suggest i ons must be not ed on t he
i nspect i on r epor t .
WHEEL ALI GNMENT

Condi t i on Code Pr ocedur e

Dog t r acki ng, shown t o be B, 2 Suggest r epai r .


caused by f aul t y al i gnment

Lead, shown t o be caused B Requi r e al i gnment .


by f aul t y al i gnment

Par t has been changed t hat B Requi r e al i gnment check.


may af f ect al i gnment

Pul l , shown t o be caused B Requi r e al i gnment .


by f aul t y al i gnment

St eer i ng wheel of f - cent er B, 2 Suggest al i gnment .

Ti r e wear , shown t o be B Requi r e al i gnment .


caused by f aul t y al i gnment

Wander , shown t o be caused B Requi r e al i gnment .


by f aul t y al i gnment

WHEEL BEARINGS, RACES, & SEALS


NOTE: When r epl aci ng or r epacki ng wheel bear i ngs, gr ease seal
r epl acement i s r equi r ed. You ar e not r equi r ed t o r epl ace
t hese component s i n axl e set s. Det er mi ne t he need t o r epl ace
based upon t he i ndi vi dual component condi t i ons t hat f ol l ow.
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 60)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
WHEEL BEARI NGS, RACES, & SEALS

Condi t i on Code Pr ocedur e

Rear axl e seal on r ear - A Requi r e r epl acement of seal and


wheel dr i ve l eaki ng i nspect i on of axl e, bear i ng,
housi ng, and vent t ube

Seal bent A, 1 Suggest r epl acement .

Seal l eaki ng A Requi r e r epl acement of seal and


i nspect i on of bear i ngs.

Seal mi ssi ng C Requi r e r epl acement .

Seal t or n A Requi r e r epl acement .

Wheel bear i ng assembl y A Requi r e r epl acement of bear i ng


f eel s r ough when r ot at ed assembl y.

Wheel bear i ng bal l s ar e A Requi r e r epl acement of bear i ng


pi t t ed assembl y.

Wheel bear i ng bal l s ar e A Requi r e r epl acement of bear i ng


wor n assembl y.

Wheel bear i ng end- pl ay A Requi r e adj ust ment of bear i ng, i f


exceeds vehi cl e possi bl e. I f pr oper adj ust ment
manuf act ur er ' s specs cannot be obt ai ned, r equi r e r epai r
or r epl acement of wor n component .

Wheel bear i ng r ace i s l oose A Requi r e r epl acement of hub


i n t he hub bor e assembl y and wheel bear i ngs.

Wheel bear i ng r aces ar e A Requi r e r epl acement of bear i ng


pi t t ed assembl y.

Wheel bear i ng r aces ar e A Requi r e r epl acement of bear i ng


wor n assembl y.

Wheel bear i ng r ol l er s ar e A Requi r e r epl acement of bear i ng


pi t t ed assembl y.

Wheel bear i ng r ol l er s ar e A Requi r e r epl acement of bear i ng


wor n assembl y.

WHEELS & TIRES


TIRES
WARNI NG: These gui del i nes do not appl y t o spl i t r i ms.
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 61)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
Some vehi cl e manuf act ur er s r est r i ct r epl acement of t i r es t o
speci f i c br ands, t ypes, or si zes.
Hi gh pr essur e t empor ar y compact spar e t i r es shoul d not be
used wi t h any ot her r i ms or wheel s, nor shoul d st andar d t i r es, snow
t i r es, wheel cover s, or t r i mr i ngs be used wi t h hi gh pr essur e compact
spar e r i ms or wheel s.
At t empt i ng t o mount a t i r e of one di amet er on a wheel of a
di f f er ent di amet er or f l ange t ype may r esul t i n ser i ous i nj ur y or
deat h.
Onl y speci al l y t r ai ned per sons shoul d de- mount or mount
t i r es. Expl osi ons of t i r e and wheel assembl y can r esul t f r omi mpr oper
mount i ng, possi bl y causi ng ser i ous i nj ur y or deat h.
Consul t t he vehi cl e owner ' s manual or vehi cl e pl acar d f or
cor r ect si ze, speed r at i ng, desi gnat i on, and col d i nf l at i on pr essur e
of t he or i gi nal t i r es. DO NOT exceed t he maxi muml oad or i nf l at i on
capaci t y of t he t i r e speci f i ed by t he Ti r e and Ri mAssoci at i on
When r epl aci ng t i r es, i t i s suggest ed t hat t he r epl acement
t i r es mat ch or exceed t he OEM speed r at i ng desi gnat i on. I f t i r es of
di f f er ent speed r at i ng desi gnat i ons ar e mi xed on t he same vehi cl e, t he
t i r es may var y i n handl i ng char act er i st i cs. DO NOT mi x di f f er ent speed
r at i ng desi gnat i ons on t he same axl e.
DO NOT mi x r adi al s wi t h non- r adi al t i r es on t he same axl e, as
t hi s may af f ect vehi cl e handl i ng and st abi l i t y. I f r adi al t i r es and
bi as or bi as- bel t ed pl y t i r es ar e mi xed on t he same vehi cl e, t he
r adi al s must be on t he r ear . Hi gh- pr essur e t empor ar y compact spar e
t i r es ar e exempt f r omt hi s r ul e.
DO NOT mi x si ze or t ype ( al l season, per f or mance, mud and
snow) of t i r es on t he same axl e.
TI RES

Condi t i on Code Pr ocedur e

Ai r pr essur e i ncor r ect B Requi r e r epai r

Bead br oken A Requi r e r epl acement .

Bead l eaki ng, caused by t i r e A Requi r e r epai r or r epl acement .

Bead wi r e/ cor d exposed A Requi r e r epl acement .

Cor d or bel t mat er i al exposed A Requi r e r epl acement .

Cor d pl y separ at i ons A Requi r e r epl acement .

Di r ect i onal / asymmet r i cal t i r es B Requi r e r emount i ng and/ or


mount ed i ncor r ect l y r eposi t i oni ng.

I r r egul ar t r ead wear , A Suggest r epl acement .


af f ect i ng per f or mance See not e ( 1) bel ow.

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 62)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
Load r at i ngs l ess t han OEM B Requi r e r epl acement .
speci f i cat i ons

Mi xed t i r e si ze desi gnat i ons A Requi r e r ot at i on or


on same axl e r epl acement .

Mi xed t r ead t ypes ( al l season, A Requi r e r ot at i on or


per f or mance, mud and snow) r epl acement .
on same axl e

Number of punct ur es exceeds B Requi r e r epl acement .


manuf act ur er ' s l i mi t

Out of bal ance B Requi r e r ebal ance of t i r e/ wheel


assembl y.

Pl y separ at i on A Requi r e r epl acement .

Pul l or l ead, caused by t i r e A Requi r e r ot at i on or


r epl acement .

Radi al and bi as or bi as- bel t ed B Requi r e r ot at i on or


pl y t i r es on same axl e r epl acement .

Radi al s ar e on t he f r ont and B Requi r e r ot at i on or


not on t he r ear r epl acement . See not e ( 2) .

Run f l at damage A Requi r e r epl acement .

Shoul der cut A Requi r e r epl acement .

Shoul der punct ur e A Requi r e r epl acement .

Shoul der wi t h pl ug A Requi r e r epl acement .

Si dewal l bul ge A Requi r e r epl acement .

Si dewal l cut A Requi r e r epl acement .

Si dewal l i ndent at i on No ser vi ce r equi r ed/ suggest ed.

Si dewal l punct ur e A Requi r e r epl acement .

Si dewal l wi t h pl ug A Requi r e r epl acement .

Speed r at i ng desi gnat i ons B Suggest r ot at i on or


di f f er ent on same axl e r epl acement .

Ti r e and wheel assembl y has B Requi r e r epai r or r epl acement


excessi ve r un- out of appr opr i at e par t . See not e
( 3) bel ow.

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 63)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
Ti r es wi t h mor e t han 1/ 4" B Requi r e r epl acement .
di amet er di f f er ence on a
f our - wheel dr i ve vehi cl e

Tr ead ar ea punct ur e l ar ger i n B Requi r e r epl acement .


di amet er t han t i r e
manuf act ur er ' s speci f i cat i ons

Tr ead mi ssi ng pi eces A Requi r e r epl acement .


( chunki ng) , exposi ng cor d

Tr ead mi ssi ng pi eces A Suggest r epl acement .


( chunki ng) , not exposi ng cor d

Tr ead separ at i ons A Requi r e r epl acement .

Tube i n t ubel ess t i r e C, 3 Suggest r emoval of t ube.


See not e ( 4) bel ow.

Weat her - checki ng No ser vi ce r equi r ed/ suggest ed.

Wor n t o t r ead wear i ndi cat or s B Requi r e r epl acement .

NOTE: ( 1) Det er mi ne and cor r ect cause of i r r egul ar t i r e wear .


( 2) I f r adi al s and bi as or bi as- bel t ed pl y t i r es ar e on t he same
vehi cl e, t he r adi al s must be on t he r ear axl e, except f or
hi gh- pr essur e t empor ar y spar es.
( 3) Excessi ve i s def i ned as enough t o cont r i but e t o per f or mance
pr obl ems. Mat ch mount i ng may cor r ect r un- out . I f not ,
r equi r e r epl acement of appr opr i at e par t . Ref er t o
manuf act ur er ' s speci f i cat i ons.
( 4) Most manuf act ur er s do not r ecommend t ubes i n t ubel ess t i r es.
I nspect t i r e and wheel assembl y t o det er mi ne t he r eason f or
a t ube i n t ubel ess t i r e. Recommendat i on f or r epai r or
r epl acement shoul d be based upon condi t i on of t i r es and/ or
wheel l i st ed i n t hese gui del i nes.

VALVE STEMS
VALVE STEMS

Condi t i on Code Pr ocedur e

Bent A, 1 Suggest r epl acement .

Br oken A Requi r e r epl acement .

Cut , but not l eaki ng A, 1 Suggest r epl acement .

Det er i or at ed ( cr acki ng, dr y r ot ) A, 1 Suggest r epl acement .

* STEERING UNIFORM INSPECTION GUIDELINES *


Article Text (p. 64)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
Leaki ng A Requi r e r epai r / r epl acement .

Mi ssi ng C Requi r e r epl acement .

Thr eads damaged A Requi r e r epai r / r epl acement .

Thr eads st r i pped ( t hr eads mi ssi ng) A Requi r e r epl acement .

Val ve cap mi ssi ng C Requi r e r epl acement of cap.

Weat her - checki ng A, 1 Suggest r epl acement .

Won' t t ake ai r A Requi r e r epai r / r epl acement .

WHEEL ATTACHMENT HARDWARE


For condi t i ons not ed bel ow, al so check condi t i ons of wheel
st ud hol es.
CAUTI ON: Pr oper l ug nut t or que i s essent i al . Fol l ow manuf act ur er ' s
t or que speci f i cat i ons and t i ght eni ng sequence. DO NOT
l ubr i cat e t hr eads unl ess speci f i ed by t he vehi cl e
manuf act ur er .
WHEEL ATTACHMENT HARDWARE

Condi t i on Code Pr ocedur e

Bent A Requi r e r epl acement .

Br oken A Requi r e r epl acement .


See not e ( 1) bel ow.

Loose B Requi r e r epai r or r epl acement


of af f ect ed component .

Lug nut i nst al l ed backwar d B Requi r e r epai r .

Lug nut mat i ng t ype i ncor r ect B Requi r e r epl acement of nut .

Lug nut mat i ng sur f ace di shed A Requi r e r epl acement of nut .

Lug nut f l at s r ounded A Requi r e r epl acement of nut .


See not e ( 2) bel ow.

Lug nut sei zed A Requi r e r epl acement of nut


and/ or st ud. See not e ( 2) bel ow.

St ud i ncor r ect B Requi r e r epl acement of st ud.

Thr eads damaged A Requi r e r epai r or r epl acement of


* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 65)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM
component wi t h damaged t hr eads.

Thr eads st r i pped ( t hr eads A Requi r e r epl acement of


mi ssi ng) component wi t h st r i pped t hr eads.

NOTE: ( 1) Some manuf act ur er s r equi r e r epl acement of al l st uds on t hat


wheel i f t wo or mor e st uds or nut s on t he same wheel ar e
br oken or mi ssi ng.
( 2) Onl y r equi r ed i f r emovi ng wheel .

WHEELS
WARNI NG: Mount i ng a r egul ar t i r e on a hi gh- pr essur e compact spar e
wheel i s not per mi t t ed. At t empt i ng t o mount a t i r e of one
di amet er on a wheel of a di f f er ent di amet er or f l ange t ype
may r esul t i n ser i ous i nj ur y or deat h. I f t he wheel
i dent i f i cat i on st amp i s not l egi bl e, or cannot be f ound,
DO NOT use t he wheel unt i l t he si ze and t ype have been
pr oper l y i dent i f i ed. Wheel s of di f f er ent di amet er , of f set ,
or wi dt h cannot be mi xed on t he same axl e. Bead seat t aper s
cannot be i nt er changed.
WHEELS

Condi t i on Code Pr ocedur e

Bead l eaki ng, caused by A Requi r e r epai r or r epl acement .


wheel r i mf l ange See caut i on bel ow.

CAUTI ON: DO NOT at t empt t o cor r ect a bent wheel r i m.

Bent wheel hub mount i ng A Requi r e r epl acement .


sur f ace

Bent wheel r i m, causi ng B, 2 Suggest r epl acement .


vi br at i on See caut i on above.

Br oken A Requi r e r epl acement .

Cast wheel por ous, causi ng A Requi r e r epai r or r epl acement .


a l eak

Cl i p- on bal ance wei ght i s B, 2 Suggest r epl acement .


i ncor r ect t ype f or wheel
r i mf l ange

Cor r osi on, af f ect i ng A Requi r e r epl acement .


st r uct ur al i nt egr i t y

Cor r osi on bui l d- up on wheel A Requi r e r epai r .


hub mount i ng sur f ace
* STEERING UNIFORM INSPECTION GUIDELINES *
Article Text (p. 66)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:55PM

Cr acked A Requi r e r epl acement .

Di r ect i onal / asymmet r i cal B Requi r e r emount i ng and/ or


wheel s mount ed i ncor r ect l y r eposi t i oni ng.

Load capaci t y l ess t han B Requi r e r epl acement .


OEM speci f i cat i ons

Of f set mi smat ched on same B Requi r e r epl acement .


axl e

Ri vet s l eaki ng A Requi r e r epl acement .

Run- out beyond OEM specs B Requi r e r epl acement .

St ud hol es el ongat ed A Requi r e r epl acement . See not e ( 1)

Wel ded or br azed r epai r B, 2 Suggest r epl acement .

Wel ds l eaki ng A Requi r e r epl acement .

Wheel hub cent er i ng ( pi l ot ) B Requi r e r epl acement .


hol e i ncor r ect

NOTE: ( 1) I nspect wheel at t achi ng har dwar e f or damage.

END OF ARTICLE
AXLE SHAFT
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
ARTICLE BEGINNING
1995- 96 DRI VE AXLES
Vol kswagen - FWD Axl e Shaf t s
Gol f
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTI NG - BASI C PROCEDURES ar t i cl e i n GENERAL
I NFORMATI ON.
REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION
AXLE SHAFT
NOTE: Two di f f er ent t ypes of j oi nt s may be used on axl e shaf t .
Types used ar e: Const ant Vel oci t y ( CV) t ype j oi nt , or
t r i pod- t ype j oi nt . CV j oi nt uses a 6 bal l and cage desi gn,
whi l e t r i pod j oi nt uses a t r i pl e- r ol l er desi gn. Thr ee
met hods may be used t o assembl e axl e shaf t t o hub assembl y
dependi ng on hub spl i ne t ype. Lat er model desi gn and new
r epl acement par t s ar e r evi sed, and r equi r e an updat ed
i nst al l at i on pr ocedur e.
NOTE: Tr i pod- t ype j oi nt s ar e used on model s equi pped wi t h a
4- cyl i nder engi ne wi t h an aut omat i c t r ansaxl e.
Engi ne/ t r ansaxl e assembl y must be r ai sed t o r emove l ef t - si de
axl e shaf t . I t i s not r equi r ed t o r ai se engi ne/ t r ansaxl e
assembl y f or r i ght - si de axl e shaf t r emoval .
Removal
1) Remove axl e shaf t nut . Rai se and suppor t vehi cl e. Remove
wheel . Remove ai r def l ect or pl at e f r oml ower cont r ol ar m( i f
equi pped) . On model s equi pped wi t h t r i pod- t ype j oi nt , r emove bol t f or
r ear t r ansaxl e mount , and bol t f or f r ont engi ne mount .
2) Usi ng Engi ne Suppor t Br i dge ( 10- 222A) and Adapt er ( 10- 222
A/ 1) , r ai se and suppor t engi ne/ t r ansaxl e assembl y. Di sconnect axl e
shaf t ( s) f r omt r ansaxl e dr i ve f l ange. Mar k posi t i on of l ower cont r ol
ar m- t o- bal l j oi nt bol t s.
3) Remove bot h out er cont r ol ar m- t o- bal l j oi nt bol t s. Loosen,
but DO NOT r emove i nner cont r ol ar m- t o- bal l j oi nt bol t . On model s
equi pped wi t h compr essed hub spl i nes, use Pr ess ( 3283) t o pr ess axl e
shaf t f r omwheel hub. Swi ng wheel assembl y out war d and suppor t i f
necessar y. Remove axl e shaf t assembl y.
Di sassembl y & Reassembl y ( CV- Type J oi nt )
1) Remove axl e shaf t boot ( s) . Usi ng a dr i f t , r emove
pr ot ect i ve cap f r omCV j oi nt ( i f equi pped) . Remove ci r cl i p f r om
t r ansaxl e- si de CV j oi nt . See Fi g. 1. Suppor t CV j oi nt wi t h axl e
assembl y on Suppor t St and ( VW402) .
AXLE SHAFT
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
2) Usi ng Dr i ver ( VW408A) , pr ess i nner CV j oi nt of f axl e
shaf t . Usi ng a sof t mal l et , dr i ve of f out er CV j oi nt f r omaxl e shaf t .
DO NOT di sassembl e out er CV j oi nt . Out er CV j oi nt i s not ser vi ceabl e,
and must be r epl aced as an assembl y i f wor n.
3) Mar k posi t i on of bal l hub i n r el at i on t o bal l cage and
housi ng f or i nst al l at i on r ef er ence of i nner j oi nt . Rot at e i nner r ace
and r emove bal l s. Cl ean and i nspect par t s f or gal l i ng or wear . Cover
bal l s wi t h gr ease and r ei nst al l i n r ace.
4) To r eassembl e, r ever se di sassembl y pr ocedur e. See
AXLE SHAFT LENGTH t abl e. Use NEWci r cl i ps and boot cl amps dur i ng
assembl y.
Fi g. 1: Expl oded Vi ew Of Axl e Shaf t Wi t h CV- Type J oi nt ( Typi cal )
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
Di sassembl y & Reassembl y ( Tr i pod- Type J oi nt )
1) Remove axl e shaf t boot ( s) . Usi ng a dr i f t , r emove
pr ot ect i ve cap f r omt r i pod j oi nt . Remove ci r cl i p f r omt r i pod j oi nt .
Remove j oi nt f r omaxl e shaf t . Mar k posi t i on of t r i pod- r ol l er assembl y
i n r el at i on t o housi ng f or i nst al l at i on r ef er ence.
2) Remove t r i pod- r ol l er assembl y f r omhousi ng. Cl ean and
i nspect par t s f or gal l i ng or wear . I nst al l housi ng wi t h a NEWboot on
axl e shaf t . Cover t r i pod- r ol l er assembl y wi t h gr ease and i nst al l i nt o
housi ng usi ng r ef er ence mar ks made dur i ng di sassembl y.
3) Push t r i pl e- r ol l er assembl y ont o axl e shaf t wi t h chamf er ed
si de of spl i nes f i r st . See Fi g. 2. I nst al l a NEWci r cl i p. Fast en boot
usi ng a NEWcl amp. Measur e axl e shaf t l engt h. See AXLE SHAFT LENGTH
t abl e.
AXLE SHAFT
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
Fi g. 2: Expl oded Vi ew Of Axl e Shaf t Wi t h Tr i pod- Type J oi nt
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
NOTE: Bonded- t ype axl e shaf t s use a l ocki ng f l ui d on mat i ng axl e
shaf t and hub spl i nes. I f r eusi ng or i gi nal hub assembl y,
appl y Locki ng Fl ui d ( D 185 400 A2) t o axl e shaf t spl i nes.
Locki ng f l ui d i s not needed i f r epl aci ng hub assembl y wi t h
AXLE SHAFT
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
r evi sed par t , si nce hub i s a compr ess- f i t desi gn.
I nst al l at i on
To i nst al l , r ever se r emoval pr ocedur e. Cl ean bol t s and nut s
t o ensur e t i ght eni ng t or que i s cor r ect . I nst al l a NEWaxl e shaf t nut .
See TORQUE SPECI FI CATI ONS.
AXLE SHAFT LENGTH TABLE

Appl i cat i on I n. ( mm)


Aut omat i c Tr ansaxl e ( 096)
Lef t Axl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. 6 ( 447. 4)
Ri ght Axl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26. 8 ( 681. 5)
Aut omat i c Tr ansaxl e ( 01M) . . . . . . . . . . . . . . . . . . . . . . . . . ( 1)
Manual Tr ansaxl e ( 02A)
Lef t Axl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. 6 ( 447. 4)
Ri ght Axl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26. 8 ( 681. 5)
Manual Tr ansaxl e ( 020)
Lef t Axl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. 9 ( 455. 5)
Ri ght Axl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27. 1 ( 691. 5)
Vi br at i on Dampener Posi t i on
1. 9L Engi ne . . . . . . . . . . . . . . ( 2) 20. 63- 20. 71 ( 524. 0- 526. 0)
2. 0L Engi ne . . . . . . . . . . . . . . ( 2) 21. 26- 21. 34 ( 540. 0- 542. 0)
( 1) - I nf or mat i on not avai l abl e at t i me of publ i cat i on.
( 2) - Measur ed f r omout er sur f ace of j oi nt t o out er sur f ace
of vi br at i on damper .

TORQUE SPECIFICATIONS
TORQUE SPECI FI CATI ONS TABLE

Appl i cat i on Ft . Lbs. ( N. m)


Axl e Shaf t Nut
Wi t h Tr i pod- Type J oi nt . . . . . . . . . . . . . . . . . . . . . . . 195 ( 265)
Wi t h Bonded Axl e Shaf t Spl i nes . . . 66 ( 90) Pl us 1/ 8 Tur n
Wi t h Compr essed Hub Spl i nes . . . . . . . . . . . . . . . . . . . . . . . ( 1)
Axl e Shaf t - To- Tr ansaxl e Fl ange Bol t
CV- Type J oi nt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Tr i pod- Type J oi nt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
Lower Cont r ol Ar m- To- Bal l J oi nt Bol t . . . . . . . . . . . . . 26 ( 35)
Wheel Lug Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 ( 110)
( 1) - Ti ght en t o 148 f t . l bs. ( 200 N. m) , t hen back of f one
t ur n. Ret i ght en t o 37 f t . l bs. ( 50 N. m) , pl us an
addi t i onal 30 degr ees.

AXLE SHAFT
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
END OF ARTICLE
CLUTCH
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
ARTICLE BEGINNING
1995- 96 CLUTCHES
Vol kswagen - FWD
Gol f
DESCRIPTION
Cl ut ches ar e si ngl e di sc t ype. A di aphr agmspr i ng i s used t o
engage pr essur e pl at e. The cl ut ch syst emi s mechani cal l y or
hydr aul i cal l y oper at ed. Mechani cal l y oper at ed cl ut ch i s cont r ol l ed by
t he cl ut ch pedal , cl ut ch cabl e, r et ur n spr i ng, r el ease f or k and
r el ease bear i ng. Hydr aul i cal l y oper at ed cl ut ch i s cont r ol l ed by cl ut ch
pedal , cl ut ch mast er cyl i nder , t r ansaxl e housi ng- mount ed r el ease
cyl i nder , r et ur n spr i ng, r el ease f or k and r el ease bear i ng.
ADJUSTMENTS
NOTE: Cabl e cl ut ch and hydr aul i c cl ut ch syst ems ar e aut omat i cal l y
adj ust ed and r equi r e no manual adj ust ment .
GEARSHIFT LEVER CABLES
1) Pl ace gear shi f t l ever i n Neut r al posi t i on. Remove
gear shi f t knob and boot . Loosen bol t and nut ( at t r ansaxl e sl ot t ed
l ever s) of bot h cabl es.
2) Loosen l ock bol t bel ow f r ont of gear shi f t l ever . See
Fi g. 1. I nst al l Shi f t Lever Gauge ( 3193) . Pi vot gauge l ocat i ng pi n
under bear i ng pl at e and t i ght en l ock nut .
3) Push gear shi f t l ever t o l ef t i nt o det ent of sl i de. Push
gear shi f t l ever and sl i de t o l ef t and hol d agai nst st op ( opposi t e
di r ect i on of ar r ow shown) . See Fi g. 1. Ti ght en gauge bol t .
4) Push gear shi f t l ever t o r i ght i nt o r i ght si de det ent
( di r ect i on of ar r ow shown) . See Fi g. 1. Ti ght en l ock bol t . I nst al l
Gauge Wedge & Locat i ng Pi n ( 3192/ 1) . See Fi g. 2.
5) Push wedge i n bet ween l ever and cover unt i l t her e i s no
f r ee pl ay i n l ever . DO NOT push i n so as t o make shi f t l ever r i de up.
Ti ght en shi f t cabl es t o l ever s. DO NOT di st ur b wedge or l ever
posi t i ons. Recheck wedge l ocat i on.
6) Remove shi f t l ever gauge, gauge wedge and l ocat i ng pi n.
Check t r ansaxl e shi f t i ng. I f gear engagement i s okay, adj ust ment i s
compl et e. I f any gear f ai l s t o engage smoot hl y, go t o next st ep.
7) Pl ace gear shi f t l ever i n 1st gear . Have an assi st ant
measur e act uat i ng ar mmovement whi l e movi ng gear shi f t l ef t . Act uat i ng
ar mshoul d not move mor e t han . 04" ( 1 mm) . I f act uat i ng ar mmovement
i s as speci f i ed, adj ust ment i s compl et e. I f act uat i ng ar mmovement i s
not as speci f i ed, go next st ep.
8) Pl ace gear shi f t l ever i n Neut r al posi t i on. Loosen nut No.
1 at act uat i ng ar mmount i ng. See Fi g. 3. Move mount i ng t owar d bul khead
and t i ght en nut . I f gear sel ect or wi l l not adj ust , check f or wor n or
CLUTCH
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
damaged par t s.
Fi g. 1: I dent i f yi ng Shi f t Lever Gauge I nst al l at i on
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
Fi g. 2: I dent i f yi ng Gauge Wedge & Locat i ng Pi n I nst al l at i on
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
CLUTCH
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
Fi g. 3: Adj ust i ng Act uat i ng Ar mPosi t i on
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
TRANSAXLE ALIGNMENT
Loosen si de engi ne mount . I f si de engi ne mount i s equi pped
wi t h a t hr ough- bol t , l oosen t hr ough- bol t onl y. Loosen t r ansaxl e t o
sub- f r ame mount . Loosen f r ont engi ne mount . Rock power t r ai n and
t i ght en si de engi ne mount ( t hr ough- bol t i f equi pped) . Ti ght en
t r ansaxl e mount and f r ont engi ne mount .
REMOVAL & INSTALLATION
NOTE: On model s wi t h t hef t pr ot ect i on syst em, obt ai n st er eo
secur i t y code f r omvehi cl e owner bef or e di sconnect i ng
bat t er y cabl e.
CLUTCH ASSEMBLY
Removal ( Cabl e Cl ut ch)
1) Di sconnect negat i ve bat t er y cabl e. Remove upper cl ut ch
housi ng- t o- t r ansaxl e bol t s. Di sconnect r i ght engi ne mount . Di sconnect
back- up l i ght swi t ch wi r es, speedomet er cabl e and cl ut ch cabl e at
t r ansaxl e. See Fi g. 4.
2) Di sconnect shi f t l i nkage at gear shi f t l ever . Di sconnect
t r ansaxl e mount i ng br acket s. At t ach Engi ne Suppor t ( 10- 222) t o engi ne.
Di sconnect f r ont engi ne suppor t br acket . Remove st ar t er and cl ut ch
shi el ds.
3) Remove exhaust pi pe br acket . Suppor t t r ansaxl e wi t h f l oor
j ack. Remove r ear t r ansaxl e mount . Di sconnect l ef t and r i ght axl e
shaf t s at t r ansaxl e. See AXLE SHAFTS - FWD ar t i cl e i n DRI VE AXLES
sect i on. Tur n st eer i ng f ul l l ef t and secur e axl e shaf t s. Remove l ar ge
cl ut ch cover pl at e bol t s ( pl at e r emai ns on engi ne) . Remove smal l
cl ut ch cover pl at e bol t s and cl ut ch cover pl at e.
4) Push engi ne as f ar t o t he r i ght as possi bl e. Pul l
CLUTCH
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
t r ansaxl e away f r omengi ne whi l e posi t i oni ng engi ne so r i ght dr i ve
f l ange cl ear s f l ywheel . Lower and r emove t r ansaxl e.
5) Wi t h t r ansaxl e r emoved, i nst al l Fl ywheel Hol der ( VW558) on
f l ywheel . Remove pr essur e pl at e- t o- cr ankshaf t bol t s i n a di agonal
pat t er n. Pr y r et ai ni ng r i ng f r omi nt er medi at e pl at e, and l i f t
i nt er medi at e pl at e f r ompr essur e pl at e. Remove cl ut ch di sc and
f l ywheel . See Fi g. 4.
Fi g. 4: I dent i f yi ng Cl ut ch Cabl e & Rel at ed Component s
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
I nspect i on
1) I nspect pr essur e pl at e sur f ace f or wear , cr acks, bur ni ng,
or war page. Measur e war page wi t h st r ai ght edge and f eel er gauge at
sever al di f f er ent poi nt s. Maxi mumpr essur e pl at e war page i s . 008" ( . 2
mm) . I nspect cl ut ch r el ease bear i ng f or smoot h oper at i on and
l ooseness. Repl ace bear i ngs i f necessar y. DO NOT wash r el ease bear i ng
i n sol vent .
2) I nspect cl ut ch di sc l i ni ng f or excessi ve wear and bur ned
or oi l - soaked condi t i on. I nspect cl ut ch di sc f or l oose r i vet s and
t or si on damper s. I nspect r i ng and i nt er medi at e pl at e. Measur e cl ut ch
di sc and f l ywheel r unout . I nspect f l ywheel r i ng gear t eet h f or wear
and damage. I nspect f l ywheel f or wear , cr acks and bur ned condi t i on.
I nst al l at i on
1) To i nst al l , r ever se r emoval pr ocedur e. Appl y gr ease t o
bal l st ud and i nner sur f ace of r el ease bear i ng. Cl ean hub spl i nes of
i nput shaf t and appl y a l i ght coat of gr ease. Ensur e cl ut ch di sc
sl i des smoot hl y on i nput shaf t spi nes.
2) Ensur e pr ot r usi on on i nt er medi at e pl at e poi nt s away f r om
CLUTCH
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
pr essur e pl at e. See Fi g. 5. I nst al l pr essur e pl at e bol t s f i nger t i ght .
Usi ng Cl ut ch Cent er i ng Pl ug ( 3190) , al i gn cl ut ch di sc and pi l ot
bushi ng hol es. Ti ght en pr essur e pl at e bol t s t o speci f i cat i on usi ng a
cr i sscr oss pat t er n.
3) Usi ng f l ywheel l ock or si mi l ar devi ce, hol d cr ankshaf t
f r omt ur ni ng. Ti ght en f l ywheel bol t s, i n a cr i sscr oss pat t er n, t o
speci f i cat i on. See TORQUE SPECI FI CATI ONS. On di esel model s, al i gn
t r ansaxl e. See TRANSAXLE ALI GNMENT under ADJ USTMENTS. Ensur e t r ansaxl e
oi l l evel i s cor r ect . Adj ust gear shi f t l ever cabl es. See
GEARSHI FT LEVER CABLES under ADJ USTMENTS.
Fi g. 5: Expl oded Vi ew Of Cl ut ch Assembl y ( Cabl e Cl ut ch)
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
Removal ( Hydr aul i c Cl ut ch)
1) Di sconnect negat i ve bat t er y cabl e. Di sconnect el ect r i cal
connect or s f r omt r ansmi ssi on. Remove connect i ng t ube t o i nt er cool er
( i f equi pped) .
2) Di sconnect gear shi f t cabl es, cabl e suppor t s and l i nkage
f r omt r ansmi ssi on. Remove cl ut ch r el ease cyl i nder , and wi r e asi de.
Di sconnect speedomet er dr i ve f r omt r ansmi ssi on. Remove upper engi ne-
t o- t r ansaxl e bol t s.
3) Remove 3 r i ght si de engi ne mount - t o- engi ne bol t s and one
l ef t si de t r ansmi ssi on mount br acket t hr ough- bol t . On vehi cl es
equi pped wi t h ABS, i t may be necessar y t o r emove cool ant over f l ow
r eser voi r t o access l ef t si de t hr ough- bol t .
4) Remove r adi at or f an, cover and mount . Remove nut f r om
f r ont t r ansmi ssi on mount . At t ach Engi ne Suppor t ( 10- 222A) and
Bases( 10- 222A/ 1) t o engi ne. Sl i ght l y t i ght en engi ne suppor t and r emove
st ar t er . Remove l ef t t r ansaxl e mount br acket .
5) Remove l ong l ef t si de t r ansmi ssi on suppor t br acket . Remove
bal ance wei ght f r ommount . Remove heat shi el d f or r i ght si de i nner CV
j oi nt .
6) Di sconnect axl e shaf t s at f l anges, and wi r e asi de. See
AXLE SHAFTS - FWD ar t i cl e i n DRI VE AXLES sect i on. Remove l ef t si de
t r ansaxl e mount f r omt r ansaxl e. Push r ear war d on mount f or cl ear ance
t o r emove l ong t r ansaxl e mount bol t .
CLUTCH
Article Text (p. 6)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
7) Push t r ansaxl e mount t o r i ght and pul l down t o r emove f r om
vehi cl e. Remove smal l gear car r i er housi ng cover . Suppor t t r ansaxl e
wi t h f l oor j ack. Remove r ear t r ansaxl e mount . Remove l ower t r ansaxl e-
t o- engi ne bol t s. Car ef ul l y pr y t r ansaxl e f r omengi ne and l ower . Pl ug
t r ansaxl e openi ngs t o pr event cont ami nat i on or f l ui d l oss.
8) Usi ng Fl ywheel Lock ( 3067) or si mi l ar devi ce, hol d
cr ankshaf t f r omt ur ni ng. Remove pr essur e pl at e bol t s. Remove pr essur e
pl at e and cl ut ch di sc. See Fi g. 6.
Fi g. 6: Expl oded Vi ew Of Cl ut ch Assembl y ( Hydr aul i c Cl ut ch)
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
I nspect i on
1) I nspect pr essur e pl at e sur f ace f or wear , cr acks, bur ni ng,
or war page. Measur e war page wi t h st r ai ght edge and f eel er gauge at
sever al di f f er ent poi nt s. Maxi mumpr essur e pl at e war page i s . 008" ( . 2
mm) . I nspect cl ut ch r el ease bear i ng f or smoot h oper at i on and
l ooseness. Repl ace bear i ngs i f necessar y. DO NOT wash r el ease bear i ng
i n sol vent .
2) I nspect cl ut ch di sc l i ni ng f or excessi ve wear and bur ned
or oi l - soaked condi t i on. I nspect cl ut ch di sc f or l oose r i vet s and
t or si on damper s. Measur e cl ut ch di sc and f l ywheel r unout . I nspect
f l ywheel r i ng gear t eet h f or wear and damage. I nspect f l ywheel f or
wear , cr acks and bur ned condi t i on.
NOTE: Pr essur e pl at e has a pr ot ect i ve gr ease coat i ng. Remove
cont act sur f ace gr ease onl y. Ser vi ce l i f e wi l l be shor t ened
i f r emai ni ng por t i ons of pr essur e pl at e pr ot ect i ve gr ease
ar e r emoved.
I nst al l at i on
1) Repl ace i nput shaf t " O" r i ng. See Fi g. 7. To i nst al l ,
r ever se r emoval pr ocedur e. Appl y gr ease t o bal l st ud and i nner sur f ace
CLUTCH
Article Text (p. 7)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
of r el ease bear i ng. Cl ean hub spl i nes of i nput shaf t and appl y a l i ght
coat of gr ease. Ensur e cl ut ch di sc sl i des on i nput shaf t spi nes.
2) I nst al l pr essur e pl at e bol t s f i nger t i ght . Usi ng Cl ut ch
Cent er i ng Pl ug ( 3190) , al i gn cl ut ch di sc and pi l ot bushi ng hol es.
Ti ght en pr essur e pl at e bol t s t o speci f i cat i on usi ng a cr i sscr oss
pat t er n.
3) On di esel model s, al i gn t r ansaxl e. See TRANSAXLE ALI GNMENT
under ADJ USTMENTS. Ensur e t r ansaxl e oi l l evel i s cor r ect . Usi ng
Fl ywheel Lock ( 3067) or si mi l ar devi ce, hol d cr ankshaf t f r omt ur ni ng.
Ti ght en f l ywheel bol t s t o speci f i cat i on. See TORQUE SPECI FI CATI ONS.
4) Push cl ut ch r el ease l ever r ear war d and t empor ar i l y i nst al l
mount i ng pi n or an 8 x 22 mmbol t t hr ough pi vot ar m. Remove pi n or
bol t af t er i nst al l at i on i s compl et e. Adj ust gear sel ect or mechani sm.
See GEARSHIFT LEVER CABLES under ADJUSTMENTS.
Fi g. 7: Expl oded Vi ew Of Tr ansaxl e Assembl y ( Hydr aul i c Cl ut ch)
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
CLUTCH CABLE
NOTE: I f i nst al l i ng new cabl e, compr ess adj ust i ng mechani smusi ng
same r et ai ni ng st r ap used t o compr ess adj ust i ng mechani smof
NEWcabl e. St r ap i s i ncl uded wi t h NEWcabl e.
CLUTCH
Article Text (p. 8)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
Removal & I nst al l at i on
1) Car ef ul l y cut 1/ 2 of r et ai ni ng st r ap eyel et . Remove
r et ai ni ng st r ap f r omnew cl ut ch cabl e, bei ng car ef ul not t o bend
cl ut ch cabl e. Depr ess cl ut ch pedal at l east 5 t i mes. I nst al l r et ai ni ng
st r ap ont o ol d cabl e. See Fi g. 8.
2) Wi t h an assi st ant , compr ess adj ust i ng mechani smand hook
r et ai ni ng st r ap t abs ont o pi ns of adj ust i ng mechani sm. I f adj ust i ng
mechani smcannot be compr essed, r epai r or r epl ace adj ust i ng mechani sm.
Remove over - cent er spr i ng and cl ut ch cabl e.
Fi g. 8: Removi ng Cl ut ch Cabl e
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
CLUTCH MASTER CYLINDER
Removal & I nst al l at i on
1) Remove cool ant expansi on t ank. Wi t h hoses at t ached move
asi de. Remove and pl ug hydr aul i c l i ne. Remove and pl ug f l ui d suppl y
hose l ocat ed bet ween cl ut ch mast er cyl i nder and br ake mast er cyl i nder
r eser voi r . Remove l ower t r i mpl at e.
2) Usi ng Cl i p Rel ease Tool ( 3309) , r emove mast er cyl i nder
push r od. Remove cl ut ch pedal mount i ng br acket . Remove mount i ng nut s
and mast er cyl i nder . To i nst al l , r ever se r emoval pr ocedur e. Bl eed
hydr aul i c syst em. See BLEEDI NG CLUTCH HYDRAULI C SYSTEM.
CLUTCH RELEASE CYLINDER
Removal & I nst al l at i on
1) Di sconnect negat i ve bat t er y cabl e. Remove cat al yt i c
conver t er and heat shi el d. Remove gear sel ect or cabl e and l ever .
Remove r el ay l ever and act uat i ng ar m. I f equi pped, r emove bal ance
wei ght . Remove cl ut ch r el ease cyl i nder .
2) To i nst al l , r ever se r emoval pr ocedur e. Bl eed hydr aul i c
CLUTCH
Article Text (p. 9)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
syst em. See BLEEDI NG CLUTCH HYDRAULI C SYSTEM. Adj ust gear sel ect or
mechani sm. See GEARSHI FT LEVER CABLES under ADJ USTMENTS.
BLEEDING CLUTCH HYDRAULIC SYSTEM
At t ach hose t o bl eeder f i t t i ng l ocat ed on cl ut ch r el ease
cyl i nder , next t o hydr aul i c l i ne. Submer ge ot her end of hose i n
cont ai ner hal f f ul l of cl ean br ake f l ui d. Fi l l r eser voi r wi t h DOT 3
br ake f l ui d. Open bl eeder f i t t i ng. Have assi st ant pr ess cl ut ch pedal
t o f ul l r el ease posi t i on. Cl ose bl eeder f i t t i ng. Rel ease cl ut ch pedal .
Repeat unt i l ai r bubbl es no l onger emer ge f r omhose. Ref i l l r eser voi r .
OVERHAUL
NOTE: Manuf act ur er r ecommends r epl acement of f aul t y cl ut ch mast er
and r el ease cyl i nder s and does not pr ovi de over haul
pr ocedur es.
TORQUE SPECIFICATIONS
TORQUE SPECI FI CATI ONS TABLE

Appl i cat i on Ft . Lbs. ( N. m)


Axl e Shaf t - To- Tr ansaxl e Bol t . . . . . . . . . . . . . . . . . . . . . 32 ( 43)
Bal ance Wei ght - To- Mount Bol t . . . . . . . . . . . . . . . . . . . . . 22 ( 30)
Cl ut ch Mast er Cyl i nder Bol t . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Cl ut ch Rel ease Cyl i nder Bol t . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Engi ne Mount - To- Subf r ame Bol t . . . . . . . . . . . . . . . . . . . . 37 ( 50)
Engi ne- To- Tr ansaxl e Bol t ( 1)
Fl ywheel - To- Cr ankshaf t . . . . . . . . . . . . . . . . 44 ( 60) + 1/ 4 Tur n
Fr ont Tr ansaxl e Mount Bol t . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Gear shi f t Cabl e Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Gear shi f t Cabl e Suppor t Bol t . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Pr essur e Pl at e Bol t
Cabl e Cl ut ch . . . . . . . . . . . . . . . . . . . . . . . . 22 ( 30) + 1/ 4 Tur n
Hydr aul i c Cl ut ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ( 20)
Ri ght Engi ne Br acket Bol t . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
St ar t er Bol t
Cabl e Cl ut ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Hydr aul i c Cl ut ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Tr ansaxl e Br acket Bol t
Cabl e Cl ut ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ( 35)
Hydr aul i c Cl ut ch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ( 25)
( 1) See Fi g. 9 or 10.

CLUTCH
Article Text (p. 10)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
Fi g. 9: I dent i f yi ng Bol t Locat i ons & Ti ght eni ng Speci f i cat i ons
( Mechani cal Cl ut ch)
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
CLUTCH
Article Text (p. 11)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:52PM
Fi g. 10: I dent i f yi ng Bol t Locat i ons & Ti ght eni ng Speci f i cat i ons
( Hydr aul i c Cl ut ch)
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
END OF ARTICLE
TRANSMISSION SERVICING - M/T
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:51PM
ARTICLE BEGINNING
MANUAL TRANSMI SSI ON SERVI CI NG
Vol kswagen
Cabr i o, Gol f , Gol f I I I , GTI VR6, J et t a, J et t a I I I , Passat
IDENTIFICATION
MANUAL TRANSAXLE APPLI CATI ONS

Appl i cat i on Model


1995
Cabr i o & Gol f I I I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
GTI VR6 & Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
J et t a I I I
4- Cyl i nder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
1996
Cabr i o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
Gol f & J et t a
4- Cyl i nder
Gas Engi ne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
Tur bo Di esel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A

LUBRICATION
SERVICE INTERVALS
No oi l changes ar e r equi r ed.
CHECKING FLUID LEVEL
Remove oi l f i l l er pl ug. Oi l l evel shoul d be up t o l ower edge
of f i l l er hol e. Add i f necessar y. I nst al l f i l l er pl ug.
RECOMMENDED FLUID
Use API G50 75W- 90 synt het i c gear oi l .
FLUID CAPACITIES
TRANSAXLE REFI LL CAPACI TI ES

Tr ansaxl e Qt s. ( L)
02A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 1 ( 2. 0)
TRANSMISSION SERVICING - M/T
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:51PM
020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 0 ( 1. 9)

ADJUSTMENTS
GEARSHIFT LINKAGE
02A Tr ansaxl e
1) Pl ace gear sel ect or l ever i n Neut r al posi t i on. Remove knob
and boot . Remove bal ance wei ght . Loosen bol t " A" and nut " B"
suf f i ci ent l y so t hat oper at i ng cabl es move f r eel y i n cent er i ng hol es.
See Fi g. 1. I nst al l Shi f t Li nkage Gauge ( 3192) . Loosen bol t " C" . See
Fi g. 2.
2) Pi vot l ocat i ng pi n under bear i ng pl at e. Ti ght en nut " D" .
Pl ace gear shi f t l ever i nt o l ef t det ent of sl i de. Move gear shi f t l ever
and sl i de t oget her t o l ef t st op. Ti ght en sl i de wi t h bol t " D" . Move
gear shi f t l ever t o r i ght det ent . Ti ght en bol t " E" . Move gear shi f t
l ever t o r i ght det ent . Ti ght en bol t " C" .
Fi g. 1: I dent i f yi ng Cent er i ng Hol es ( 02A Tr ansaxl e)
Cour t esy of Vol kswagen of Amer i ca, I nc.
Fi g. 2: I nst al l i ng Shi f t Li nkage Gauge ( 02A Tr ansaxl e)
Cour t esy of Vol kswagen of Amer i ca, I nc.
TRANSMISSION SERVICING - M/T
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:51PM
020 Tr ansaxl e
1) Pl ace shi f t l ever i n Neut r al posi t i on. Ensur e t r ansaxl e i s
al so i n Neut r al . Loosen l ower shi f t er r od cl amp. See Fi g. 3. Sel ect or
l ever must move f r eel y on shi f t er r od.
2) Remove gear shi f t knob and boot . Posi t i on Adj ust ment Gauge
( 3104) over shi f t r od. See Fi g. 4. Wi t h t r ansaxl e i n Neut r al , al i gn
shi f t r od wi t h sel ect or l ever . Ti ght en shi f t er r od cl amp t o 19 f t .
l bs. ( 26 N. m) .
3) Move gear shi f t l ever t hr ough al l gear posi t i ons. Gear s
must engage smoot hl y and wi t hout j ammi ng. Rei nst al l gear shi f t knob and
boot .
Fi g. 3: Looseni ng Shi f t Rod Cl amp ( 020 Tr ansaxl e)
Cour t esy of Vol kswagen of Amer i ca, I nc.
Fi g. 4: Locat i ng Adj ust ment Gauge ( 020 Tr ansaxl e)
Cour t esy of Vol kswagen of Amer i ca, I nc.
END OF ARTICLE
TRANSMISSION REMOVAL & INSTALLATION - M/T
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:51PM
ARTICLE BEGINNING
MANUAL TRANSMI SSI ON REMOVAL
Vol kswagen
Cabr i o, Gol f , Gol f I I I , GTI VR6, J et t a, J et t a I I I , Passat
MODEL IDENTIFICATION
MANUAL TRANSAXLE APPLI CATI ONS

Appl i cat i on Model


1995
Cabr i o & Gol f I I I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
GTI VR6 & Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
J et t a I I I
4- Cyl i nder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
1996
Cabr i o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
Gol f & J et t a
4- Cyl i nder
Gas Engi ne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020
Tur bo Di esel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A
Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02A

REMOVAL & INSTALLATION


NOTE: Tr ansaxl e may be l ower ed out of vehi cl e wi t hout r emovi ng
engi ne.
CAUTI ON: On model s wi t h t hef t pr ot ect i on syst em, obt ai n st er eo
secur i t y code f r omvehi cl e owner bef or e di sconnect i ng
bat t er y cabl e.
CABRIO, GOLF, GTI & JETTA (02A TRANSAXLE)
Removal & I nst al l at i on
1) Di sconnect bat t er y cabl es and r emove bat t er y. Remove power
st eer i ng f l ui d r eser voi r . Remove bat t er y br acket . Di sconnect al l
el ect r i cal connect i ons t o t r ansaxl e and posi t i on har ness asi de.
2) Remove bol t f r omr i ght - si de engi ne mount . Remove wi r e
har ness br acket l ocat ed next t o engi ne mount i f necessar y. Remove
bal ance wei ght l ocat ed near gear sel ect or cabl e.
3) Di sconnect gear sel ect or cabl e f r omgear sel ect or l ever .
Di sconnect gat e sel ect or cabl e at act uat i ng ar m/ r el ay l ever . Remove
cabl e br acket - t o- t r ansmi ssi on bol t s. Remove cl ut ch sl ave cyl i nder ( DO
NOT open hydr aul i c syst em) and posi t i on asi de.
TRANSMISSION REMOVAL & INSTALLATION - M/T
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:51PM
4) Remove bol t f r oml ef t - si de t r ansaxl e mount . Remove
t r ansaxl e suppor t ( i f equi pped) . Remove connect or at t achment f r om
f r ont t r ansaxl e br acket . Suppor t engi ne and t r ansaxl e wi t h Suppor t
Br i dge ( 10- 222A) and Adapt er Spi ndl es ( 10- 222A3) . Sl i ght l y l i f t engi ne
wi t h suppor t .
5) Remove engi ne under cover . Remove st ar t er . Di sconnect bot h
axl e shaf t s f r omf l anges. Tur n st eer i ng wheel t o f ul l - l ef t l ock. Ti e
axl e shaf t s out of way. Remove l ower suppor t bet ween engi ne and
t r ansaxl e ( i f equi pped) .
6) Remove smal l cl ut ch cover pl at e. Push engi ne/ t r ansaxl e
assembl y as f ar r i ght as possi bl e. Remove t r ansaxl e mount . Push
engi ne/ t r ansaxl e assembl y r ear war d, t owar ds bul khead. Remove l ower
mount i ng bol t .
7) Lower engi ne/ t r ansaxl e assembl y t o pr evi ous posi t i on.
Remove cl ut ch cover pl at e. Remove bol t f r omt r ansaxl e mount above
r i ght - si de axl e f l ange. Pl ace t r ansmi ssi on j ack under t r ansaxl e.
8) Remove l ower engi ne- t o- t r ansaxl e bol t . Separ at e t r ansaxl e
f r omengi ne and r emove f r omvehi cl e. To i nst al l , r ever se r emoval
pr ocedur e. Ensur e engi ne/ t r ansaxl e mount s ar e f r ee of st r ess when
t i ght eni ng. Ti ght en bol t s t o speci f i cat i on. See TORQUE SPECI FI CATI ONS.
CABRIO, GOLF, GTI & JETTA (020 TRANSAXLE)
Removal & I nst al l at i on
1) Di sconnect negat i ve bat t er y cabl e. Di sconnect al l
el ect r i cal connect or s f r omt r ansaxl e and posi t i on har ness asi de.
Remove upper t r ansaxl e- t o- engi ne bol t s.
2) Remove r i ght - si de engi ne suppor t br acket bol t . Remove
connect or suppor t pl at e ( i f equi pped) . On Cabr i o, r emove f r ont engi ne-
t o- body suppor t . On al l model s, di sconnect bot h sel ect or r ods f r om
sel ect or l ever .
3) Remove l ong sel ect or r od f r omr el ay l ever . Remove 2 upper
bol t s f r omt r ansaxl e br acket at l ef t si de of t r ansaxl e. On Cabr i o,
r emove t r ansaxl e- t o- body suppor t .
4) On al l model s, r emove f r ont br acket - t o- engi ne mount bol t .
At t ach Engi ne Suppor t ( 10- 222A) and Adapt or Spi ndl es ( 10- 222 A/ 1) .
Sl i ght l y l i f t engi ne/ t r ansaxl e assembl y. Remove engi ne under cover .
5) Remove st ar t er . Remove f r ont br acket . Remove engi ne mount
at t achi ng bol t s and l ar ge cl ut ch shi el d. Remove smal l cl ut ch shi el d
f r ombehi nd r i ght - si de axl e shaf t f l ange.
6) Remove l ef t - si de t r ansaxl e br acket . Usi ng l ef t - si de
adapt er spi ndl e, l ower l ef t si de of t r ansaxl e. Remove l ef t - si de
t r ansaxl e suppor t i f equi pped. Di sconnect bot h axl e shaf t s f r om
t r ansaxl e. I f necessar y, r emove heat shi el d f r omi nner Const ant
Vel oci t y ( CV) j oi nt .
7) Tur n st eer i ng wheel t o f ul l - l ef t l ock. Suspend bot h axl e
shaf t s as hi gh as possi bl e. Push engi ne/ t r ansaxl e assembl y t owar d
f r ont of vehi cl e. Pl ace t r ansmi ssi on j ack under t r ansaxl e.
8) Remove l ower t r ansaxl e- t o- engi ne bol t . Separ at e t r ansaxl e
f r omengi ne. Car ef ul l y l ower and r emove t r ansaxl e f r omvehi cl e. To
i nst al l , r ever se r emoval pr ocedur e. Ensur e engi ne/ t r ansaxl e mount s ar e
f r ee of st r ess when t i ght eni ng. Ti ght en bol t s t o speci f i cat i on. See
TRANSMISSION REMOVAL & INSTALLATION - M/T
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:51PM
TORQUE SPECI FI CATI ONS.
PASSAT (4-CYLINDER ENGINE)
Removal
1) Di sconnect bat t er y cabl es and r emove bat t er y. Remove
r adi at or cover . Di sconnect al l el ect r i cal connect i ons t o t r ansaxl e and
posi t i on har ness asi de.
2) Remove bal ance wei ght and di sconnect gear sel ect or cabl e
f r omgear sel ect or l ever . Remove bol t wi t h t hr eaded sl eeve f r omshi f t
l ever . Remove gear sel ect or cabl e al ong wi t h washer and squar e sel f -
l ocki ng nut .
3) Di sconnect gat e sel ect or cabl e f r omact uat i ng ar m/ r el ay
l ever . Remove cabl e br acket suppor t . Remove cl ut ch sl ave cyl i nder ( DO
NOT open hydr aul i c syst em) and posi t i on asi de.
4) Remove ai r i nt ake duct bet ween ai r cl eaner and i nt ake ai r
el bow. Remove 3 bol t s f r omr i ght - si de engi ne mount . Remove gr ound
st r ap f r omupper t r ansaxl e- t o- engi ne bol t . Remove upper r ear
t r ansaxl e- t o- engi ne bol t s. Loosen, but DO NOT r emove f r ont t r ansaxl e-
t o- engi ne bol t s.
5) Remove bol t f r oml ef t - si de t r ansaxl e mount , and nut f r om
f r ont mount br acket . Suppor t engi ne/ t r ansaxl e assembl y wi t h Suppor t
Br i dge ( 10- 222A) and Adapt er Spi ndl es ( 10- 222 A/ 1) . Sl i ght l y r ai se
engi ne. Remove engi ne under cover .
6) Remove st ar t er . Remove power st eer i ng br acket f r om
t r ansaxl e. Remove f r ont mount i ng br acket and engi ne mount . Mar k
bal ance wei ght at subf r ame f or i nst al l at i on r ef er ence. Remove bal ance
wei ght .
7) Di sconnect exhaust syst emi n f r ont of Thr ee- Way Cat al yt i c
Conver t er ( TWC) . Remove r i ght - si de i nner Const ant Vel oci t y ( CV) j oi nt
pr ot ect i ve cover f r omengi ne. Remove l ef t - si de ai r def l ect or f r om
l ower cont r ol ar m.
8) Di sconnect bot h axl e shaf t s f r omf l anges. Tur n st eer i ng
wheel t o f ul l - l ef t l ock. Push engi ne/ t r ansaxl e assembl y as f ar f or war d
as possi bl e. Ti e axl e shaf t s out of way.
9) Remove t r ansaxl e- t o- mount br acket . Remove adapt er spi ndl es
and l i f t engi ne/ t r ansaxl e assembl y unt i l exhaust syst emcont act s heat
shi el d. Push engi ne/ t r ansaxl e assembl y f or war d and r emove l ower
t r ansaxl e br acket mount i ng bol t .
10) Remove smal l cl ut ch cover f r ombehi nd r i ght - si de axl e
f l ange. Remove l ar ge cl ut ch cover pl at e. Lower engi ne t o pr evi ous
posi t i on, t hen push as f ar as possi bl e t owar d r i ght si de and l ower
engi ne usi ng l ef t - si de adapt er spi ndl e.
11) Remove l ower t r ansaxl e- t o- engi ne bol t . Push
engi ne/ t r ansaxl e assembl y f or war d f r omunder neat h vehi cl e usi ng Set - Up
Pr ess ( 3300A) . Pl ace t r ansmi ssi on j ack under t r ansaxl e. Remove f or war d
bol t f r omupper engi ne/ t r ansaxl e suppor t . Separ at e t r ansaxl e f r om
engi ne. Lower t r ansaxl e and r emove f r omvehi cl e.
I nst al l at i on
1) To i nst al l , r ever se r emoval pr ocedur e. Pl ug t r ansaxl e
openi ngs t o pr event cont ami nat i on or f l ui d l oss. Push cl ut ch r el ease
TRANSMISSION REMOVAL & INSTALLATION - M/T
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:51PM
l ever r ear war d and t empor ar i l y i nst al l mount i ng pi n or an 8 x 35 mm
bol t t hr ough pi vot ar m. Remove pi n or bol t af t er i nst al l at i on i s
compl et e.
2) Ensur e engi ne/ t r ansaxl e mount s ar e f r ee of st r ess when
t i ght eni ng. Ti ght en bol t s and nut s t o speci f i cat i on. See
TORQUE SPECI FI CATI ONS.
PASSAT (V6 ENGINE)
Removal
1) Di sconnect bat t er y cabl es and r emove bat t er y. Remove upper
sect i on of ai r cl eaner housi ng. Remove r adi at or cover . Remove r i ght -
si de br acket - t o- engi ne mount bol t and br acket . Di sconnect al l
el ect r i cal connect i ons t o t r ansaxl e and posi t i on har ness asi de.
2) Remove bal ance wei ght and di sconnect gear sel ect or cabl e
f r omgear sel ect or l ever . Di sconnect gat e sel ect or cabl e f r om
act uat i ng ar m/ r el ay l ever . Uncl i p cl ut ch sl ave cyl i nder hose at cabl e
suppor t br acket . Remove cabl e suppor t br acket .
3) Remove cl ut ch sl ave cyl i nder ( DO NOT open hydr aul i c
syst em) and posi t i on asi de. Remove upper t r ansaxl e- t o- engi ne bol t s.
Remove cool i ng syst emr ecover y t ank and posi t i on asi de.
4) Remove l ef t - si de t r ansaxl e mount bol t . Remove br acket and
mount . I nst al l Engi ne Suppor t ( 10- 222A) and Adapt or Spi ndl es ( 10- 222
A/ 1 and 10- 222 A/ 3) . Sl i ght l y l i f t engi ne/ t r ansaxl e assembl y.
5) Remove l ower bel t guar d and engi ne under cover . Remove
st ar t er . Remove bal ance wei ght f r omsubf r ame. Di sconnect exhaust
syst emi n f r ont of Thr ee- Way Cat al yt i c Conver t er ( TWC) .
6) Di sconnect bot h axl e shaf t s f r omf l anges. Tur n st eer i ng
wheel t o f ul l - l ef t l ock. Ti e bot h axl e shaf t s asi de, as hi gh as
possi bl e. Push engi ne/ t r ansaxl e assembl y as f ar r i ght as possi bl e.
7) Remove accessi bl e t r ansaxl e mount - t o- br acket bol t s. Usi ng
adapt er spi ndl es, l i f t engi ne/ t r ansaxl e assembl y unt i l exhaust syst em
cont act s heat shi el d. Remove r emai ni ng bol t s and t r ansaxl e br acket
( push engi ne/ t r ansaxl e assembl y r ear war d, t owar d bul khead as needed) .
8) Lower engi ne/ t r ansaxl e assembl y t o pr evi ous posi t i on.
Usi ng l ef t - si de adapt er spi ndl e, t i l t engi ne. Remove cl ut ch cover
pl at e. Remove t r ansaxl e- t o- engi ne bol t s above r i ght - si de axl e f l ange.
9) Pl ace t r ansmi ssi on j ack under t r ansaxl e. Remove l ower
t r ansaxl e- t o- engi ne mount i ng bol t . Separ at e t r ansaxl e f r omengi ne.
Usi ng Engi ne Suppor t ( 3300) , push engi ne f or war d unt i l i t cont act s
subf r ame. Lower t r ansaxl e and r emove f r omvehi cl e.
I nst al l at i on
1) To i nst al l , r ever se r emoval pr ocedur e. Pl ug t r ansaxl e
openi ngs t o pr event cont ami nat i on or f l ui d l oss. Push cl ut ch r el ease
l ever r ear war d and t empor ar i l y i nst al l mount i ng pi n or an 8 x 35 mm
bol t t hr ough pi vot ar m. Remove pi n or bol t af t er i nst al l at i on i s
compl et e.
2) Ensur e engi ne/ t r ansaxl e mount s ar e f r ee of st r ess when
t i ght eni ng. Ti ght en bol t s and nut s t o speci f i cat i on. See
TORQUE SPECI FI CATI ONS.
TRANSMISSION REMOVAL & INSTALLATION - M/T
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:51PM
TORQUE SPECIFICATIONS
TORQUE SPECI FI CATI ONS

Appl i cat i on Ft . Lbs. ( N. m)


Cabr i ol et , Gol f , GTI , & J et t a
02A Tr ansaxl e
Axl e Shaf t - To- Fl ange Bol t s . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Lef t - Si de Br acket - To- Engi ne Bol t . . . . . . . . . . . . . . 18 ( 25)
Lower St ar t er Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Lower Tr ansaxl e Suppor t Bol t s . . . . . . . . . . . . . . . . . 33 ( 45)
Ri ght - Si de Br acket - To- Subf r ame Bol t . . . . . . . . . . . 44 ( 60)
Sel ect or Cabl e Suppor t Br acket Bol t s . . . . . . . . . . 18 ( 25)
Sel ect or Cabl e- To- Sel ect or Lever Bol t . . . . . . . . . 18 ( 25)
Tr ansaxl e Mount i ng Bol t s
M10 X 30 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
M10 X 45 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
M10 X 62 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Tr ansaxl e- To- Engi ne Bol t s
M7 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ( 10)
M10 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
M12 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
020 Tr ansaxl e
Axl e Shaf t - To- Fl ange Bol t s . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Engi ne Mount - To- Subf r ame Bol t . . . . . . . . . . . . . . . . . 37 ( 50)
Engi ne Suppor t - To- Body ( 1)
Bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
Nut s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
Lef t - Si de Br acket - To- Tr ansaxl e Bol t . . . . . . . . . . . 26 ( 35)
Ri ght - Si de Br acket - To- Subf r ame Bol t . . . . . . . . . . . 44 ( 60)
Sl ave Cyl i nder - To- Engi ne Bol t . . . . . . . . . . . . . . . . . 22 ( 30)
Tr ansaxl e Mount i ng Bol t s
M10 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ( 10)
M10 X 30 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
M10 X 45 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
M10 X 60 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Tr ansaxl e Suppor t - To- Body Bol t s ( 1) . . . . . . . . . . . 37 ( 50)
Tr ansaxl e- To- Engi ne Bol t s
M6 X 8 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
M7 X 12 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ( 10)
M10 X 140 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
M12 X 55 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
M12 X 64 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
Passat
Axl e Shaf t - To- Fl ange Bol t s . . . . . . . . . . . . . . . . . . . . . 33 ( 45)
Bal ance Wei ght - To- Assembl y Car r i er . . . . . . . . . . . . . 22 ( 30)
Bal ance Wei ght - To- Sel ect or Lever Bol t . . . . . . . . . . 18 ( 25)
Lef t - Si de Br acket - To- Engi ne . . . . . . . . . . . . . . . . . . . . 18 ( 25)
Lower St ar t er Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
Lower Tr ansaxl e Suppor t Bol t s . . . . . . . . . . . . . . . . . . 33 ( 45)
Ri ght - Si de Br acket - To- Subf r ame . . . . . . . . . . . . . . . . . 44 ( 60)
TRANSMISSION REMOVAL & INSTALLATION - M/T
Article Text (p. 6)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:51PM
Sel ect or Cabl e Suppor t Br acket Bol t s . . . . . . . . . . . 18 ( 25)
Sel ect or Cabl e- To- Sel ect or Lever Bol t . . . . . . . . . . 18 ( 25)
Tr ansaxl e Mount i ng Bol t s
M10 X 30 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
M10 X 45 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ( 50)
Tr ansaxl e- To- Engi ne Bol t s
M7 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ( 10)
M10 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ( 60)
M12 Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ( 80)
( 1) - Cabr i o onl y.

END OF ARTICLE
SCHEDULED SERVICES
Article Text
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
ARTICLE BEGINNING
1993- 96 MAI NTENANCE
Vol kswagen Mai nt enance & Ser vi ce I nt er val s
Gol f I I I ,
GTI ( 1995- 96) ,
J et t a I I I
Cabr i o ( 1995- 96)
* PLEASE READ THIS FIRST *
NOTE: Al l SERVI CE SCHEDULES ar e l i st ed f or nor mal ser vi ce
vehi cl es. I f vehi cl e i s oper at ed under sever e ser vi ce
condi t i ons, see SEVERE SERVI CE REQUI REMENTS ( PERFORM
W/ SERVI CE SCHEDULES) f or i t ems r equi r i ng addi t i onal
mai nt enance.
NOTE: Thi s ar t i cl e cont ai ns schedul ed mai nt enance ser vi ce
i nf or mat i on. Fl ui d t ypes and capaci t i es l i st ed wi t h each
ser vi ce i n t hi s ar t i cl e ar e onl y t hose necessar y t o per f or m
t hat schedul ed ser vi ce. For speci f i cat i ons per t ai ni ng t o
f l ui d capaci t i es f or t he ent i r e vehi cl e, f use and ci r cui t
br eaker i dent i f i cat i on, wheel and t i r e si ze, bat t er y t ype,
war r ant y i nf or mat i on, or model i dent i f i cat i on r ef er t o t he
MAI NTENANCE I NFORMATI ON ar t i cl e i n t hi s sect i on.
CAUTIONS & WARNINGS
BATTERY WARNING
WARNI NG: When bat t er y i s di sconnect ed, vehi cl es equi pped wi t h
comput er s may l ose memor y dat a. When bat t er y power i s
r est or ed, dr i veabi l i t y pr obl ems may exi st on some vehi cl es.
These vehi cl es may r equi r e a r el ear n pr ocedur e. See COMPUTER
RELEARN PROCEDURES ar t i cl e i n GENERAL I NFORMATI ON sect i on.
REPLACING BLOWN FUSES
Bef or e r epl aci ng a bl own f use, r emove i gni t i on key, t ur n of f
al l l i ght s and accessor i es t o avoi d damagi ng t he el ect r i cal syst em. Be
sur e t o use f use wi t h t he cor r ect i ndi cat ed amper age r at i ng. The use
of an i ncor r ect amper age r at i ng f use may r esul t i n a danger ous
el ect r i cal syst emover l oad.
BRAKE PAD REPLACEMENT
WARNI NG: Use caut i on when checki ng and/ or changi ng br ake pads, some
pads may cont ai n asbest os whi ch can i r r i t at e eyes and may
cause ot her heal t h hazar ds. A wat er based sol ut i on shoul d be
used t o cl ean br ake dust f r omwheel and br ake component s.
SCHEDULED SERVICES
Article Text (p. 2)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
DO NOT use compr essed ai r t o bl ow of f br ake dust .
BRAKE SYSTEM
CAUTI ON: I f br ake war ni ng l i ght comes on whi l e dr i vi ng i t i ndi cat es
a l ow f l ui d l evel or f ai l ur e i n one of t he br aki ng
ci r cui t s. I f t he br ake pedal can be depr essed f ur t her t han
nor mal i t i s an i ndi cat i on t hat one of t he br ake ci r cui t s
i s not f unct i oni ng. St op vehi cl e and check br ake r eser voi r
f l ui d l evel . I f l evel i s bel ow MI N mar k, DO NOT dr i ve
vehi cl e. Have i t t owed t o a r epai r shop. I f l evel i s
bet ween t he MI N and MAX mar ks, pr oceed caut i ousl y t o a
r epai r shop.
BRAKE PAD WEAR INDICATOR
I ndi cat or wi l l cause a squeal i ng or scr api ng noi se, war ni ng
t hat br ake pads need r epl acement .
BRAKE PEDAL PRESSURE WITH ENGINE NOT RUNNING
CAUTI ON: Br ake pedal r equi r es ext r eme pr essur e t o st op t he vehi cl e
when t he engi ne i s not r unni ng.
CATALYTIC CONVERTER
Cont i nued oper at i on of vehi cl e wi t h a sever e mal f unct i on
coul d cause conver t er t o over heat , r esul t i ng i n possi bl e damage t o
conver t er and vehi cl e.
Any modi f i cat i on t o t he exhaust syst emon t ur bo model s, whi ch
r educes exhaust backpr essur e, wi l l l ead t o l ean f uel mi xt ur es and
excessi ve spar k advance. Thi s coul d cause ser i ous engi ne damage.
COOLANT (PROPYLENE-GLYCOL FORMULATIONS)
To avoi d possi bl e damage t o vehi cl e use onl y et hyl ene- gl ycol
based cool ant s wi t h a mi xt ur e r at i o f r om44- 68%ant i - f r eeze.
DO NOT use 100%ant i - f r eeze as i t wi l l cause t he f or mat i on
of cool i ng syst emdeposi t s. Thi s r esul t s i n cool ant
t emper at ur es of over 300 F ( 149C) whi ch can mel t pl ast i cs.
100%ant i - f r eeze has a f r eeze poi nt of onl y - 8 F ( - 22C) .
CAUTI ON: Pr opyl ene- Gl ycol Mi xt ur es has a smal l er t emper at ur e r ange
t han Et hyl ene- Gl ycol . The t emper at ur e r ange ( f r eeze- boi l )
of a 50/ 50 Ant i - Fr eeze/ Wat er Mi x i s as f ol l ows:
Pr opyl ene- Gl ycol - 26 F ( - 32C) - 257 F ( 125C)
Et hyl ene- Gl ycol - 35 F ( - 37C) - 263 F ( 128C)
CAUTI ON: Pr opyl ene- Gl ycol / Et hyl ene- Gl ycol Mi xt ur es can cause t he
dest abi l i zat i on of var i ous cor r osi on i nhi bi t or s. Al so
Pr opyl ene- Gl ycol / Et hyl ene- Gl ycol has a di f f er ent speci f i c
gr avi t y t han Et hyl ene- Gl ycol cool ant , whi ch wi l l r esul t i n
SCHEDULED SERVICES
Article Text (p. 3)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
i naccur at e f r eeze poi nt cal cul at i ons.
ELECTRIC SHOCK HAZARD
WARNI NG: Cont act wi t h l i ve component s of i gni t i on syst emwhi l e
engi ne i s r unni ng coul d l ead t o a f at al el ect r i c shock.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
WARNI NG: Many sol i d st at e el ect r i cal component s can be damaged by
st at i c el ect r i ci t y ( ESD) . Some wi l l di spl ay a war ni ng l abel ,
but many wi l l not . Di schar ge per sonal st at i c el ect r i ci t y by
t ouchi ng a met al gr ound poi nt on t he vehi cl e pr i or t o
ser vi ci ng any ESD sensi t i ve component .
ENGINE OIL
CAUTI ON: Never use non- det er gent or st r ai ght mi ner al oi l .
FUEL SYSTEM SERVICE
WARNI NG: Rel i eve f uel syst empr essur e pr i or t o ser vi ci ng any f uel
syst emcomponent ( f uel i nj ect i on model s) .
HALOGEN BULBS
Hal ogen bul bs cont ai n pr essur i zed gas whi ch may expl ode i f
over heat ed. DO NOT t ouch gl ass por t i on of bul b wi t h bar e hands. Eye
pr ot ect i on shoul d be wor n when handl i ng or wor ki ng ar ound hal ogen
bul bs.
RADIATOR CAP
CAUTI ON: Al ways di sconnect t he f an mot or when wor ki ng near t he
r adi at or f an. The f an i s t emper at ur e cont r ol l ed and coul d
st ar t at any t i me even when t he i gni t i on key i s i n t he OFF
posi t i on. DO NOT l oosen or r emove r adi at or cap when cool i ng
syst emi s hot .
RADIATOR FAN
WARNI NG: Keep hands away f r omr adi at or f an. Fan i s cont r ol l ed by a
t her most at i c swi t ch whi ch may come on or r un f or up t o
15 mi nut es even af t er engi ne i s t ur ned of f .
SERVICE POINT LOCATIONS
SCHEDULED SERVICES
Article Text (p. 4)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
Fi g. 1: Ser vi ce Poi nt Locat i ons ( Gasol i ne Engi ne)
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
ADDITIONAL SERVICE INFORMATION
ALIGNING CAMSHAFT TIMING MARKS
Fi g. 2: Camshaf t Spr ocket Posi t i oni ng ( Gasol i ne)
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
NOTE: For mor e i nf or mat i on r egar di ng camshaf t t i mi ng bel t ser vi ce
r ef er t o t he 1. 7L 4- CYL ar t i cl e i n t he
SCHEDULED SERVICES
Article Text (p. 5)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
ENGI NE MECHANI CAL sect i on.
VALVE CLEARANCE ADJUSTMENT
Fi g. 3: Assembl ed Vi ew of Val ve and Camshaf t
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
NOTE: For mor e i nf or mat i on r egar di ng val ve cl ear ance adj ust ment s
r ef er t o t he 1. 7L 4- CYL ar t i cl e i n t he
ENGI NE MECHANI CAL sect i on.
JACKING & HOISTING POINTS
Fi g. 4: Fl oor J ack, Fl oor Hoi st & Vehi cl e J ack
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
SCHEDULED SERVICES
Article Text (p. 6)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
Fi g. 5: Vehi cl e Li f t i ng Poi nt s - Except Pi ckup
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
NOTE: For mor e i nf or mat i on r egar di ng j acki ng and hoi st i ng poi nt s
r ef er t o t he J ACKI NG & HOI STI NG ar t i cl e i n
t he WHEEL ALI GNMENT sect i on.
INFORMATION LABEL LOCATIONS
Fi g. 6: I nf or mat i on Label Locat i ons
Cour t esy of Vol kswagen Uni t ed St at es, I nc.
CAMSHAFT TIMING BELT REPLACEMENT INFORMATION
CAUTI ON: Fai l ur e t o r epl ace a f aul t y camshaf t t i mi ng bel t may r esul t
i n ser i ous engi ne damage.
The condi t i on of camshaf t dr i ve bel t s shoul d al ways be
checked on vehi cl es whi ch have mor e t han 50, 000 mi l es. Al t hough some
manuf act ur er s do not r ecommend bel t r epl acement at a speci f i ed
mi l eage, ot her s r equi r e i t at 60, 000- 100, 000 mi l es. A camshaf t dr i ve
bel t f ai l ur e may cause ext ensi ve damage t o i nt er nal engi ne component s
on most engi nes, al t hough some desi gns do not al l ow pi st on- t o- val ve
SCHEDULED SERVICES
Article Text (p. 7)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
cont act . These desi gns ar e of t en cal l ed " Fr ee Wheel i ng" .
Many manuf act ur er s changed t hei r mai nt enance and war r ant y
schedul es i n t he mi d- 1980' s t o r ef l ect t i mi ng bel t i nspect i on and/ or
r epl acement at 50, 000- 60, 000 mi l es. Most ser vi ce i nt er val schedul es i n
t hi s manual r ef l ect t hese changes.
Bel t s or component s shoul d be i nspect ed and r epl aced i f any
of t he f ol l owi ng condi t i ons exi st :
* Cr acks Or Tear s I n Bel t Sur f ace
* Mi ssi ng, Damaged, Cr acked Or Rounded Teet h
* Oi l Cont ami nat i on
* Damaged Or Faul t y Tensi oner s
* I ncor r ect Tensi on Adj ust ment
I nspect t i mi ng bel t at 20, 000 mi l e i nt er val s. Repl ace bel t as
necessar y.
SEVERE & NORMAL SERVICE DEFINITIONS
NOTE: Use t he Sever e Ser vi ce schedul e i f t he vehi cl e t o be ser vi ced
i s oper at ed under ANY ( one or mor e) of t hese condi t i ons:
Ser vi ce i s r ecommended at mi l eage i nt er val s based on vehi cl e
oper at i on. Ser vi ce schedul es ar e based on t he f ol l owi ng pr i mar y
oper at i ng condi t i ons:
Nor mal Ser vi ce
* Dr i ven Mor e Than 10 Mi l es Dai l y
* No Oper at i ng Condi t i ons Fr omSever e Ser vi ce Schedul e
Sever e Ser vi ce ( Uni que Dr i vi ng Condi t i ons)
* Shor t Tr i ps I n Fr eezi ng Temper at ur es
* Towi ng Or Heavi l y Loaded
* Sever e Dust Condi t i ons
* Hot Weat her , St op- And- Go Dr i vi ng
* Ext ensi ve I dl i ng
SEVERE SERVICE REQUIREMENTS (PERFORM W/SERVICE SCHEDULES)
NOTE: The f ol l owi ng ser vi ces ar e t o be per f or med on vehi cl es
subj ect ed t o sever e ser vi ce. See SEVERE & NORMAL SERVI CE
DEFI NI TI ONS. Thi s ser vi ce i s t o be per f or med i n addi t i on
t o t he nor mal ser vi ces l i st ed i n t he NORMAL MAI NTENANCE
SERVI CE SCHEDULES.
SEVERE SERVI CE CONDI TI ONS/ ACTI ONS TABLE

Condi t i on Act i on I t em Per f or mEver y ( 1)

SCHEDULED SERVICES
Article Text (p. 8)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
Shor t Tr i ps I n Repl ace Engi ne Oi l & 3, 750 Mi l es or 3 Mont hs
Fr eezi ng Fi l t er
Temper at ur es
Repl ace A/ T Fl ui d 15, 000 Mi l es

Towi ng Or Heavi l y Repl ace Engi ne Oi l & 3, 750 Mi l es or 3 Mont hs


Loaded Fi l t er

Repl ace A/ T Fl ui d 15, 000 Mi l es

Sever e Dust Repl ace Engi ne Oi l & 3, 750 Mi l es or 3 Mont hs


Condi t i ons Fi l t er

Repl ace A/ T Fl ui d 15, 000 Mi l es

Hot Weat her , Repl ace Engi ne Oi l & 3, 750 Mi l es or 3 Mont hs


St op- And- Go Fi l t er
Dr i vi ng
Repl ace A/ T Fl ui d 15, 000 Mi l es

Ext ensi ve I dl i ng Repl ace Engi ne Oi l & 3, 750 Mi l es or 3 Mont hs


Fi l t er

Repl ace A/ T Fl ui d 15, 000 Mi l es


( 1) - Per f or mt hese ser vi ces at t he mi l eage or number of mont hs
( si nce t he l ast t i me) , whi chever comes f i r st .

NORMAL MAINTENANCE SERVICE SCHEDULES


CAUTI ON: The f ol l owi ng ser vi ce schedul es r ef er t o vehi cl es dr i ven
under nor mal oper at i ng condi t i ons. For vehi cl es dr i ven under
sever e condi t i ons, addi t i onal ser vi ces may be necessar y.
See SEVERE SERVI CE REQUI REMENTS ( PERFORM W/ SERVI CE SCHEDULES)
above i n t hi s ar t i cl e f or addi t i onal ser vi ce r equi r ement s.
7500 MILE (12,000 KM) SERVICE
7500 MI LE ( 12, 000 KM) SERVI CE

Ser vi ce Or I nspect

Check Fl ui d Level s

I nspect Cool ant Hoses and Cl amps

I nspect Br ake Syst em

I nspect Exhaust Syst em


SCHEDULED SERVICES
Article Text (p. 9)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM

I nspect CV J oi nt Boot s

Lubr i cat e Chassi s

Repl ace

Engi ne Oi l

Oi l Fi l t er

Lubr i cat i on Speci f i cat i ons

Appl i cat i on Speci f i cat i on



Engi ne Oi l
Ambi ent Temper at ur es
Gr eat er Than 14 F ( - 10C) . . SAE 15W- 40 Or 20W- 50 API SG/ CD
14- 50F ( - 10 To +10C) . . . . SAE 10W- 30 Or 10W- 40 API SG/ CD
Less Than 50F ( 10C) . . . . . . . . . . SAE 5W- 30 Or 5W- 40 API SG/ CD

Fl ui d Capaci t i es

Appl i cat i on ( 1) Quant i t y



Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)

( 1) - Capaci t i es ar e r ecommended or cal cul at ed l evel s. Al ways use
di pst i ck ( i f avai l abl e) t o measur e l evel .
( 2) - I ncl udes f i l t er change.

15,000 MILE (24,000 KM) SERVICE


15, 000 MI LE ( 24, 000 KM) SERVI CE

Ser vi ce Or I nspect

Ver i f y Last Maj or Ser vi ce Was Per f or med

Di agnost i c Syst emRead Out

I nspect For Fl ui d Leaks

I nspect Camshaf t Ti mi ng Bel t ( Repl ace i f Requi r ed)

Check/ Adj ust Val ve Cl ear ance

Check/ Adj ust I dl e Speed

Per f or mCompr essi on Test

SCHEDULED SERVICES
Article Text (p. 10)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
Check Cr ankcase Vent i l at i on Syst em

Check Fuel Evapor at i on Syst em

Check EGR Syst em( Reset Mi l eage Count er - I f Appl i cabl e)

Check Fl ui d Level s

I nspect Cool ant Hoses and Cl amps

Cool i ng & Heat i ng Syst em

Check Cool ant St r engt h

I nspect / Adj ust Accessor y Dr i ve Bel t s ( Repl ace i f Requi r ed)

Wi ndshi el d Washer Syst em

Cl ean Bat t er y and Bat t er y Ter mi nal s

Thr ot t l e Li nkage

I nspect Fuel / Tank/ Cap/ Li nes

I nt ake Ai r Syst em

Cl ut ch Hydr aul i c Syst em

I nspect CV J oi nt Boot s

Dr i ve Shaf t s For Leaks & Damage

Check Oper at i on of Hor n, Wi per s/ Washer s & Al l Ext er i or Li ght s

I nspect Condi t i on of Wi per Bl ades

Check Headl i ght Al i gnment

Check Seat Bel t Webbi ng and Rel ease Mechani sms

Check Par ki ng Br ake Oper at i on

Check Shi f t / Cl ut ch I nt er l ock Oper at i on

I nspect Br ake Syst emHoses & Li nes

Br ake Di scs & Cal i per s

I nspect Fr ont Br ake Pads & Rot or s

I nspect Rear Br ake Li ni ngs & Dr ums

SCHEDULED SERVICES
Article Text (p. 11)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
Lubr i cat e Chassi s

I nspect St eer i ng Li nkage/ Fr ont Suspensi on

Suspensi on & Wheel Bear i ngs

St eer i ng Oper at i on, Ti e Rods, Gear Box & Boot s

Lubr i cat e Weat her st r i ppi ng wi t h Si l i cone

Lubr i cat e Door Hi nges

Lubr i cat e Door Locks

Check Body Dr ai n Hol es

I nspect Shocks/ St r ut s f or Leakage

I nspect Ti r e Wear Pat t er n

Rot at e Ti r es and Adj ust Ai r Pr essur e ( I ncl udi ng Spar e)

Repl ace

Engi ne Oi l

Oi l Fi l t er

Cl ean Ai r Fi l t er El ement ( Repl ace i f Requi r ed)

Lubr i cat i on Speci f i cat i ons

Appl i cat i on Speci f i cat i on



Aut omat i c Tr ansaxl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexr on- I I E ATF
Br ake Fl ui d . . . . . . . . . . . . . . . . . . . . . . DOT 4 Br ake Fl ui d ( SAE J 1703)
Cool ant . . . . . . . . . . . . . . . . . . . . . . 50/ 50 Mi x Wat er & Et hyl ene Gl ycol
Engi ne Oi l ( 1)
Ambi ent Temper at ur es
Gr eat er Than 14 F ( - 10C) . . SAE 15W- 40 Or 20W- 50 API SG/ CD
14- 50F ( - 10 To +10C) . . . . SAE 10W- 30 Or 10W- 40 API SG/ CD
Less Than 50F ( 10C) . . . . . . . . . . SAE 5W- 30 Or 5W- 40 API SG/ CD
Power St eer i ng Fl ui d . . . . . . . . . . . . . . . . VWHydr aul i c Oi l G- 002- 000
Manual Tr ansaxl e . . . . . . . . . . . Hypoi d Gear Oi l SAE 75W- 90 API GL- 4
Or SAE 75W- 90 ( G50 Synt het i c)
Fi nal Dr i ve ( A/ T & M/ T)
( Di f f er ent i al ) . . . . . . . . . . . SAE 75W- 90 ( G50 Synt het i c Gear Oi l )
Wheel Bear i ngs . . . . . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
St eer i ng Li nkage ( 2) ( 3) . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Bal l J oi nt s ( 2) ( 4) . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Weat her st r i p . . . . . . . . . . . . . . . . . . . . . . . . Di el ect r i c Si l i cone Gr ease

SCHEDULED SERVICES
Article Text (p. 12)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
( 1) - SAE 15W- 40 or 20W- 40 engi ne oi l i s r ecommended f or ext r eme
condi t i ons or ext ended hi ghway oper at i on.
( 2) - Use l ow pr essur e gr ease gun t o pr event seal damage.
( 3) - Fi l l unt i l l ubr i cant squeezes out f r omt he base of seal s.
( 4) - Fi l l bal l j oi nt unt i l seal st ar t s t o swel l .

Fl ui d Capaci t i es

Appl i cat i on ( 1) Quant i t y



Cool i ng Syst em
Conver t i bl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1 Qt s. ( 4. 8L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Aut omat i c Tr ansaxl e
Fl ui d Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 2 Qt s. ( 3. 0L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
Fi nal Dr i ve ( Di f f er ent i al )
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)
Manual Tr ansaxl e ( 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 0 Qt s. ( 1. 9L)

( 1) - Capaci t i es ar e r ecommended or cal cul at ed l evel s. Al ways use
di pst i ck ( i f avai l abl e) t o measur e l evel .
( 2) - I ncl udes f i l t er change.
( 3) - Li f et i me f i l l .
( 4) - Si ngl e case i ncl udes manual t r ansaxl e & di f f er ent i al .

Ser vi ce Labor Ti mes

Appl i cat i on ( 1) ( 2) ( 3) Hour s



Gasol i ne Engi ne
Aut omat i c Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 5
Manual Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 7

( 1) - Add . 2 hr . i f equi pped wi t h A/ C.
( 2) - Add . 1 hr . i f equi pped wi t h cr ui se cont r ol .
( 3) - Add . 5 hr . f or 1983- 84 J et t a, Rabbi t and Pi ckup.

22,500 MILE (36,000 KM) SERVICE


22, 500 MI LE ( 36, 000 KM) SERVI CE

Ser vi ce Or I nspect

Ver i f y Last Maj or Ser vi ce Was Per f or med

Check Fl ui d Level s

I nspect Cool ant Hoses and Cl amps

I nspect Br ake Syst em


SCHEDULED SERVICES
Article Text (p. 13)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM

I nspect Exhaust Syst em

I nspect CV J oi nt Boot s

Lubr i cat e Chassi s

Repl ace

Engi ne Oi l

Oi l Fi l t er

Lubr i cat i on Speci f i cat i ons

Appl i cat i on Speci f i cat i on



Engi ne Oi l
Ambi ent Temper at ur es
Gr eat er Than 14 F ( - 10C) . . SAE 15W- 40 Or 20W- 50 API SG/ CD
14- 50F ( - 10 To +10C) . . . . SAE 10W- 30 Or 10W- 40 API SG/ CD
Less Than 50F ( 10C) . . . . . . . . . . SAE 5W- 30 Or 5W- 40 API SG/ CD

Fl ui d Capaci t i es

Appl i cat i on ( 1) Quant i t y



Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)

( 1) - Capaci t i es ar e r ecommended or cal cul at ed l evel s. Al ways use
di pst i ck ( i f avai l abl e) t o measur e l evel .
( 2) - I ncl udes f i l t er change.

30,000 MILE (48,000 KM) SERVICE


30, 000 MI LE ( 48, 000 KM) SERVI CE

Ser vi ce Or I nspect

Ver i f y Last Maj or Ser vi ce Was Per f or med

Di agnost i c Syst emRead Out

I nspect For Fl ui d Leaks

I nspect Camshaf t Ti mi ng Bel t ( Repl ace i f Requi r ed)

Check/ Adj ust Val ve Cl ear ance

Check/ Adj ust I dl e Speed

SCHEDULED SERVICES
Article Text (p. 14)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
Per f or mCompr essi on Test

Check Cr ankcase Vent i l at i on Syst em

Check Fuel Evapor at i on Syst em

Check EGR Syst em( Reset Mi l eage Count er - I f Appl i cabl e)

Check Fl ui d Level s

I nspect Cool ant Hoses and Cl amps

Cool i ng & Heat i ng Syst em

Cr ankcase Vent i l at i on Syst em

Check Cool ant St r engt h

I nspect / Adj ust Accessor y Dr i ve Bel t s ( Repl ace i f Requi r ed)

Wi ndshi el d Washer Syst em

Cl ean Bat t er y and Bat t er y Ter mi nal s

Thr ot t l e Li nkage

Fuel Syst em

I nt ake Ai r Syst em

Cl ut ch Hydr aul i c Syst em

I nspect CV J oi nt Boot s

Dr i ve Shaf t s For Leaks & Damage

Check Oper at i on of Hor n, Wi per s/ Washer s & Al l Ext er i or Li ght s

I nspect Condi t i on of Wi per Bl ades

Check Headl i ght Al i gnment

Check Seat Bel t Webbi ng and Rel ease Mechani sms

Check Par ki ng Br ake Oper at i on

Check Shi f t / Cl ut ch I nt er l ock Oper at i on

I nspect Br ake Syst emHoses & Li nes

Br ake Di scs & Cal i per s

SCHEDULED SERVICES
Article Text (p. 15)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
I nspect Fr ont Br ake Pads & Rot or s

I nspect Rear Br ake Li ni ngs & Dr ums

Lubr i cat e Chassi s

I nspect St eer i ng Li nkage/ Fr ont Suspensi on

Suspensi on & Wheel Bear i ngs

St eer i ng Oper at i on, Ti e Rods, Gear Box & Boot s

Lubr i cat e Weat her st r i ppi ng wi t h Si l i cone

Lubr i cat e Door Hi nges

Lubr i cat e Door Locks

Check Body Dr ai n Hol es

I nspect Shocks/ St r ut s f or Leakage

I nspect Ti r e Wear Pat t er n

Rot at e Ti r es and Adj ust Ai r Pr essur e ( I ncl udi ng Spar e)

Repl ace

Engi ne Oi l

Oi l Fi l t er

Ai r Fi l t er El ement

Spar k Pl ugs

Fuel Fi l t er

Change Aut omat i c Tr ansaxl e Fl ui d & Cl ean St r ai ner

Dr ai n, Fl ush and Ref i l l Engi ne Cool ant

Dr ai n, Ref i l l and Bl eed Br ake Syst emFl ui d

Lubr i cat i on Speci f i cat i ons

Appl i cat i on Speci f i cat i on



Aut omat i c Tr ansaxl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexr on- I I E ATF
Br ake Fl ui d . . . . . . . . . . . . . . . . . . . . . . DOT 4 Br ake Fl ui d ( SAE J 1703)
Cool ant . . . . . . . . . . . . . . . . . . . . . . 50/ 50 Mi x Wat er & Et hyl ene Gl ycol
Engi ne Oi l ( 1)
SCHEDULED SERVICES
Article Text (p. 16)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
Ambi ent Temper at ur es
Gr eat er Than 14 F ( - 10C) . . SAE 15W- 40 Or 20W- 50 API SG/ CD
14- 50F ( - 10 To +10C) . . . . SAE 10W- 30 Or 10W- 40 API SG/ CD
Less Than 50F ( 10C) . . . . . . . . . . SAE 5W- 30 Or 5W- 40 API SG/ CD
Power St eer i ng Fl ui d . . . . . . . . . . . . . . . . VWHydr aul i c Oi l G- 002- 000
Manual Tr ansaxl e . . . . . . . . . . . Hypoi d Gear Oi l SAE 75W- 90 API GL- 4
Or SAE 75W- 90 ( G50 Synt het i c)
Fi nal Dr i ve ( A/ T & M/ T)
( Di f f er ent i al ) . . . . . . . . . . . SAE 75W- 90 ( G50 Synt het i c Gear Oi l )
Wheel Bear i ngs . . . . . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
St eer i ng Li nkage ( 2) ( 3) . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Bal l J oi nt s ( 2) ( 4) . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Weat her st r i p . . . . . . . . . . . . . . . . . . . . . . . . Di el ect r i c Si l i cone Gr ease

( 1) - SAE 15W- 40 or 20W- 40 engi ne oi l i s r ecommended f or ext r eme
condi t i ons or ext ended hi ghway oper at i on.
( 2) - Use l ow pr essur e gr ease gun t o pr event seal damage.
( 3) - Fi l l unt i l l ubr i cant squeezes out f r omt he base of seal s.
( 4) - Fi l l bal l j oi nt unt i l seal st ar t s t o swel l .

Fl ui d Capaci t i es

Appl i cat i on ( 1) Quant i t y



Cool i ng Syst em
Conver t i bl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1 Qt s. ( 4. 8L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Aut omat i c Tr ansaxl e
Fl ui d Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 2 Qt s. ( 3. 0L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
Fi nal Dr i ve ( Di f f er ent i al )
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)
Manual Tr ansaxl e ( 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 0 Qt s. ( 1. 9L)

( 1) - Capaci t i es ar e r ecommended or cal cul at ed l evel s. Al ways use
di pst i ck ( i f avai l abl e) t o measur e l evel .
( 2) - I ncl udes f i l t er change.
( 3) - Li f et i me f i l l .
( 4) - Si ngl e case i ncl udes manual t r ansaxl e & di f f er ent i al .

Ser vi ce Labor Ti mes

Appl i cat i on ( 1) ( 2) ( 3) Hour s



Gasol i ne Engi ne
Aut omat i c Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 2
Manual Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 6

( 1) - Add . 2 hr . i f equi pped wi t h A/ C.
( 2) - Add . 1 hr . i f equi pped wi t h cr ui se cont r ol .
( 3) - Add t he f ol l owi ng t i mes t o r epl ace camshaf t t i mi ng bel t .
2. 2 hour s on engi nes wi t h ai r condi t i oni ng and 1. 8 hour s
SCHEDULED SERVICES
Article Text (p. 17)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
on engi nes wi t hout ai r condi t i oni ng.

37,500 MILE (60,000 KM) SERVICE


37, 500 MI LE ( 60, 000 KM) SERVI CE

Ser vi ce Or I nspect

Ver i f y Last Maj or Ser vi ce Was Per f or med

Check Fl ui d Level s

I nspect Cool ant Hoses and Cl amps

I nspect Br ake Syst em

I nspect Exhaust Syst em

I nspect CV J oi nt Boot s

Lubr i cat e Chassi s

Repl ace

Engi ne Oi l

Oi l Fi l t er

Lubr i cat i on Speci f i cat i ons

Appl i cat i on Speci f i cat i on



Engi ne Oi l
Ambi ent Temper at ur es
Gr eat er Than 14 F ( - 10C) . . SAE 15W- 40 Or 20W- 50 API SG/ CD
14- 50F ( - 10 To +10C) . . . . SAE 10W- 30 Or 10W- 40 API SG/ CD
Less Than 50F ( 10C) . . . . . . . . . . SAE 5W- 30 Or 5W- 40 API SG/ CD

Fl ui d Capaci t i es

Appl i cat i on ( 1) Quant i t y



Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)

( 1) - Capaci t i es ar e r ecommended or cal cul at ed l evel s. Al ways use
di pst i ck ( i f avai l abl e) t o measur e l evel .
( 2) - I ncl udes f i l t er change.

45,000 MILE (72,000 KM) SERVICE


SCHEDULED SERVICES
Article Text (p. 18)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:49PM
45, 000 MI LE ( 72, 000 KM) SERVI CE

Ser vi ce Or I nspect

Ver i f y Last Maj or Ser vi ce Was Per f or med

Di agnost i c Syst emRead Out

I nspect For Fl ui d Leaks

I nspect Camshaf t Ti mi ng Bel t ( Repl ace i f Requi r ed)

Check/ Adj ust Val ve Cl ear ance

Check/ Adj ust I dl e Speed

Per f or mCompr essi on Test

Check Cr ankcase Vent i l at i on Syst em

Check Fuel Evapor at i on Syst em

Check EGR Syst em( Reset Mi l eage Count er - I f Appl i cabl e)

Check Fl ui d Level s

I nspect Cool ant Hoses and Cl amps

Cool i ng & Heat i ng Syst em

Cr ankcase Vent i l at i on Syst em

Check Cool ant St r engt h

I nspect / Adj ust Accessor y Dr i ve Bel t s ( Repl ace i f Requi r ed)

Wi ndshi el d Washer Syst em

Cl ean Bat t er y and Bat t er y Ter mi nal s

Thr ot t l e Li nkage

Fuel Syst em

I nt ake Ai r Syst em

Cl ut ch Hydr aul i c Syst em

I nspect CV J oi nt Boot s

Dr i ve Shaf t s For Leaks & Damage


SCHEDULED SERVICES
Article Text (p. 19)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:50PM

Check Oper at i on of Hor n, Wi per s/ Washer s & Al l Ext er i or Li ght s

I nspect Condi t i on of Wi per Bl ades

Check Headl i ght Al i gnment

Check Seat Bel t Webbi ng and Rel ease Mechani sms

Check Par ki ng Br ake Oper at i on

Check Shi f t / Cl ut ch I nt er l ock Oper at i on

I nspect Br ake Syst emHoses & Li nes

Br ake Di scs & Cal i per s

I nspect Fr ont Br ake Pads & Rot or s

I nspect Rear Br ake Li ni ngs & Dr ums

Lubr i cat e Chassi s

I nspect St eer i ng Li nkage/ Fr ont Suspensi on

Suspensi on & Wheel Bear i ngs

St eer i ng Oper at i on, Ti e Rods, Gear Box & Boot s

Lubr i cat e Weat her st r i ppi ng wi t h Si l i cone

Lubr i cat e Door Hi nges

Lubr i cat e Door Locks

Check Body Dr ai n Hol es

I nspect Shocks/ St r ut s f or Leakage

I nspect Ti r e Wear Pat t er n

Rot at e Ti r es and Adj ust Ai r Pr essur e ( I ncl udi ng Spar e)

Repl ace

Engi ne Oi l

Oi l Fi l t er

Cl ean Ai r Fi l t er El ement ( Repl ace i f Requi r ed)

Spar k Pl ugs ( Except Cal i f or ni a Model s)


SCHEDULED SERVICES
Article Text (p. 20)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:50PM

Fuel Fi l t er

Lubr i cat i on Speci f i cat i ons

Appl i cat i on Speci f i cat i on



Aut omat i c Tr ansaxl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexr on- I I E ATF
Br ake Fl ui d . . . . . . . . . . . . . . . . . . . . . . DOT 4 Br ake Fl ui d ( SAE J 1703)
Cool ant . . . . . . . . . . . . . . . . . . . . . . 50/ 50 Mi x Wat er & Et hyl ene Gl ycol
Engi ne Oi l ( 1)
Ambi ent Temper at ur es
Gr eat er Than 14 F ( - 10C) . . SAE 15W- 40 Or 20W- 50 API SG/ CD
14- 50F ( - 10 To +10C) . . . . SAE 10W- 30 Or 10W- 40 API SG/ CD
Less Than 50F ( 10C) . . . . . . . . . . SAE 5W- 30 Or 5W- 40 API SG/ CD
Power St eer i ng Fl ui d . . . . . . . . . . . . . . . . VWHydr aul i c Oi l G- 002- 000
Manual Tr ansaxl e . . . . . . . . . . . Hypoi d Gear Oi l SAE 75W- 90 API GL- 4
Or SAE 75W- 90 ( G50 Synt het i c)
Fi nal Dr i ve ( A/ T & M/ T)
( Di f f er ent i al ) . . . . . . . . . . . SAE 75W- 90 ( G50 Synt het i c Gear Oi l )
Wheel Bear i ngs . . . . . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
St eer i ng Li nkage ( 2) ( 3) . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Bal l J oi nt s ( 2) ( 4) . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Weat her st r i p . . . . . . . . . . . . . . . . . . . . . . . . Di el ect r i c Si l i cone Gr ease

( 1) - SAE 15W- 40 or 20W- 40 engi ne oi l i s r ecommended f or ext r eme
condi t i ons or ext ended hi ghway oper at i on.
( 2) - Use l ow pr essur e gr ease gun t o pr event seal damage.
( 3) - Fi l l unt i l l ubr i cant squeezes out f r omt he base of seal s.
( 4) - Fi l l bal l j oi nt unt i l seal st ar t s t o swel l .

Fl ui d Capaci t i es

Appl i cat i on ( 1) Quant i t y



Cool i ng Syst em
Conver t i bl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1 Qt s. ( 4. 8L)
Pi ckup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 9 Qt s. ( 6. 4L)
Rabbi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 2 Qt s. ( 5. 0L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Aut omat i c Tr ansaxl e
Fl ui d Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 2 Qt s. ( 3. 0L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
Fi nal Dr i ve ( Di f f er ent i al )
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)
Manual Tr ansaxl e ( 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 0 Qt s. ( 1. 9L)

( 1) - Capaci t i es ar e r ecommended or cal cul at ed l evel s. Al ways use
di pst i ck ( i f avai l abl e) t o measur e l evel .
( 2) - I ncl udes f i l t er change.
( 3) - Li f et i me f i l l .
( 4) - Si ngl e case i ncl udes manual t r ansaxl e & di f f er ent i al .
SCHEDULED SERVICES
Article Text (p. 21)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:50PM

52,500 MILE (84,000 KM) SERVICE


52, 500 MI LE ( 84, 000 KM) SERVI CE

Ser vi ce Or I nspect

Ver i f y Last Maj or Ser vi ce Was Per f or med

Check Fl ui d Level s

I nspect Cool ant Hoses and Cl amps

I nspect Br ake Syst em

I nspect Exhaust Syst em

I nspect CV J oi nt Boot s

Lubr i cat e Chassi s

Repl ace

Engi ne Oi l

Oi l Fi l t er

Lubr i cat i on Speci f i cat i ons

Appl i cat i on Speci f i cat i on



Engi ne Oi l
Ambi ent Temper at ur es
Gr eat er Than 14 F ( - 10C) . . SAE 15W- 40 Or 20W- 50 API SG/ CD
14- 50F ( - 10 To +10C) . . . . SAE 10W- 30 Or 10W- 40 API SG/ CD
Less Than 50F ( 10C) . . . . . . . . . . SAE 5W- 30 Or 5W- 40 API SG/ CD

Fl ui d Capaci t i es

Appl i cat i on ( 1) Quant i t y



Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)

( 1) - Capaci t i es ar e r ecommended or cal cul at ed l evel s. Al ways use
di pst i ck ( i f avai l abl e) t o measur e l evel .
( 2) - I ncl udes f i l t er change.

60,000 MILE (96,000 KM) SERVICE


SCHEDULED SERVICES
Article Text (p. 22)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:50PM
60, 000 MI LE ( 96, 000 KM) SERVI CE

Ser vi ce Or I nspect

Ver i f y Last Maj or Ser vi ce Was Per f or med

Di agnost i c Syst emRead Out

I nspect For Fl ui d Leaks

I nspect Camshaf t Ti mi ng Bel t ( Repl ace i f Requi r ed)

Check/ Adj ust Val ve Cl ear ance

Check/ Adj ust I dl e Speed

Per f or mCompr essi on Test

Check Cr ankcase Vent i l at i on Syst em

Check Fuel Evapor at i on Syst em

Check EGR Syst em( Reset Mi l eage Count er - I f Appl i cabl e)

Check Fl ui d Level s

I nspect Cool ant Hoses and Cl amps

Cool i ng & Heat i ng Syst em

Cr ankcase Vent i l at i on Syst em

Check Cool ant St r engt h

I nspect / Adj ust Accessor y Dr i ve Bel t s ( Repl ace i f Requi r ed)

Wi ndshi el d Washer Syst em

Cl ean Bat t er y and Bat t er y Ter mi nal s

Thr ot t l e Li nkage

Fuel Syst em

I nt ake Ai r Syst em

Cl ut ch Hydr aul i c Syst em

I nspect CV J oi nt Boot s

Dr i ve Shaf t s For Leaks & Damage

SCHEDULED SERVICES
Article Text (p. 23)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:50PM
Check Oper at i on of Hor n, Wi per s/ Washer s & Al l Ext er i or Li ght s

I nspect Condi t i on of Wi per Bl ades

Check Headl i ght Al i gnment

Check Seat Bel t Webbi ng and Rel ease Mechani sms

Check Par ki ng Br ake Oper at i on

Check Shi f t / Cl ut ch I nt er l ock Oper at i on

I nspect Br ake Syst emHoses & Li nes

Br ake Di scs & Cal i per s

I nspect Fr ont Br ake Pads & Rot or s

I nspect Rear Br ake Li ni ngs & Dr ums

Lubr i cat e Chassi s

I nspect St eer i ng Li nkage/ Fr ont Suspensi on

Suspensi on & Wheel Bear i ngs

St eer i ng Oper at i on, Ti e Rods, Gear Box & Boot s

Lubr i cat e Weat her st r i ppi ng wi t h Si l i cone

Lubr i cat e Door Hi nges

Lubr i cat e Door Locks

Check Body Dr ai n Hol es

I nspect Shocks/ St r ut s f or Leakage

I nspect Ti r e Wear Pat t er n

Rot at e Ti r es and Adj ust Ai r Pr essur e ( I ncl udi ng Spar e)

Repl ace

Engi ne Oi l

Oi l Fi l t er

Spar k Pl ugs

Oxygen Sensor ( Reset Mi l eage Count er - I f Appl i cabl e)

SCHEDULED SERVICES
Article Text (p. 24)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:50PM
Ai r Fi l t er El ement

Fuel Fi l t er

Change Aut omat i c Tr ansaxl e Fl ui d & Cl ean St r ai ner

A/ T Di f f er ent i al Oi l Level ( Repl ace i f Requi r ed)

Manual Tr ansaxl e Fl ui d Level ( Repl ace i f Requi r ed)

Dr ai n, Fl ush and Ref i l l Engi ne Cool ant

Dr ai n, Ref i l l and Bl eed Br ake Syst emFl ui d

Lubr i cat i on Speci f i cat i ons

Appl i cat i on Speci f i cat i on



Aut omat i c Tr ansaxl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexr on- I I E ATF
Br ake Fl ui d . . . . . . . . . . . . . . . . . . . . . . DOT 4 Br ake Fl ui d ( SAE J 1703)
Cool ant . . . . . . . . . . . . . . . . . . . . . . 50/ 50 Mi x Wat er & Et hyl ene Gl ycol
Engi ne Oi l ( 1)
Ambi ent Temper at ur es
Gr eat er Than 14 F ( - 10C) . . SAE 15W- 40 Or 20W- 50 API SG/ CD
14- 50F ( - 10 To +10C) . . . . SAE 10W- 30 Or 10W- 40 API SG/ CD
Less Than 50F ( 10C) . . . . . . . . . . SAE 5W- 30 Or 5W- 40 API SG/ CD
Power St eer i ng Fl ui d . . . . . . . . . . . . . . . . VWHydr aul i c Oi l G- 002- 000
Manual Tr ansaxl e . . . . . . . . . . . Hypoi d Gear Oi l SAE 75W- 90 API GL- 4
Or SAE 75W- 90 ( G50 Synt het i c)
Fi nal Dr i ve ( A/ T & M/ T)
( Di f f er ent i al ) . . . . . . . . . . . SAE 75W- 90 ( G50 Synt het i c Gear Oi l )
Wheel Bear i ngs . . . . . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
St eer i ng Li nkage ( 2) ( 3) . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Bal l J oi nt s ( 2) ( 4) . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Weat her st r i p . . . . . . . . . . . . . . . . . . . . . . . . Di el ect r i c Si l i cone Gr ease

( 1) - SAE 15W- 40 or 20W- 40 engi ne oi l i s r ecommended f or ext r eme
condi t i ons or ext ended hi ghway oper at i on.
( 2) - Use l ow pr essur e gr ease gun t o pr event seal damage.
( 3) - Fi l l unt i l l ubr i cant squeezes out f r omt he base of seal s.
( 4) - Fi l l bal l j oi nt unt i l seal st ar t s t o swel l .

Fl ui d Capaci t i es

Appl i cat i on ( 1) Quant i t y



Cool i ng Syst em
Conver t i bl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1 Qt s. ( 4. 8L)
Pi ckup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 9 Qt s. ( 6. 4L)
Rabbi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 2 Qt s. ( 5. 0L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Aut omat i c Tr ansaxl e
SCHEDULED SERVICES
Article Text (p. 25)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:50PM
Fl ui d Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 2 Qt s. ( 3. 0L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
Fi nal Dr i ve ( Di f f er ent i al )
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)
Manual Tr ansaxl e ( 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 0 Qt s. ( 1. 9L)

( 1) - Capaci t i es ar e r ecommended or cal cul at ed l evel s. Al ways use
di pst i ck ( i f avai l abl e) t o measur e l evel .
( 2) - I ncl udes f i l t er change.
( 3) - Li f et i me f i l l .
( 4) - Si ngl e case i ncl udes manual t r ansaxl e & di f f er ent i al .

Ser vi ce Labor Ti mes

Appl i cat i on ( 1) ( 2) ( 3) Hour s



Gasol i ne Engi ne
Aut omat i c Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 1
Manual Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 5

( 1) - Add . 2 hr . i f equi pped wi t h A/ C.
( 2) - Add . 1 hr . i f equi pped wi t h cr ui se cont r ol .
( 3) - Add t he f ol l owi ng t i mes t o r epl ace camshaf t t i mi ng bel t .
2. 2 hour s on engi nes wi t h ai r condi t i oni ng and 1. 8 hour s
on engi nes wi t hout ai r condi t i oni ng.

67,500 MILE (108,000 KM) SERVICE


67, 500 MI LE ( 108, 000 KM) SERVI CE

Ser vi ce Or I nspect

Ver i f y Last Maj or Ser vi ce Was Per f or med

Check Fl ui d Level s

I nspect Cool ant Hoses and Cl amps

I nspect Br ake Syst em

I nspect Exhaust Syst em

I nspect CV J oi nt Boot s

Lubr i cat e Chassi s

Repl ace

Engi ne Oi l

Oi l Fi l t er
SCHEDULED SERVICES
Article Text (p. 26)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:50PM

Lubr i cat i on Speci f i cat i ons

Appl i cat i on Speci f i cat i on



Engi ne Oi l
Ambi ent Temper at ur es
Gr eat er Than 14 F ( - 10C) . . SAE 15W- 40 Or 20W- 50 API SG/ CD
14- 50F ( - 10 To +10C) . . . . SAE 10W- 30 Or 10W- 40 API SG/ CD
Less Than 50F ( 10C) . . . . . . . . . . SAE 5W- 30 Or 5W- 40 API SG/ CD

Fl ui d Capaci t i es

Appl i cat i on ( 1) Quant i t y



Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)

( 1) - Capaci t i es ar e r ecommended or cal cul at ed l evel s. Al ways use
di pst i ck ( i f avai l abl e) t o measur e l evel .
( 2) - I ncl udes f i l t er change.

75,000 MILE (120,000 KM) SERVICE


75, 000 MI LE ( 120, 000 KM) SERVI CE

Ser vi ce Or I nspect

Ver i f y Last Maj or Ser vi ce Was Per f or med

Di agnost i c Syst emRead Out

I nspect For Fl ui d Leaks

I nspect Camshaf t Ti mi ng Bel t ( Repl ace i f Requi r ed)

Check/ Adj ust Val ve Cl ear ance

Check/ Adj ust I dl e Speed

Per f or mCompr essi on Test

Check Cr ankcase Vent i l at i on Syst em

Check Fuel Evapor at i on Syst em

Check EGR Syst em( Reset Mi l eage Count er - I f Appl i cabl e)

Check Fl ui d Level s

I nspect Cool ant Hoses and Cl amps

SCHEDULED SERVICES
Article Text (p. 27)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:50PM
Cool i ng & Heat i ng Syst em

Cr ankcase Vent i l at i on Syst em

Check Cool ant St r engt h

I nspect / Adj ust Accessor y Dr i ve Bel t s ( Repl ace i f Requi r ed)

Wi ndshi el d Washer Syst em

Cl ean Bat t er y and Bat t er y Ter mi nal s

Thr ot t l e Li nkage

Fuel Syst em

I nt ake Ai r Syst em

Cl ut ch Hydr aul i c Syst em

I nspect CV J oi nt Boot s

Dr i ve Shaf t s For Leaks & Damage

Check Oper at i on of Hor n, Wi per s/ Washer s & Al l Ext er i or Li ght s

I nspect Condi t i on of Wi per Bl ades

Check Headl i ght Al i gnment

Check Seat Bel t Webbi ng and Rel ease Mechani sms

Check Par ki ng Br ake Oper at i on

Check Shi f t / Cl ut ch I nt er l ock Oper at i on

I nspect Br ake Syst emHoses & Li nes

Br ake Di scs & Cal i per s

I nspect Fr ont Br ake Pads & Rot or s

I nspect Rear Br ake Li ni ngs & Dr ums

Lubr i cat e Chassi s

I nspect St eer i ng Li nkage/ Fr ont Suspensi on

Suspensi on & Wheel Bear i ngs

St eer i ng Oper at i on, Ti e Rods, Gear Box & Boot s

SCHEDULED SERVICES
Article Text (p. 28)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:50PM
Lubr i cat e Weat her st r i ppi ng wi t h Si l i cone

Lubr i cat e Door Hi nges

Lubr i cat e Door Locks

Check Body Dr ai n Hol es

I nspect Shocks/ St r ut s f or Leakage

I nspect Ti r e Wear Pat t er n

Rot at e Ti r es and Adj ust Ai r Pr essur e ( I ncl udi ng Spar e)

Repl ace

Engi ne Oi l

Oi l Fi l t er

Cl ean Ai r Fi l t er El ement ( Repl ace i f Requi r ed)

Spar k Pl ugs ( Except Cal i f or ni a Model s)

Fuel Fi l t er

Lubr i cat i on Speci f i cat i ons

Appl i cat i on Speci f i cat i on



Aut omat i c Tr ansaxl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexr on- I I E ATF
Br ake Fl ui d . . . . . . . . . . . . . . . . . . . . . . DOT 4 Br ake Fl ui d ( SAE J 1703)
Cool ant . . . . . . . . . . . . . . . . . . . . . . 50/ 50 Mi x Wat er & Et hyl ene Gl ycol
Engi ne Oi l ( 1)
Ambi ent Temper at ur es
Gr eat er Than 14 F ( - 10C) . . SAE 15W- 40 Or 20W- 50 API SG/ CD
14- 50F ( - 10 To +10C) . . . . SAE 10W- 30 Or 10W- 40 API SG/ CD
Less Than 50F ( 10C) . . . . . . . . . . SAE 5W- 30 Or 5W- 40 API SG/ CD
Power St eer i ng Fl ui d . . . . . . . . . . . . . . . . VWHydr aul i c Oi l G- 002- 000
Manual Tr ansaxl e . . . . . . . . . . . Hypoi d Gear Oi l SAE 75W- 90 API GL- 4
Or SAE 75W- 90 ( G50 Synt het i c)
Fi nal Dr i ve ( A/ T & M/ T)
( Di f f er ent i al ) . . . . . . . . . . . SAE 75W- 90 ( G50 Synt het i c Gear Oi l )
Wheel Bear i ngs . . . . . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
St eer i ng Li nkage ( 2) ( 3) . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Bal l J oi nt s ( 2) ( 4) . . . . . . . . . . . . . . . . . NLGI Gr ade 2 Cat egor y GC- LB
Weat her st r i p . . . . . . . . . . . . . . . . . . . . . . . . Di el ect r i c Si l i cone Gr ease

( 1) - SAE 15W- 40 or 20W- 40 engi ne oi l i s r ecommended f or ext r eme
condi t i ons or ext ended hi ghway oper at i on.
( 2) - Use l ow pr essur e gr ease gun t o pr event seal damage.
( 3) - Fi l l unt i l l ubr i cant squeezes out f r omt he base of seal s.
SCHEDULED SERVICES
Article Text (p. 29)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:50PM
( 4) - Fi l l bal l j oi nt unt i l seal st ar t s t o swel l .

Fl ui d Capaci t i es

Appl i cat i on ( 1) Quant i t y



Cool i ng Syst em
Conver t i bl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1 Qt s. ( 4. 8L)
Pi ckup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 9 Qt s. ( 6. 4L)
Rabbi t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 2 Qt s. ( 5. 0L)
Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)
Aut omat i c Tr ansaxl e
Fl ui d Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. 2 Qt s. ( 3. 0L)
Dr y Fi l l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 9 Qt s. ( 5. 6L)
Fi nal Dr i ve ( Di f f er ent i al )
A/ T ( 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 8 Qt . ( . 75L)
Manual Tr ansaxl e ( 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 0 Qt s. ( 1. 9L)

( 1) - Capaci t i es ar e r ecommended or cal cul at ed l evel s. Al ways use
di pst i ck ( i f avai l abl e) t o measur e l evel .
( 2) - I ncl udes f i l t er change.
( 3) - Li f et i me f i l l .
( 4) - Si ngl e case i ncl udes manual t r ansaxl e & di f f er ent i al .

Ser vi ce Labor Ti mes

Appl i cat i on ( 1) ( 2) Hour s



Gasol i ne Engi ne
Aut omat i c Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 5
Manual Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 7

( 1) - Add . 2 hr . i f equi pped wi t h A/ C.
( 2) - Add . 1 hr . i f equi pped wi t h cr ui se cont r ol .

82,500 MILE (132,000 KM) SERVICE


82, 500 MI LE ( 132, 000 KM) SERVI CE

Ser vi ce Or I nspect

Ver i f y Last Maj or Ser vi ce Was Per f or med

Check Fl ui d Level s

I nspect Cool ant Hoses and Cl amps

I nspect Br ake Syst em

I nspect Exhaust Syst em

SCHEDULED SERVICES
Article Text (p. 30)
1996 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Thursday, August 19, 1999 11:50PM
I nspect CV J oi nt Boot s

Lubr i cat e Chassi s

Repl ace

Engi ne Oi l

Oi l Fi l t er

Lubr i cat i on Speci f i cat i ons

Appl i cat i on Speci f i cat i on



Engi ne Oi l
Ambi ent Temper at ur es
Gr eat er Than 14 F ( - 10C) . . SAE 15W- 40 Or 20W- 50 API SG/ CD
14- 50F ( - 10 To +10C) . . . . SAE 10W- 30 Or 10W- 40 API SG/ CD
Less Than 50F ( 10C) . . . . . . . . . . SAE 5W- 30 Or 5W- 40 API SG/ CD

Fl ui d Capaci t i es

Appl i cat i on ( 1) Quant i t y



Engi ne Oi l ( 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. 7 Qt s. ( 4. 5L)

( 1) - Capaci t i es ar e r ecommended or cal cul at ed l evel s. Al ways use
di pst i ck ( i f avai l abl e) t o measur e l evel .
( 2) - I ncl udes f i l t er change.

90,000 MILE (144,000 KM) SERVICE


90, 000 MI LE ( 144, 000 KM) SERVI CE

Ser vi ce Or I nspect

Ver i f y Last Maj or Ser vi ce Was Per f or med

Di agnost i c Syst emRead Out

I nspect For Fl ui d Leaks

I nspect Camshaf t Ti mi ng Bel t ( Repl ace i f Requi r ed)

Check/ Adj ust Val ve Cl ear ance

Check/ Adj ust I dl e Speed

Per f or mCompr essi on Test