Golf & Golf Plus - Maintenance Handbook.pdf

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Service
Maintenance
Edition 11.2009
Golf 2004 ➤
Golf Plus 2005 ➤
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Service Department. Technical Information
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Service
Maintenance
Heading
1. Engine list
2. Service work
3. General
4. Descriptions of work
5. Exhaust emissions test
6. Glossary
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg
K0058991520
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Golf 2004 ➤ , Golf Plus 2005 ➤
Maintenance - Edition 11.2009
Contents
1
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.27
4.28
4.29
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Service work . . . .
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Information on
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long-life service and time or distance dependent service . . . . . . . . . . . . .
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Service tables
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7
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7
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9
Delivery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil change service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Interval service ▸2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Interval service 2008▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Interval service inspection ▸2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspection service 2008▸ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Time or distance dependent additional work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Raising vehicle with lifting platform and trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
RME fuel (biodiesel) for vehicles up to 05.2006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removable towing bracket: Check and clean if necessary . . . . . . . . . . . . . . . . . . . . . . . . 41
Swivel joints: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Driving light assist and cornering light: Check function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Automatic gearbox: Check ATF level, 09G gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Automatic gearbox: Change ATF (09G gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Battery: Check battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . . . 45
Battery: Check using battery tester with printer VAS 5097A or VAS 6161 . . . . . . . . . . . . . . 48
Checking tyres: Condition, wear pattern, tyre pressure, tread depth and age of tyres . . . . 48
Brake and clutch system: Change brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Brake fluid level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Brake system and shock absorbers: Perform visual check for leaks and damage . . . . . . 58
Front and rear brake pads/linings: Check thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Checking diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6-speed dual clutch gearbox (DSG) 02E: Change oil and filter . . . . . . . . . . . . . . . . . . . . . . 61
Electric windows: Check positioning (open and close functions) . . . . . . . . . . . . . . . . . . . . 61
Vehicle system test: Perform test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Front passenger front airbag: Check key switch and “On/Off function” . . . . . . . . . . . . . . . . 63
Protective bellows: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Haldex coupling (Golf 4motion): Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Poly V-belt: Adjust tension on engines without automatic tensioning roller . . . . . . . . . . . . 69
Poly V-belt: Check condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Calibrating compass (for North American region) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Cooling system: Check frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Fuel filter: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Air filter: Clean housing and renew filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Engine cover -top-: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Removing and installing engine compartment cover -bottom- (noise insulation) . . . . . . . . 99
Engine and components in engine compartment (from above and below): Perform visual
check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Engine oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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Engine list . . . . . . . . . . . . .
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Contents
i
Golf 2004 ➤ , Golf Plus 2005 ➤
Maintenance - Edition 11.2009
4.30
4.31
4.32
4.33
4.34
4.35
4.36
4.37
4.38
4.39
4.40
4.41
4.42
4.43
4.44
4.45
4.46
4.47
4.48
4.49
4.50
4.51
4.52
4.53
4.54
4.55
4.56
4.57
5
5.1
5.2
5.3
6
Engine oil: Drain or extract; renew oil filter and replenish engine oil . . . . . . . . . . . . . . . . . .
Performing road test (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . .
Wheel securing bolts: Tighten to prescribed torque setting . . . . . . . . . . . . . . . . . . . . . . . .
Reading radio code using vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radio/radio navigation system: Enter PIN of anti-theft coding and store local radio stations
to station buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tyre pressure monitoring: Perform basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tyre repair set: Check bottle for damage and if used;
V
check
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and enter date of tyre sealant
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Dust and pollen filter: Clean housing
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Headlight adjustment: Check . .
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Service interval display: Reset
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Service interval display: Recode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sunroof: Check function, clean and grease guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sliding sunroof drains: Check flow and clean if necessary . . . . . . . . . . . . . . . . . . . . . . . .
Window wash/wipe system and headlight washer system: Check function . . . . . . . . . . . .
Wiper blade protection: Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiper blades: Check park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Track rod ends: Check play, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary heater: Set weekday in menu of combi-instrument . . . . . . . . . . . . . . . . . . . . . . . .
Door arrester: Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transportation mode: Switch off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transportation devices: Remove blocking pieces from front axle springs . . . . . . . . . . . . . .
Underbody: Visual check for damage to underbody sealant, underbody panels, routing of
lines, plugs etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clock and date: Set to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toothed belt and toothed belt tensioning roller: Renew (TDI unit injector) . . . . . . . . . . . .
Camshaft drive toothed belt: Renew (only 2.0 l FSI and TFSI) . . . . . . . . . . . . . . . . . . . . . .
Camshaft drive toothed belt: Check (4-cylinder petrol engines 1.4 l 55 kW and 1.6 l 75 kW)
........................................................................
Spark plugs: Renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front and rear final drive: Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust emissions test for petrol engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust emissions test for diesel engines without OBD . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust emissions test for diesel engines with OBD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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101
112
112
114
115
116
118
118
119
126
127
129
129
131
137
139
140
140
141
141
143
143
144
145
145
145
146
159
160
160
167
171
180
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Contents
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Golf 2004 ➤ , Golf Plus 2005 ➤
Maintenance - Edition 11.2009
1
Engine list
In this chapter you will obtain information for
♦ Petrol engines
⇒ page 1
♦ Diesel engines
⇒ page 5
Note
To ease the search for an engine, the engine codes are listed in
alphabetical order.
Petrol engines
Engines:
Capacity
Engine code
⇒
I
Petrol engine
2.0
AXW
Petrol engine
2.0
AXX
Petrol en‐
gine
1.6
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No. of cylinders/valves per cylinder
Output
kW at rpm
Torque
Nm at rpm
Bore
∅ mm
Stroke
mm
Compression ratio
Injection/ignition
RON
Camshaft drive
4/4
4/4
4/4
110/6000
147/5700
85/6000
200/3500
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280/2000
155/4000
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76.5
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86.9
92.8
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11.5
10.5
11.5
Motronic MED
Motronic MED 9.1
Motronic
9.5.10
TFSI
MED
FSI
9.5.10
FSI
Petrol unleaded, at least
95
95
95
Toothed belt
Toothed belt
Chain
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Engines:
Capacity
Engine code
⇒
I
Petrol engine
1.4
BCA
4/4
55/5000
126/3300
76.5
75.6
10.5
Motronic MED
7.5.10
SRE
95
1
Toothed belt
Petrol engine
2.5
BGP
5/4
110/5000
228/3750
82.5
92.8
10
Motronic ME 7.1.1
SRE
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Petrol engine
2.5
BGQ
5/4
110/5000
228/3750
82.5
92.8
10
Motronic ME
7.1.1
SRE
91
Chain
RON
Camshaft drive
Petrol unleaded, at least
91
Chain
1) 91 RON also permitted, but reduced output
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No. of cylinders/valves per cylinder
Output
kW at rpm
Torque
Nm at rpm
Bore
∅ mm
Stroke
mm
Compression ratio
Injection/ignition
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1. Engine list
1

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