Get Descriptions of work -> Headlight adjustment: Checking, adjusting if necessary Guide for Volkswagen Lupo 2 Door First Generation (1998-2005)

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Sequence:

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

calipers:

Wheel brake cylinders,

brake calipers

3

Front left

200-250 cm

Total quantity: approx. 1.1 litres

– Close bleeder screws after procedure.

– Switch off brake filling and bleeding unit.

– Take connection off brake fluid reservoir and remove brake

pedal depressor.

– Check pedal pressure and brake pedal free play. Free play:

1

max. / of pedal travel.

3

– Depress clutch pedal several times.

4.46

Brake fluid level (dependent upon brake

pad/lining wear): check.

♦ Instructions for use and safety ⇒ page 98

♦ Brake fluid specification ⇒ page 98

Please note the following:

Delivery inspection:

At delivery inspection the fluid level must be at MAX. marking.

Note

To prevent that brake fluid flows out of reservoir, the MAX marking

must not be exceeded.

Inspection service:

– The fluid level must always be judged in conjunction with lin‐

ing/pad wear. When vehicle is in use, fluid level tends to drop

slightly due to lining/pad wear and automatic adjustment.

– When fluid level is at MIN. marking or just above, fluid should

not be topped up if linings are almost at wear limit.

– If linings/pads are new or well within wear limit, then fluid level

must be between MIN. and MAX. markings.

– If fluid level is below MIN. marking, the brake system should

be checked before fluid is added. (repair measure).

4.47

Headlight adjustment: Checking, adjust‐

ing if necessary

Adjusting headlights with gas discharge bulbs ⇒ page 104 .

Special tools and workshop equipment required

100

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Headlight adjustment unit - VAS 5046-

♦ or:

♦ Headlight adjustment unit - VAS 5047-

The following test and adjustment instructions are applicable in

all countries. However, national guidelines and regulations of the

respective country are to be followed.

Conditions for testing and adjustment:

♦ Tyre pressures OK.

♦ Lenses must not be damaged or dirty

♦ Reflectors and bulbs OK.

♦ Vehicle must be loaded.

Loading: with one person or 75 kg on the driver seat and the ve‐

hicle otherwise unloaded (unladen weight).

The unladen weight is the weight of vehicle ready for operation

with a full fuel tank (at least 90 %) including weight of all equip‐

ment normally carried (e.g. spare wheel, tools, jack, fire extin‐

guisher etc.).

If the fuel tank is not at least 90 % full, then load as follows:

– Read off fuel level in fuel tank on fuel gauge -arrow-. Deter‐

mine additional weight from following table and place weight

in luggage compartment.

Fuel gauge table

Fuel

Additional weight

in kg

gauge

1/4

1/2

3/4

Full

20

15

5

0

Example:

4. Descriptions of work:

101

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

When the fuel tank is half full an additional weight of 15 kg must

be placed in the luggage compartment.

Note

The additional weight is best produced using fuel canisters filled

with water (a 5 litre fuel canister filled with water weighs approx.

5 kg).

The vehicle must be rolled forward or backward several metres

or front and rear springs must be bounced fully several times so

that springs settle.

♦ Vehicle and headlight adjuster must be on a level surface. ⇒

Headlight adjuster operating instructions.

♦ Vehicle and headlight adjuster must be aligned.

♦ Inclination must be set.

Inclination information in “%” is stamped into trim above headlight.

Headlights must be adjusted according to this information. Per‐

centage given is based on a projection distance of 10 metres.

Example: Converting a dip setting of e.g. 1.2 % is equivalent to

12 cm.

Note

♦ The main beam is only height-adjustable. The lateral adjust‐

ment is preset and must not be changed.

♦ If the vehicle is equipped with separate dipped and main

beam, adjust main beam additionally. When adjusting main

beam ensure that the adjustment unit is set to 0%.

♦ The headlight range control thumb wheel must be in position

(-).

4.47.1

Checking headlight adjustment (using

test screen without 15° setting line)

Headlights:

Please check the following:

– Whether, with the dipped beam switched on, the horizontal

light-dark border contacts the dividing line -1- of the test area

and

– Whether the breaking point -2- between the horizontal part of

the bright/dark boundary on the left and the rising part on the

right lies on the vertical line of the central point -3-. The bright

core of the light beam must be to the right of the vertical line.

102

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Note

♦ To simplify finding the breaking point -2-, cover and uncover

left (from driver perspective) half of the headlight a few times.

Then check dipped beam again.

♦ After correct adjustment of dipped beams, the centre point of

the main beam must lie on the centre mark -3-.

♦ The 15° setting line on the test screen must be ignored.

Fog lights:

– Check whether the upper bright/dark boundary touches the

setting line and runs horizontally over the entire width of the

test screen.

Other additional lights:

Additionally retrofitted lights of other systems must be checked

and set according to valid guidelines.

4.47.2

Adjusting headlights

Left headlight

•

-1- Lateral adjustment

-2- Height adjustment

Both adjustment screws on right-hand headlight are a mirror im‐

age.

– Adjust headlight at front using a suitable cross head screw‐

driver.

Note

Please check also that both headlights move evenly when head‐

light range control is operated.

Left fog light:

Engine codes ANY, AYZ

4. Descriptions of work:

103

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– To adjust the fog light, unclip cover -arrow- in lower part of

bumper.

Continued for all vehicles:

– To reduce the beam range turn adjustment screw -arrow- to

the right. There is no provision for lateral adjustment.

Location of adjustment screw on right-hand headlight is a mirror

image.

4.47.3

Headlights with gas discharge bulbs:

adjusting

The following test and adjustment instructions are applicable in

all countries. However, national guidelines and regulations of the

respective country are to be followed.

The following are prerequisites for adjusting headlights gas dis‐

charge bulbs:

•

Tyre pressures OK.

Lenses must not be damaged or dirty

Reflectors and bulbs OK.

Handbrake must be released and no gear selected.

The steering wheel must be in straight-ahead position.

The vehicle must not be moved during the basic settings (do

not “open or close” doors or lean on or enter vehicle).

•

Nobody may be in the vehicle and the vehicle must not be

loaded.

The vehicle must be rolled forward or backward several me‐

tres or front and rear springs must be bounced fully several

times so that springs settle.

•

Vehicle and headlight adjuster must be on a level surface. ⇒

Headlight adjuster operating instructions.

•

Vehicle and headlight adjuster must be aligned.

Inclination must be set.

Inclination information in “%” is stamped into trim above headlight.

Headlights must be adjusted according to this information. Per‐

centage given is based on a projection distance of 10 metres.

Example: Converting a dip setting of e.g. 1.2 % is equivalent to

12 cm.

104

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Headlights

Note

Vehicles with gas discharge bulbs are equipped with automatic

headlight range control. On these vehicles, the procedure “Basic

setting” for adjusting headlights must be carried out.

Because the automatic headlight range control does not have a

manual adjustment, the basic setting procedure must be per‐

formed to adjust the headlights.

After the headlights have been adjusted, the fault memory must

be read. Therefore, the procedure described here must be strictly

followed.

4.47.4

Carrying out basic setting using vehicle

diagnosis, testing and information sys‐

tem - VAS 5051- or vehicle diagnosis

and service information system - VAS

5052-

Special tools and workshop equipment required

♦ Vehicle diagnostic, testing and information system - VAS

5051-

♦ Diagnostic cable - VAS 5051/6A-

4. Descriptions of work:

105

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

♦ Vehicle diagnostic and service information system - VAS

5052-

♦ Diagnostic cable, 2 m - VAS 5052/3 A-

♦ Headlight adjustment unit - VAS 5046-

♦ or

♦ Headlight adjustment unit - VAS 5047-

Carry out following procedure:

Connect vehicle diagnosis, testing and information system - VAS

5051- or vehicle diagnosis and service information system - VAS

5052- .

– Apply handbrake.

– Automatic gearbox: Move selector lever to position “P” or “N”.

– Manual gearbox: gear lever in neutral.

Connect vehicle diagnostic, testing and information system - VAS

5051- or vehicle diagnostic and service information system - VAS

5052- with ignition switched off as follows:

– Pull ashtray insert out of centre console.

– Connect vehicle diagnostic, testing and information system -

VAS 5051- or vehicle diagnostic and service information sys‐

tem - VAS 5052- using diagnostic cable - VAS 5051/6A- with

ignition switched off.

106

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

– Switch on ignition.

Indicated on display:

Select operating mode:

– Press button for Vehicle self-diagnosis on display

-arrow-.

Note

If the display is not as shown in the procedure: ⇒ Operating in‐

structions for vehicle diagnosis, testing and information system -

VAS 5051- or ⇒ Operating instructions for vehicle diagnosis and

service information system - VAS 5052- .

Indicated on display:

– Press “55 - Headlight range control” on display -arrow-.

Indicated on display:

The control unit identification and coding are displayed -arrow-.

Indicated on display:

– Press “04 - Initiate basic setting” on display -arrow-.

4. Descriptions of work:

107

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Press 001 in number block of display -arrow- (001 selects

“display group number 001”).

– Confirm entry with Q button on display number block.

After “Wait” is indicated on display, the following message ap‐

pears:

Indicated on display:

– Now adjust headlights ⇒ page 110 .

– After adjusting headlights, press ← -arrow- on display.

Indicated on display:

– Press 002 in number block of display -arrow- (002 selects

“display group number 002”).

– Confirm entry with Q button on display number block.

Indicated on display:

The reference position of the headlight will now be “learnt” by the

control unit.

– Press ← -arrow- on display.

108

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Press ← -arrow- on display.

Indicated on display:

– Press “02 - Read fault memory” on display -arrow-.

Indicated on display:

Any system faults that are stored will be displayed one after the

other.

If faults are stored, repairs are necessary. The fault log must ac‐

company vehicle to repair.

– Press ← -arrow- on display.

Indicated on display:

– Press GoTo button on display -arrow-.

4. Descriptions of work:

109

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

Indicated on display:

– Press the End button on display -arrow-.

– Press End button in End menu.

– Switch off ignition and separate diagnosis connections.

– Install ashtray insert.

4.47.5

Adjusting headlights

Headlight adjustment: checking

Headlights:

Please check the following:

– Whether, with the dipped beam switched on, the horizontal

light-dark border contacts the dividing line -1- of the test area

and

– Whether the breaking point -2- between the horizontal part of

the bright/dark boundary on the left and the rising part on the

right lies on the vertical line of the central point -3-. The bright

core of the light beam must be to the right of the vertical line.

Note

♦ To simplify finding the breaking point -2-, cover and uncover

left (from driver perspective) half of the headlight a few times.

Then check dipped beam again.

♦ After correct adjustment of dipped beams, the centre point of

the main beam must lie on the centre mark -3-.

Left headlight

•

-1- Lateral adjustment

-2- Height adjustment

Both adjustment screws on right-hand headlight are a mirror im‐

age.

– Adjust headlight at front using a suitable cross head screw‐

driver.

110

4. Descriptions of work:

Lupo 1999 ➤ , Lupo 3L 1999 ➤

Maintenance - Edition 03.2018

4.47.6

Adjusting main beam

Headlight adjustment: checking

– Check whether the upper bright/dark boundary touches the

setting line and runs horizontally over the entire width of the

test screen.

Main beam (right):

•

-1- Lateral adjustment

-2- Height adjustment

Both adjustment screws on the left-hand headlight are a mirror

image.

– Adjust headlights using a 6 mm socket.

Other additional lights:

Additionally retrofitted lights of other systems must be checked

and set according to valid guidelines.

4.48

Carry out road test

Which of the following can be checked depends on vehicle equip‐

ment and local conditions (urban/country).

– Check the following during a road test:

♦ Engine: output, misfiring, idling speed, acceleration

♦ Clutch: pulling away, pedal pressure, odours

♦ Gear selection: ease of operation, stick position

♦ Automatic gearbox: Selector lever position, shift lock / ignition

key removal lock, shift behaviour

♦ Dual clutch gearbox: Selector lever position, shift lock / ignition

key removal lock, shift behaviour

♦ Foot brake and handbrake: function, free travel and effective‐

ness, pulling to one side, juddering, squeal

♦ Steering: function, steering free clearance, steering wheel

centred when vehicle is travelling straight ahead

♦ Tilting roof: function

♦ Folding fabric sunroof: function

♦ Radio: Reception, GALA, interference

♦ Multi-function indicator (MFI): functions

♦ Air conditioning system: function

♦ Vehicle: pulling to one side when travelling straight-ahead

(level road)

♦ Imbalance: Wheels, drive shafts

4. Descriptions of work:

111

Descriptions of work -> Headlight adjustment: Checking, adjusting if necessary for Your Volkswagen Lupo 2 Door First Generation (1998-2005)

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