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If you lack the
skills, tools and equipment, or a suitable workshop for any procedure
described in this manual, 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.
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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. |
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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 manual are for reference only.
Always check with your authorized Volkswagen retailer parts department
for the latest information.
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Any time the
battery has been disconnected on an automatic transmission vehicle, it
will be necessary to re-establish Transmission Control Module (TCM) basic
settings using the VAG 1551 Scan Tool (ST). |
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Never work under
a lifted vehicle unless it is solidly supported on stands designed for
the purpose. Do not support a vehicle on cinder blocks, hollow tiles or
other props that may crumble under continuous load. Never work under a
vehicle that is supported solely by a jack. Never work under the vehicle
while the engine is running.
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For vehicles
equipped with an anti-theft radio, be sure of the correct radio
activation code before disconnecting the battery or removing the radio.
If the wrong code is entered when the power is restored, the radio may
lock up and become inoperable, even if the correct code is used in a
later attempt.
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If you are going
to work under a vehicle on the ground, make sure that the ground is
level. Block the wheels to keep the vehicle from rolling. Disconnect the
battery negative terminal (ground strap) to prevent others from starting
the vehicle while you are under it.
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Do not attempt to
work on your vehicle if you do not feel well. You increase the danger of
injury to yourself and others if you are tired, upset or have taken
medicine or any other substances that may impair you or keep you from
being fully alert. |
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Never run the
engine unless the work area is well ventilated. Carbon monoxide (CO)
kills. |
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Always observe
good workshop practices. Wear goggles when you operate machine tools or
work with acid. Wear goggles, gloves and other protective clothing
whenever the job requires working with harmful substances.
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Tie long hair
behind your head. Do not wear a necktie, a scarf, loose clothing, or a
necklace when you work near machine tools or running engines. If your
hair, clothing, or jewellery were to get caught in the machinery, severe
injury could result. |
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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
manual-replace these fasteners with new parts where indicated, and any
other time it is deemed necessary by inspection.
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Illuminate the
work area adequately but safely. Use a portable safety light for working
inside or under the vehicle. Make sure the bulb is enclosed by a wire
cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil. |
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Friction
materials such as brake pads and clutch discs may contain asbestos fibres. Do not create dust by grinding, sanding, or by cleaning with
compressed air. Avoid breathing asbestos fibres and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or
cancer, and may result in death.
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Finger rings
should be removed so that they cannot cause electrical shorts, get
caught in running machinery, or be crushed by heavy parts. |
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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, parts and
procedures will not make good repairs.
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Catch draining
fuel, oil or brake fluid in suitable containers. Do not use empty food
or beverage containers that might mislead someone into drinking from
them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn
spontaneously.
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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. |
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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. |
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Be mindful of the
environment and ecology. Before you drain the crankcase, find out the
proper way to dispose of the oil. Do not pour oil onto the ground, down
a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
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The
air-conditioning (A/C) system is filled with a chemical refrigerant that
is hazardous. The A/C system should be serviced only by trained
automotive service technicians using approved refrigerant
recovery/recycling equipment, trained in related safety precautions, and
familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
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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. |
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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. |
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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).
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Some of the
vehicles covered by this manual are equipped with a supplemental
restraint system (SRS), that automatically deploys an airbag in the
event of a frontal impact. The airbag is operated by an explosive
device. Handled improperly or without adequate safeguards, it can be
accidentally activated and cause serious personal injury. To guard
against personal injury or airbag system failure, only trained
Volkswagen Service technicians should test, disassemble or service the
airbag system.
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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. |
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Never use a test
light to conduct electrical tests of the airbag system. The system must
only be tested by trained Volkswagen Service technicians using the VAG
1551 ScanTool (ST) or an approved equivalent. The airbag unit must never
be electrically tested while it is not installed in the vehicle. |
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Some aerosol tire
inflators are highly flammable. Be extremely cautious when repairing a
tire that may have been inflated using an aerosol tire inflator. Keep
sparks, open flame or other sources of ignition away from the tire
repair area. Inflate and deflate the tire at least four times before
breaking the bead from the rim. Completely remove the tire from the rim
before attempting any repair.
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When driving or
riding in an airbag-equipped vehicle, never hold test equipment in your
hands or lap while the vehicle is in motion. Objects between you and the
airbag can increase the risk of injury in an accident. |