Volkswagen Golf / Golf GTI / Jetta. Manual — part 1236

- Connect collecting bottle bleeder hose - 1 - to front
bleeder screw

)

, open bleeder screw and allow the

appropriate quantity to flow out (see table on side). Close
bleeder screw.

Repeat procedure on left front.

Table - Sequence / quantity of brake fluid

Sequence:
brake wheel
cylinder,
brake caliper

Brake fluid quantity which must flow out of wheel brake cylinders or
brake calipers:

Right rear

0.25 liter

Left rear

0.25 liter

Right front

0.25 liter

Left front

0.25 liter

Total quantity: approx. 1.25 liter

)

Including brake fluid extracted from brake fluid reservoir

and quantity from clutch slave cylinder.

- Install cover caps on brake wheel cylinder and/or brake
caliper bleeder screws.

- Move filler lever on Brake filler and bleeder unit VAS 5234
or Brake filler and bleeder unit V.A.G 1869/ to position - B -
(see operating instructions).

- Remove filler hose from adapter.

- Unscrew adapter from brake fluid reservoir.

- Check brake fluid level and correct if necessary.

- Install cap to brake fluid reservoir.

- Remove brake pedal depressor.

- Check pedal pressure and brake pedal free play. Free
play: max. 1/3 of pedal travel

Description of work (part 2 of 2)

13/2/2005

Brake fluid level (depending on brake pad
wear), checking

Use only new brake fluid with replacement part number B
000 700 A (corresponds to US standard FMVSS 116 DOT
4)

Warning!

Brake fluid must never come into contact with fluids
containing mineral oils (oil, gas, cleaning solutions).
Oils containing minerals damage seals and sleeves on
brake systems.

Brake fluid is poisonous. Due to its caustic nature, it
must also never be brought into contact with paint.

Brake fluid is hygroscopic, which means that it
absorbs moisture from the air. Always store brake fluid
in air-tight containers.

Wash off brake fluid spillage using plenty of water.

Observe waste disposal regulations!

Note the following:

Delivery inspection:

At time of delivery inspection, brake fluid level must be at
MAX mark.

Note:

To prevent the brake fluid from overflowing from the
reservoir, the level must not be over the MAX mark.

Inspection service:

- The fluid level must always be judged in conjunction with

Description of work (part 2 of 2)

13/2/2005

brake pad wear. When vehicle is in use, the fluid level
tends to drop slightly due to brake pad wear and automatic
adjustment.

- With brake fluid at MIN mark or slightly above, topping off
brake fluid is not necessary when wear limit of brake pads
has been almost reached.

- When brake pads are new or if there is still enough brake
lining left, the brake fluid level must be between MIN and
MAX marks.

- If brake fluid level is below MIN mark, check brake system
(repair procedure), before adding brake fluid.

Headlight adjustment, checking

Checking headlight adjustment for headlights with gas
discharge lamps

01-8, Headlight adjustment, checking

headlight with gas discharge lamps

Special tools, testers and auxiliary items required

Headlight setting unit VAS 5046/

or

Headlight setting unit VAS 5047/

The following test- and adjustment instructions are
applicable to all countries. But national legislation and
regulations of the respective country is to be adhered to.

Check and adjustment conditions:

Tire pressure OK.

Lenses must not be damaged or dirty.

Reflectors and bulbs OK.

Vehicle must be properly loaded.

Load: Vehicle must be loaded with one person on the
drivers seat, weighing 75 kg, otherwise vehicle must be
empty (curb weight).

The curb weight is the weight of the vehicle ready to be
operated with filled fuel tank (at least 90% filled), including
the weight of all equipment usually carried in the car such
as spare wheel, tools, car jack, fire extinguisher, etc.

Description of work (part 2 of 2)

13/2/2005

If the fuel tank is not at least 90% full, adjust the weight as
follows:

- Read fuel level from fuel gauge. Calculate additional
weight needed using the following table. Place extra weight
in luggage compartment.

Tank filling table

Fuel level according

to fuel gauge

Additional weight

in luggage compartment in lbs (kg)

1/4

66 (30)

1/2

44 (20)

3/4

22 (10)

Full

0 (0)

Example:

If the fuel tank is half full, place a weight of 44 lbs (20kg) in
the luggage compartment.

Note:

For additional weight use containers filled with water. A
container filled with 5 liters of water weighs approx. 12 lbs
(5kg) .

Move vehicle back and forth for 1 meter (3 to 4 feet) or
bounce front and rear of vehicle several times up and down
to settle suspension.

Vehicle and headlight adjuster must be on a level surface.

User manual for headlight adjuster.

Vehicle and headlight adjuster must be aligned.

Inclination must be set.

In the trim above the headlight, inclination measurements
are stamped in "%" . The headlights must be adjusted
according to these measurements. Percentage information
is based on a projection distance of 10 meters. For
example: inclination of 1.2 % converts to approx. 12 cm.

The adjusting wheel for the beam width regulation must be
located in basic setting (-).

Checking headlight setting (with new test screen
without 15 -setting line)

Headlights:

Description of work (part 2 of 2)

13/2/2005