Vehicle Damage Warnings
IMPORTANT:The contents of this information have been and will continue to be updated by Technical Bulletins. This has been updated to include information from Technical Bulletins available at the time of release that specifically cover changes or additions to repair procedures and specifications.
Technical Bulletins covering other important data, and those that have been created since the release of this information, are not included. Before using this information, be sure to look up the latest Technical Bulletins.
Please read these WARNINGS and CAUTIONS before proceeding with maintenance and repair work.
- If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this information, we suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered wholly or in part by any of the extensive warranties issued by Volkswagen.
- Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications are made applicable to earlier models. Therefore, part numbers listed in this information are for reference only. Always check with your authorized Volkswagen retailer parts department for the latest information.
- Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
- Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
- For vehicles equipped with an anti-theft radio, be sure of the correct radio activation cod,e before disconnecting the battery or removing the radio. If the wrong code is entered when power is restored, the radio may lock up and become inoperable, even if the correct code is used in a later attempt.
- Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the recommendations in this data, replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.
- Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is ignited, it will ignite gas trapped in the cells and cause the battery to explode.
- Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase system pressure and may cause the system to burst.
- Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the instructions thoroughly, do not attempt shortcuts. Use tools that are appropriate to the work and use only replacement parts meeting Volkswagen specifications. Makeshift tools, pants and procedures will not make good repairs.
- Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque listed.
- Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery negative terminal (ground strap) and the ABS control module connector.
- When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these components is not separately fused, disconnect the control module connector(s).
- Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.