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EnginesEdition 09.04
S00.5301.14.2002-3 page 12 02
–Perform a test drive and again check the coolant anti-
freeze protection.
Inspecting coolant level (volume)
–The coolant expansion reservoir is located on the right
of the engine compartment.
–Inspect coolant level only when the engine is not run-
ning.
Specified coolant level for the Inspection Service:
•Engine cold: between„MAX“ and „MIN“ marking.
•Engine warm: slightly above the „MAX“ marking.
♦The cooling system is filled all year round with a mix-
ture of water and antifreeze/anti-corrosion agent.
Coolant additives prevent damage from frost and cor-
rosion and the accumulation of lime scale while also
raising the boiling point of the coolant. For these rea-
sons the cooling system must always be filled all year
round with radiator antifreeze and anti-corrosion
agent offering these properties.
♦Coolant additive G12 - red in colour, complying with
standard TL VW 774 D, must not be mixed with other
coolant additives which comply with standard TL VW
774 C(B) -bluish-green in colour-. If these two coolant
additives are mixed the coolant will turn brown. Brown
coolant must be drained immediately, the cooling sys-
tem flushed out with drinking water and filled with
fresh coolant. If this is not done the engine and cooling
system may suffer damage. Engine Coolant capacity
1.2 ltr./40 kW and 1.2
ltr./47 kWapprox. 5.1 ltr.
1.4 ltr./55 kW and 1.4
ltr./74 kWapprox. 5.5 ltr.
1.0 ltr./37 kW; 1.4 ltr/
44 kW and 1.4 ltr./50
kWapprox. 6.0 ltr.
1.4 ltr./55 TDI PD approx. 6.2 ltr.
1.9 ltr./47 kW SDI approx. 6.6 ltr.
1.9 ltr./74 kW TDI PD
and 1.9 ltr./96 kW TDI
PDapprox. 6.8 ltr.
2.0 ltr./85 kW approx. 6.9 ltr.
S02-0303
WARNING!
Coolant additives are toxic!
Do not inhale coolant vapours, do not swallow
coolant, avoid contact with skin and eyes; haz-
ardous if consumed!
Note
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EnginesEdition 09.04
S00.5301.14.2002-3 page 19 02
–Unlock hooks -arrows-.
–Loosen the fuel filter and remove.
Installing
–Install new fuel filter.
–Lock hooks -arrows-.
–Fit the new O-ring for the regulating valve.
–Install regulating valve -4- with the connected fuel
hoses.
–Attach retaining clips -3-.
–Install the fuel hoses -1- and -2- and secure with hose
clamps.
The direction of flow is indicated with arrows (do not
switch connections).
–Inspect the fuel system for tightness (visual inspec-
tion).
Draining the fuel filter (diesel engine)
♦Make sure no diesel fuel comes into contact with the
coolant hoses. If necessary clean the hoses immedi-
ately!
♦Collect fuel in a suitable vessel!
♦It is absolutely necessary to observe the oil disposal
instructions!
–Remove retaining clip -2- and remove regulating valve
-1- with the connected fuel hoses.
–Unlock hooks -arrows-.
–Loosen the fuel filter and remove.
Note
Note
S02-0324
1
2
1
2
3
4
S02-0323
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BodyEdition 09.04
S00.5301.14.2002-7 page 3 02
The materials and the corresponding work instructions
are listed in the ⇒Technical Service Handbook, Part 6 -
Technology of paint repairs, chemical materials.
Inspecting plenum chamber and water
drain openings for dirt, cleaning if neces-
sary
Carry out a visual inspection for soiling through the cover
of the plenum chamber -arrows-. Remove the cover if it is
necessary to clean the plenum chamber (repair meas-
ure).
The water drain openings must not be blocked with wax
or underbody sealant.
Windscreen wiper/washer system:
Check for proper operation
Fluid in windscreen washer fluid reservoir
The fluid reservoir for the windscreen washer system
must be filled up to the brim.
♦If it is necessary to add fluid, always mix windscreen
cleaner to the water (in summer) or antifreeze agent
(in the winter).
♦If the vehicle is fitted with a headlight washing system
and the headlights have plastic - (polycarbonate) -
lenses, one must only use fluids for topping up the
headlight washing system which do not damage the
polycarbonate.
Inspecting setting of nozzles of windscreen
washer system, adjusting nozzles if necessary:
Nozzles of windscreen washer system
The nozzles on the windscreen washer system are set by
the manufacturer and cannot be subsequently altered.
–The water spray should strike the windscreen in a
cone-shaped pattern.
If the spray flows out unevenly, replace the spray nozzle
(repair measure).
Windscreen wiper arms: Inspecting park posi-
tion, adjusting if necessary
–Wiper arms are positioned relative to the round mark-
ings in the windscreen.
S02-0298
Note
Note
S02-0300
Note