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InspectionEdition 09.04
S00.5301.14.2002-2 page 10 02
Oil change (QG1, QG2)
Work involvedChapter
–Change engine oil
–Replace engine oil filter02-3
–Disc brake pads: Inspect thickness02-5
–Reset service interval display02-6
–Drain away water from the fuel filter (diesel engine with fuel operation, which does not
comply with DIN EN 590-standard)
After each oil change
–Enter the next service date on the „Next Service“ sticker and affix sticker to the side of
the dash panel on the driver's side, that is according to the indicator or the kilometer
schedule (also the date for changing the brake fluid)
–Complete and attach service mirror tag to the interior rear-view mirror
–Hand customer the completed and signed form
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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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ChassisEdition 02.04
S00.5301.13.2002-5 page 4 02
–Repeat the procedure for all wheels in the following
sequence: rear left, front right and front left.
1)
–Insert strainer in the brake fluid reservoir and fill with
brake fluid up to the specified level.
–Inspect pedal position and idle travel at brake pedal.
Idle travel: max. 1/3 of pedal travel.
Vehicles with ABS or ABS/EDL:
A road test on such models must be carried out after
bleeding the brake system. While doing so perform at
least one ABS adjustment!
Inspecting the brake fluid level
Use only fresh genuine brake fluid FMVSS 571.116 DOT
4.
The brake fluid must not be above the „MAX“ marking to
prevent fluid flowing out of the reservoir.
Delivery Inspection
The brake fluid level during the delivery inspection should
be at the „MAX“ marking.
Inspection Service:
–The brake fluid level (volume) must always be as-
sessed on the basis of the brake pad wear. When driv-
ing a slight drop in the brake fluid level occurs as a
result of wear-and-tear and the automatic slack ad-
justment of the brake pads.
–If the fluid brake level is on the „MIN“ marking or slight-
ly above, it is not necessary to top up the brake fluid if
the brake pads have practically reached their wear
limit.
–If the brake pads are new or far off the brake wear lim-
it, the brake fluid level must be between the „MIN“ and
„MAX“ markings.
–If the brake fluid level has dropped below the „MIN“
marking, it is necessary to inspect the brake system
before topping up the brake fluid ⇒02-5 page 2; car-
ry out repair measure if necessary.
1)for right-hand drive vehicles the following sequence applies: rear right, front left and front right
WARNING!
Brake fluid is toxic. Because of its caustic effect
brake fluid must not come into contact with
paint.
Brake fluid is hygroscopic, i.e. it absorbs mois-
ture from the surrounding air . Therefore it
should always be stored in airtight containers.
Note
S02-0305
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ChassisEdition 02.04
S00.5301.13.2002-5 page 5 02
Track rod ends: Inspect play, correct at-
tachment and joint boots
–Raise vehicle (wheel clear of the ground) and inspect
play by moving the track rods and wheels. Clearance:
There must not be any play present.
–Inspect attachment.
–Inspect seals for damage and correct installation.
Inspecting tyres (including spare wheel)
Only tyres of the same type may be fitted to the vehicle.
Tyres of the same brand and tread pattern must always
be fitted to wheels on the same axle!
Delivery Inspection:
–Inspect the tyre tread and side wall for damage, if nec-
essary remove any foreign bodies from the tyres, such
as nails or glass splinters.
Inspection Service:
–Inspect the tyre tread and side wall for damage, if nec-
essary remove any foreign bodies from the tyres, such
as nails or glass splinters.
–Inspect tyres for scrubbing, tread worn down on one
side, porous side walls, cuts and punctures. Any de-
fects found must be advised to the customer and the
customer's attention must be drawn to any necessary
repair measures!
Inspecting tyre wear
–The wear pattern on the front tyres makes it possible
to assess whether it is necessary to inspect the wheel
toe and camber:
♦The formation of ridges on the tyre tread is an indica-
tion of wheel toe errors.
♦Tread worn on one side is usually attributable to cam-
ber errors.
–If such signs of wear are found, determine the cause
by checking the chassis alignment (repair measure).
Note
WARNING!
Tyres that are more than 6 years old must only be
used in case of emergency and while driving very
carefully.
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Electrical SystemEdition 09.04
S00.5301.14.2002-6 page 4 02
Operate the vehicle system tester by referring to the
read-out on the display:
Read out on display:
–Enter 00 for address word „Automatic test sequence“
and confirm with .
The automatic test sequence is carried out with address
word 00, i.e. the fault memory of all self-diagnosable sys-
tems in the vehicle is interrogated.
If a control unit responds with its identification, the display
will show the number of faults stored in the memory or
„No fault detected!“ Eventuell gespeicherte Fehler eines
Systems werden nacheinander angezeigt.
Any faults stored for one of the systems are displayed in
sequence.
If faults are stored, it is necessary to carry out a repair
measure. Displayed faults are to be entered.
–Switch off ignition.
The vehicle system tester -V.A.G 1552 - may have to re-
main connected for the exhaust emission test and for re-
setting the service interval display.
Resetting service interval display (SID)
QG0
If the due date of a service is reached, the service event
appears in the short journey counter below the speedom-
eter as a flashing display, after the ignition is switched on.
The service event also continues flashing for about 60
seconds after the engine is started.
The following displays are possible:
OIL - Oil change service
INSP - Inspection Service
The service event is shown on the indicator when the
service interval has been reached.
The service interval display should be adapted when car-
rying out the Delivery Inspection or during every Inspec-
tion Service.
The following intervals are set when adapting the service
interval display (SID):
Vehicle system test HELP
K cable does not connect to earth
Vehicle system test HELP
K cable does not connect to pos. term.
Vehicle system test HELP
Enter address word XX
Q
Note
Service event Nominal value
(distance)Nominal value
(time)
OIL 15 000 km -
INSP 30 000 km 365 days
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Electrical SystemEdition 09.04
S00.5301.14.2002-6 page 5 02
Resetting service interval display (SID) with
-V.A.G 1552- (QG0)
–Connect -V.A.G 1552-.
–Switch on ignition.
–Enter address word 17 „Dash Panel Insert“ and con-
firm with .
–Press key.
Readout on display (e.g.):
–Press key.
Readout on display:
–Enter function 10 „Adaptation“ and confirm with the
key.
Readout on display:
–Select adaptation channel of the service event to be
reset: for display „service OIL“ channel 10; for display
„service INSP“ channel 10, 11 and 12.
♦Entry of the relevant adaptation value for the short
journey counter can only be made in steps of 100 km;
consequently the read-out in the display is also in
units of 100 km.
♦Adaptation values must be entered as a 5-digit
number (e.g. 00150 for adaptation value 150, equals
a distance of 15 000 km to the next service event).
♦The value entered is counted back to 0 km.
♦The time counter for the „INSP service“ can be adapt-
ed with a maximum of 370 days.
♦Only a direct data entry is possible using the keypad
of the vehicle system tester!
♦If an incorrect figure is entered the „Adaptation“ func-
tion is terminated and must be adapted again.
Example:
Resetting SID for „OIL service“:
Readout on display:
6Y1919870B COMBIINSTRUMENT VDO X09 ->
Coding 20141 WSC 12345
Q
TMBMC46Y0Y7000001 SKZ7Z0W0204038 ->
Vehicle system test HELP
Select function XX
Q
Adjustment
Enter channel number XX
Service
eventad-
just-
ment
chan
nelCounter con-
tentsAdaptation
value
OIL 10 Distance in 100
km00150
INSP 11 Distance in 100
km00300
INSP 12 Time in days 00370
Note
Channel 10 Adjustment 1 ->
actual value OIL in 100 km - -
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Electrical SystemEdition 09.04
S00.5301.14.2002-6 page 6 02
„in 100 km“ = adaptation value x100
The current read-out of the short journey counter for the
OIL service is displayed (is still 100 km in our example
until the next OIL service).
–Press key.
Readout on display:
The short journey counter must be reset to 150 (equals
15 000 km) for setting the SID for the OIL service.
–Enter adaptation value 00150.
Readout on display:
–Confirm the entry with key .
Read-out on display after entering adaptation value
00150:
–Confirm the entry with key .
Readout on display:
–Confirm the entry with key .
Readout on display:
–Press key.
Readout on display:
–Enter 06 for „End output“.
Readout on display:
–Confirm the entry with key .
–Observe short journey counter.
–Switch off ignition.
After switching off the ignition the short journey counter
display should show the entered service interval for a
short time.
–Switch on ignition.
After switching on the ignition the short journey counter
display does not show a service interval.
The service interval display is now reset.
–Switch off ignition.
–Switch off -V.A.G 1552-.
Resetting service interval display (SID) without
-V.A.G 1552- (QG0)
After completing the service work, the appropriate serv-
ice message „OIL“ or „INSP“ must be reset.
Note
Channel 10 Adaptation 1
Enter adjustment value XXXXX
Channel 10 adjustment 1 Q
Enter adaptation value 00150
Q
Channel 10 adjustment 150 Q
actual value OIL in 100 km - -
Q
Channel 10 adjustment 15 Q
Store changed value?
Q
Channel 10 Adjustment 150 ->
Changed value stored
Vehicle system test HELP
Select function XX
Vehicle system test HELP
06 End output
Q
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Electrical SystemEdition 09.04
S00.5301.14.2002-6 page 7 02
♦For vehicles with the dash panel insert 6Y0 920 xxx x,
the SID with the set button -1- cannot be reset before
a service is required.
♦Always only reset the desired service interval („OIL
service“ or „INSP service“), otherwise an incorrect
date for another service interval will be set.
–Switch off ignition.
–Press set button -1- and hold and simultaneously
switch on ignition.
–As soon as the display „OIL service“ appears, release
the set button.
–Turn set button -1- to the right.
„- - -“ appears in the display.
–Move forward to the next service message by once
again pressing the set button -1-.
–As soon as the display „INSP service“ appears, re-
lease set button -1-.
–Turn set button -1- to the right.
„- - -“ appears in the display.
–Switch off ignition.
Resetting service interval display (SID)
QG1 and QG2
The pre-information about an up-coming service will be
displayed 30 days before the service interval. The read-
out appears on the display for the kilometre counter after
switching on the ignition whereby the number of remain-
ing kilometres required to reach the distance interval will
be displayed for the first 10 seconds while the number of
days remaining to reach the time interval will be shown in
the next 10 seconds. This interval will reduce later in
steps while driving down to 1 day or 100 kilometres. This
display stops blinking after 20 minutes, after starting the
engine or after pressing the reset button of the short jour-
ney counter.
If the due date of a service is reached, the key symbol ap-
pears in the short journey counter below the speedome-
ter as a flashing display, after the ignition is switched on,
whereby there are no numbers displayed. The display is
accompanied by an audible tone signal. This display
stops blinking after 20 seconds, after starting the engine
or after pressing the reset button of the short journey
counter.
If no inspection service is made the display will appear in
a similar way to that for reaching the service interval but
minus values will be both displayed and accumulated.
The pre-information display shows 30 days before the
due date of an inspection.
Note
S02-03061
Note