Volkswagen Golf 2004 Service Manual
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Volkswagen Golf 2004 Service Manual

Golf 2004; golf plus 2005
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Service
Maintenance
Golf 2004 ➤
Golf Plus 2005 ➤
Edition 11.2009
Service Department. Technical Information

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Summary of Contents for Volkswagen Golf 2004

  • Page 1 Service Maintenance Golf 2004 ➤ Golf Plus 2005 ➤ Edition 11.2009 Service Department. Technical Information...
  • Page 2 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...

  • Page 3: Table Of Contents

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Contents Engine list ............. .
  • Page 4 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.30 Engine oil: Drain or extract; renew oil filter and replenish engine oil ....101 4.31...

  • Page 5: Petrol Engines

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 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.
  • Page 6 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Engines: ⇒ Petrol engine Petrol engine Petrol engine Capacity Engine code No. of cylinders/valves per cylinder Output kW at rpm 75/5600 66/5000 85/5800 Torque Nm at rpm 148/3800...
  • Page 7 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Engines: ⇒ Petrol engine Petrol engine Petrol engine Capacity Engine code Camshaft drive Toothed belt Toothed belt Toothed belt Engines: ⇒ Petrol engine Petrol engine Petrol engine Capacity Engine code No.
  • Page 8 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Engines: ⇒ Petrol engine Petrol engine Petrol engine Capacity Engine code Compression ratio 11.5 11.5 11.5 Injection/ignition Motronic MED Motronic MED Motronic MED 9.5.10 9.5.10 9.5.10 Petrol unleaded, at least...
  • Page 9 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Engines: ⇒ Petrol engine Petrol engine Petrol engine Flex Fuel Capacity Engine code CBUA CCSA CCTA No. of cylinders/valves per cylinder Output kW at rpm 125/5000 75/5600 147/5100...6000...
  • Page 10 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Engines: ⇒ Diesel engine Diesel engine Diesel engine Capacity Engine code Diesel particulate filter Camshaft drive Toothed belt Toothed belt Toothed belt Engines: ⇒ Diesel engine Diesel engine...

  • Page 11: Service Work

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Service work In this chapter you will obtain information on the following sub‐ jects: Information on long-life service and time or distance dependent service ⇒ page 7 Service tables ⇒...

  • Page 12: Service Interval Display

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 For vehicles with long-life service the service interval is deter‐ mined by the control unit and is indicated on service interval display (SID) ⇒ page 8 Therefore the service intervals for long-life service are flexible.

  • Page 13: Service Tables

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Flexible service interval display (only vehicles with long-life serv‐ ice, PR number QG1) Calculation of service intervals: ♦ To calculate the service intervals for vehicles with long-life service, input values such as distance driven, fuel consump‐...

  • Page 14: Service Intervals

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 2.2.1 Service intervals Caution Only valid for diesel engines: • In some countries the sulphur content in diesel fuel ex‐ ceeds 2000 ppm. • The high sulphur content leads to excessive wear of cyl‐...
  • Page 15 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Golf/Golf Plus Service intervals 2008▸ From - to Engine/Engine code/ Service/intervals Indicated on PR No./Remarks service interval display SID (includes oil change) 2008▸ QG0/QG2/QG3 or Oil change service...
  • Page 16 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Note Vehicles with retrofitted diesel particulate filter are allocated in the table to diesel engines without diesel particulate filter. 2.2.3 Filter change intervals Golf/Golf Plus FILTER CHANGE INTERVALS...
  • Page 17 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Golf/Golf Plus TOOTHED BELT CHANGE INTERVALS, TENSIONING ROLLER CHANGE INTERVALS SDI-PD Since introduc‐ Every 120,000 km Every 240,000 km tion TDI-PD AZV, BEE, BJB, Since introduc‐ Every 120,000 km ▸2006...

  • Page 18: Delivery Inspection

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Golf/Golf Plus Spark plug change intervals 1.8 TSI, 2.0 TSI; 2.0 TFSI AXX, BPY, BWA, BYD, CAVD, EVERY 90,000 km and V6 FSI CAWB, CBFA, CBRA, CCTA • Mileage more than 90,000 km in 6 years EVERY 6 years •...
  • Page 19 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Work to be completed Page – Tyre inflation pressure of all 4 wheels and spare wheel: Set to correct pressures (in the factory ⇒ the tyres are inflated to 3.5 bar).

  • Page 20: Oil Change Service

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Oil change service Note The oil change service is always a time or distance dependent ♦ service “QG0/QG2” ⇒ page 8 Inform the customer if faults are found during service and re‐...

  • Page 21: Interval Service ▸2007

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Interval service ▸2007 Note The interval service is a time or distance dependent service ♦ “QG0/QG2” ⇒ page 8 and also a long-life service ⇒ page 7 The interval service always includes an engine oil change! ♦...

  • Page 22: Interval Service 2008

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Work to be completed Page – Tyre repair set: Check bottle for damage and if used; check and enter date of tyre sealant ⇒ __________ page 118 •...
  • Page 23 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Check if storage life date of first aid box has been exceeded and if warning triangle is fitted. – Removing and installing engine compartment cover -bottom- (noise insulation tray) ⇒...

  • Page 24: Interval Service Inspection ▸2007

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Interval service inspection ▸2007 Note Inform the customer if faults are found during service and re‐ ♦ pair measures are necessary. If service work has been performed for the interval service at ♦...
  • Page 25 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Work to be completed Page – Vehicle system test: Perform test ⇒ page 62 – Service interval display: Reset ⇒ page 126 Vehicle exterior – Window wash/wipe system and headlight washer system: Check function and settings ⇒...

  • Page 26: Inspection Service 2008

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Work to be completed Page – Brake system: Perform visual check for leaks and damage ⇒ page 58 – Front and rear brake pads/linings: Check thickness ⇒ page 59 –...
  • Page 27 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Caution Only valid for diesel engines: • In some countries the sulphur content in diesel fuel ex‐ ceeds 2000 ppm. • The high sulphur content leads to excessive wear of cyl‐...
  • Page 28 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Work to be completed Page – Tyre repair set: Check bottle for damage and if used; check and enter date of tyre sealant ⇒ __________ page 118 •...

  • Page 29: Time Or Distance Dependent Additional Work

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Time or distance dependent additional work Depending on conditions under which the vehicle is used ⇒ page 36 and vehicle equipment, extra service work must be performed in addition to the interval service, inspection service or interval service inspection.
  • Page 30 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Additional work Page – Air filter element: Renew and clean housing ⇒ page 80 • Valid for Golf GTI “Edition 30” and Golf GTI “Pirelli” • Rubber buffers for engine cover in conjunction with “Renewing air filter element”...
  • Page 31 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Every 150,000 km Additional work Page – Camshaft drive toothed belt: Renew ⇒ page 145 • Only valid for 4-cylinder TDI unit injector engines from model year 2007 •...
  • Page 32 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Every 2 years Additional work Page – Brake and clutch system: Change brake fluid ⇒ page 53 • Only valid for vehicles ▸2007 – Renew dust and pollen filter (cabin filter) ⇒...

  • Page 33: General

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 General In this chapter you will obtain information on the following sub‐ jects: Raising vehicle with lifting platform and trolley jack ⇒ page 29 Sticker ⇒ page 30 Entries in service schedule ⇒...

  • Page 34: Sticker

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Rear lifting point: – Position support plate, in area of side member marking -arrow A-, at vertical reinforcement of floor pan -arrow B-. WARNING Ensure that side member reinforcement seats centrally on support plate of hoist mounting.

  • Page 35: Service Schedule

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Apply sticker on driver side door pillar (B-pillar) -arrow-; the sticker is located on an instruction which is attached at front in the vehicle wallet. Destroy the instruction after attaching the sticker! 3.2.2...

  • Page 36: Entries In Service Schedule

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 3.2.4 Attaching hotline sticker – Attach hotline sticker to the inside of glove box cover as shown. • Only valid for Germany Entries in service schedule If a component is changed which has a change interval prescribed by the manufacturer, e.g.
  • Page 37 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Vehicle diagnostic, testing and information system -VAS 5051B- ♦ Diagnostic cable -VAS 5051/6A- ♦ Vehicle diagnostic and service information system -VAS 5052- or subsequent units ♦ Diagnostic system -VAS 5053-...

  • Page 38: Vehicle Identification Number

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Diagnostic cable -VAS 5052/3- Note Ensure that the selected vehicle diagnostic tester is only used with the respective diagnostic cable. WARNING ♦ Always secure testing and measuring equipment on the rear seat during a road test.
  • Page 39 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Vehicle identification number on suspension strut mounting ⇒ page 35 Location engine compartment 3.5.1 Vehicle identification number on lower edge of windscreen The vehicle identification number (chassis number) -arrow- is lo‐...

  • Page 40: Vehicle Data Sticker

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Vehicle data sticker The vehicle data sticker -arrow- is located in rear of vehicle on the left in spare wheel recess. The vehicle data sticker is also found in the service schedule for the customer.

  • Page 41: Engine Code And Engine Number

    For vehicles as of 06.2006 RME fuel must not be used. RME fuel may be used only in vehicles which have been approved for this purpose by Volkswagen - either in the standard version or in vehicles which have had special equipment (PR No. 2G0) for this purpose.

  • Page 42: Type Plate

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Note When using biodiesel observe the changed intervals for ♦ changing the fuel filter ⇒ page 16 If it is planned not to use the vehicle for approx. two weeks, it ♦...

  • Page 43: Descriptions Of Work

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Descriptions of work In this chapter you will obtain information on the following sub‐ jects: Removable towing bracket: Check and clean if necessary ⇒ page 41 Swivel joints: Visual check ⇒...
  • Page 44 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Engine and components in engine compartment (from above and below): Perform visual check for leaks and damage ⇒ page 100 Oil level: Check ⇒ page 101 Engine oil: Drain or extract; renew oil filter and replenish engine ⇒...

  • Page 45: Removable Towing Bracket: Check And Clean If Necessary

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Removable towing bracket: Check and clean if necessary This chapter describes how to check and repair a removable tow‐ ing bracket. Note Note that checking towing bracket is included in the respective service.
  • Page 46 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Check contact surfaces -arrows- of ball head mounting for corrosion. – If contact surfaces are corroded, eliminate corrosion with a tri‐ angular scraper and clean the treated areas with silicone remover.

  • Page 47: Swivel Joints: Visual Check

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Swivel joints: Visual check – Check swivel joint boots -arrow- for leaks and damage. Driving light assist and cornering light: Check function ♦ Checking driving light assist ⇒ page 43 ♦...

  • Page 48: Automatic Gearbox: Check Atf Level, 09G Gearbox

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Turn light switch -4- to position O -1- and switch off ignition. 4.3.2 Checking cornering light (static corner‐ ing light) • Vehicle stationary, steering in straight-ahead position...

  • Page 49: Battery: Check Battery Terminal Clamps For Secure Seating

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Afghanistan Turkey Israel Battery: Check battery terminal clamps for secure seating Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- Note A securely seated battery clamp ensures trouble free function ♦...
  • Page 50 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Loosen the -NEGATIVE- battery clamp and remove. – Tighten the -POSITIVE- battery clamp to 9 Nm using torque wrench -V.A.G 1331- and ratchet -V.A.G. 1331/1- . – Reconnect the -NEGATIVE- battery clamp to 9 Nm using tor‐...
  • Page 51 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Reinstall cover, if fitted. After connecting battery perform the following work steps: Procedure Vehicle electrics → Electrical system ⇒ Rep. Gr. 27 → Discon‐ necting and connecting battery → Connecting battery → Work...

  • Page 52: Battery: Check Using Battery Tester With Printer Vas 5097A Or Vas 6161

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Disconnect battery terminal clamp -2- from battery negative terminal first. – Tighten battery terminal clamp -1- on battery positive terminal to 6 Nm. – Reconnect battery clamp -2- to battery negative terminal and tighten to 6 Nm.
  • Page 53 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Checking tyre pressure using tyre inflator -VAS 5216- , correct if necessary, Golf 2004▸ ⇒ page 52 Checking tyre pressure using tyre inflator -VAS 5216- , correct if necessary, Golf Plus 2005▸...

  • Page 54: General Notes

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.8.3 Tread depth (including spare wheel): Check – Check tyre tread depth. Minimum tread depth: 1.6 mm Note This figure may vary according to legislation in individual coun‐...
  • Page 55 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Winter tyres Note Important information on recommended winter tyres can be ♦ found in Wheels and Tyres Guide - Standard → ⇒ Running gear; Rep. Gr. 44 ; Recommended winter tyres If winter tyres are fitted, a sticker, visible for the customer and ♦...
  • Page 56 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.8.6 Tyre pressures for Golf 2004▸ Check tyre pressure using tyre inflator -VAS 5216- , correct if necessary. Petrol engines ⇒ page 52 Diesel engines ⇒ page 52...

  • Page 57: Brake And Clutch System: Change Brake Fluid

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Brake and clutch system: Change brake fluid Instructions for use and safety ⇒ page 53 Brake fluid specification ⇒ page 53 Changing brake fluid ⇒ page 53 4.9.1...
  • Page 58 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Brake bleeding wrench -VAS 5519- ♦ Brake bleeding tool -VAS 6564- – Unscrew cap -1- from brake fluid reservoir. – Extract as much brake fluid as possible using suction hose from brake filling and bleeding equipment -VAS 5234- .
  • Page 59 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Screw adapter -1- onto brake fluid reservoir. Observe ⇒ operating instructions for -VAS 5234- ! – Adjust correct pressure on brake filling and bleeding equip‐ ment -VAS 5234- : Running gear, brake systems ⇒ Running gear, brake systems;...
  • Page 60 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Push collector bottle bleeder hose -1- onto rear left bleeder valve. – Open bleeder valve and let appropriate quantity of brake fluid run out (see table). Close bleeder valve. Torque: Running gear →...

  • Page 61: Brake Fluid Level: Check

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Unscrew adapter from brake fluid reservoir. – Check brake fluid level and correct if necessary. It must be between position -1- and -2-. – Screw on cap -1- of brake fluid reservoir.

  • Page 62: Brake System And Shock Absorbers: Perform Visual Check For Leaks And Damage

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.10.1 Brake fluid level (dependent upon lining/ pad wear): Check Brake fluid level at delivery inspection: – For delivery inspection, fluid must be at MAX. marking -1-. Note In order that brake fluid does not overflow the reservoir, MAX marking -1- must not be exceeded.

  • Page 63: Front And Rear Brake Pads/Linings: Check Thickness

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 WARNING Faults found must always be rectified (repair measure). 4.12 Front and rear brake pads/linings: Check thickness Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- ♦...

  • Page 64: Checking Diesel Particulate Filter

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Measure thickness of inner and outer pads. a - Pad thickness “without” backplate Wear limit: 2 mm The brake pads have reached their wear limit at a pad thickness of 2 mm (without backplate) and must be renewed (repair meas‐...

  • Page 65: 6-Speed Dual Clutch Gearbox (Dsg) 02E: Change Oil And Filter

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Switch on ignition. – Touch the field or button on the screen for “GUIDED FUNC‐ TIONS”. If the display is not as shown in the procedure: ⇒ Operating in‐...

  • Page 66: Vehicle System Test: Perform Test

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Note The following work description applies to the front left window regulator. Reactivate the other window automatic functions in the same manner by operating the respective switch in the driver door.

  • Page 67: Front Passenger Front Airbag: Check Key Switch And "On/Off Function

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Press button again to reach the test plan. > – Now finish guided fault finding using GoTo button and then End. All fault memories are read again.
  • Page 68 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Switch on ignition. Warning lamp “passenger airbag off” -arrow- must also light up after self-test (passenger airbag de‐ activated). – Switch off ignition. – Using vehicle key -arrow-, turn key switch to position “Airbag ON”.

  • Page 69: Protective Bellows: Visual Check

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Switch on ignition. – Warning lamp “Passenger airbag off” -arrow A- must also light up after self-test (passenger airbag deactivated). – Switch off ignition. – Using vehicle key, turn key switch -arrow A- to position “Airbag ON”...

  • Page 70: Haldex Coupling (Golf 4Motion): Change Oil

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.19 Haldex coupling (Golf 4motion): Change Note On vehicles with Haldex coupling the drain plugs and sealing ♦ plugs of both systems are often interchanged, due to the in‐...
  • Page 71 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Charging device for Haldex coupling 2 -VAS 6291- ♦ Vehicle diagnostic, testing and information system -VAS 5051B- ♦ Diagnostic cable -VAS 5051/6A- Procedure – Raise vehicle with lifting platform and place used oil collection and extraction unit -V.A.G 1782- below Haldex coupling.
  • Page 72 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Separate angled piece -B- from adapter -A- and screw adapter fully in oil filler hole. – Reconnect angled piece and route hose above drive shaft to prevent sagging.

  • Page 73: Poly V-Belt: Adjust Tension On Engines Without Automatic Tensioning Roller

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Check for correct filling by raising the vehicle again, and check if oil has flown out of adapter -A-. – If no oil has flown out, lower the vehicle again and continue with filling.

  • Page 74: Poly V-Belt: Check Condition

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Tensioning lever -3297- – Loosen securing bolts -1 + 2-. 3 - Tensioning arm 4 - Alternator – Fit tensioning lever, secure with pin -arrow- and swing alter‐...

  • Page 75: Calibrating Compass (For North American Region)

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Check poly V-belt/s -1- for: ♦ Substructure cracks (cracks, core ruptures, cross sectional breaks) ♦ Layer separation (top layer, cord strands) ♦ Base break-up ♦ Fraying of cord strands ♦...

  • Page 76: Cooling System: Check Frost Protection And Coolant Level

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.23 Cooling system: Check frost protection and coolant level Note From model year 2008 all engines are filled with coolant ad‐ ♦ ditive G12 Plus Plus (purple). Because of its positive charac‐...
  • Page 77 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 The scale -1- of the refractometer is calibrated for coolant addi‐ tives G12; G12 Plus, G12 Plus Plus and G11. The scale -2- is only calibrated for coolant additive G13. (originally...

  • Page 78: Fuel Filter: Renew

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Delivery inspection: Coolant level above “MIN. marking” -arrow-. ♦ Inspection service: Coolant level above “MIN. marking” -arrow-. – If coolant level is too low, replenish required amount according to mixture ratio.
  • Page 79 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Note There are two different fuel filter systems. ♦ System 1 is fitted with a water extraction plug -1-, descriptions ♦ of work ⇒ page 75 System 2 is “not” fitted with a water extraction plug, see illus‐...
  • Page 80 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Note Ensure that no diesel fuel contacts other components in the ♦ engine compartment. Clean immediately, if necessary. Observe disposal regulations! ♦ Carry out the following procedure: – Remove water extraction plug -1-.
  • Page 81 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Insert new easy change filter into fuel filter lower part. – Moisten new seal -1- lightly with diesel fuel and fit on fuel filter upper part. – Place fuel filter upper part with seal properly onto fuel filter lower part, press on firmly and evenly until the fuel filter upper part is correctly seated.
  • Page 82 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Angled screwdriver -VAS 6543- Remove engine cover ⇒ page 89 Removing: Caution ♦ Do NOT pull fuel hoses off fuel filter cover and do NOT lever at connection. Leaks could occur and the fuel filter upper part can be damaged.
  • Page 83 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Take filter -3- out of fuel filter lower part. – Remove old seal -2- from fuel filter upper part -1- by levering seal out of respective groove -arrow-.

  • Page 84: Air Filter: Clean Housing And Renew Filter Element

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Screw all bolts into fuel filter lower part and tighten hand-tight. – Then tighten bolts to 5 Nm according to sequence shown in illustration -arrows-. Caution This procedure prevents the seal from being damaged.
  • Page 85 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Remove air filter housing lower part -1- and air filter element -2-. Note Observe disposal regulations! – Clean air filter housing lower part. – Insert new filter element -1- into air filter housing lower part -2-.
  • Page 86 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.25.2 Removing and installing air filter ele‐ ment: 1.6 l engine Removing – Remove engine cover ⇒ page 89 – Remove bolts -arrows-. – Remove air filter housing lower part -1- and air filter element -2-.
  • Page 87 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Tighten bolts -arrows- to max. 3 Nm. 4.25.3 Removing and installing air filter ele‐ ment: 2.0 l FSI, 1.4 l TFSI engine and Flex Fuel engine – Remove the 4 screws -arrows- and remove cover.
  • Page 88 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Place engine cover with upper side on a soft surface to prevent damage to chrome applications. – Unscrew bolts -arrows- from engine cover lower side. – Separate air filter housing lower part -1- from air filter housing upper part -3-.
  • Page 89 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Both parts of housing must be flush -arrows-. – Tighten bolts -arrows- to max. 3 Nm. 4.25.5 Removing and installing air filter ele‐ ment: 2.5 l petrol injection engine Removing –...
  • Page 90 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Lift air filter housing lower part -1- upwards in direction of arrow and remove. – Remove air filter element -1- from air filter housing lower part -2-.
  • Page 91 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Both parts of housing must be flush -arrows-. Check if parts of housing -1- and -2- are flush (front part) – Both parts of housing must be flush -arrows-.
  • Page 92 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Take out used filter element -3-. Note Observe disposal regulations! Installing: – Clean filter housing -4- and install new filter element -3-. – Insert filter housing upper part -2- and tighten bolts -1- to 5 Nm.

  • Page 93: Engine Cover -Top-: Removing And Installing

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Remove air filter housing upper part and air filter element -1-. Note Observe disposal regulations! – Clean air filter housing lower part. – Insert new air filter element and fit air filter housing upper part.
  • Page 94 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Removing and installing engine cover: 2.0 l PD diesel engines (Golf GT) ⇒ page 99 Renewing rubber buffers for engine cover ⇒ page 95 4.26.1 Removing and installing engine cover: 1.4 l and 1.6 l FSI petrol direct injection...
  • Page 95 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Fit hose and tighten clip -A-. – Slide oil dipstick -1- into guide tube. 4.26.2 Removing and installing engine cover: 1.4 l injection engines • There are two different versions of engine covers: ♦...
  • Page 96 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.26.3 Removing and installing engine cover: 1.4 l TSI engines Engine cover version 1 Removing: – If fitted, pull hose off connection -arrow A -. – Disengage engine cover at securing points -arrows B- and raise.
  • Page 97 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.26.4 Removing and installing engine cover: 1.6 l injection engines The Flex Fuel engine has no engine cover. Removing: – Pull out dipstick -1-. – Unclip engine cover at the securing points -2- and remove up‐...
  • Page 98 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Vehicles up to model year 2005 Removing – Relieve clips on air mass meter -A- and on air intake nozzle -B- using spring-type clip pliers -VAS 6499- and push back.
  • Page 99 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – First disengage engine cover at securing points -arrows 3- and then at securing points -arrows 4- and raise. Installing Note Dot not grease or lubricate rubber buffers of engine cover panel before installation.
  • Page 100 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.26.8 Removing and installing engine cover: 2.0 l TSI engine Removing: – Unclip engine cover at securing points -arrows- and remove upwards. Installing: Install in reverse order. 4.26.9 Removing and installing engine cover: 2.5 l petrol injection engines...
  • Page 101 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Pull connector -C- off air mass meter, and place connector to side. – First disengage engine cover at securing points -arrows A- and carefully remove from fastenings.
  • Page 102 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Installing: – Fit engine cover at securing points and press on, so that the cover engages. – Slide oil dipstick -1- into guide tube. Two-piece engine cover: Removing: Note The engine cover consists of two individual parts.

  • Page 103: Removing And Installing Engine Compartment Cover -Bottom- (Noise Insulation)

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Fit engine cover onto securing points -arrows- and press on. – Then fit outer part -1- at securing points -arrows- and press on, so that cover engages.

  • Page 104: Engine And Components In Engine Compartment (From Above And Below): Perform Visual Check For Leaks And Damage

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Torque wrench -V.A.G 1783- ♦ Cordless power driver 12 V / 2.0 Ah -VAS 5826- Removing Panel bolts, Qty. 8, torque setting 2 Nm. Combi-bolts, Qty. 3, torque setting 6 Nm.

  • Page 105: Engine Oil Level: Check

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Note Arrange for defects to be rectified as repair measures. ♦ If fluid loss is greater than can be expected through normal ♦ use, determine cause and rectify (repair measure).
  • Page 106 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.30.1 Draining or extracting engine oil Caution ♦ For engines with standing oil filter the oil filter must be re‐ newed before changing the engine oil ⇒ page 109 ⇒...
  • Page 107 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.30.2 Renewing oil filter Renewing oil filter: 1.4 l TSI and 1.4 l TFSI engines ⇒ page 103 Renewing oil filter: 1.6 l injection engines and Flex Fuel engine ⇒...
  • Page 108 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Remove oil filter cover -1- with oil filter element -4- and valve -5-. Installing – Renew O-ring -2- of oil filter cover and O-ring -3- of valve.
  • Page 109 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Screw in new oil filter -arrow- by hand. – Then tighten to 20 Nm. 4.30.4 Renewing oil filter: 1.6 l injection en‐ gines and Flex Fuel engine Special tools and workshop equipment required ♦...
  • Page 110 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Torque wrench -V.A.G 1331- Note Observe disposal regulations! ♦ Oil new O-rings before installing. ♦ Prevent engine oil from dripping onto subframe. ♦ Removing Remove engine cover, see ⇒...
  • Page 111 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Installing – Insert new filter element -4- into threaded cap. – Renew sealing ring -2-. – Lightly oil seal. – Clean thread -3- and lightly moisten with oil.
  • Page 112 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Installing – Oil rubber seal lightly on new filter. – Screw in filter and tighten hand-tight. The remaining assembly steps are basically a reverse of the dis‐ mantling procedure.
  • Page 113 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Insert oil drain adapter -T40057- into oil filter housing and hold hose in oil drip tray. Note When the oil drain adapter -T40057- is screwed in, a valve is opened in oil filter housing.
  • Page 114 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Loosen cover cap -arrow-. Note Before draining or extracting release sealing cap, so that the en‐ gine oil can flow out of filter housing. – Clean sealing surfaces on threaded cap and oil filter housing.
  • Page 115 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Drain oil via plug -1-. – Loosen filter lower part -3- on hexagon -2- or on circumference -4- and remove. – Take out used filter element. – Wipe filter housing with a cloth.

  • Page 116: Performing Road Test (Driving Behaviour, Noises, Air Conditioner Etc.)

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 For dipstick as illustrated: A - Oil must not be replenished. B - Oil may be replenished. It may happen that the oil level after‐ wards is in the -A- region.
  • Page 117 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Hub cap ♦ Full wheel trim – Remove the respective wheel bolt cover, if fitted. Note The puller hook to remove the cover caps or the wheel hub trim is located in the vehicle tool kit.

  • Page 118: Reading Radio Code Using Vehicle Diagnostic Tester

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Adapter set for tamper-proof wheel bolts -T10101- – Slide adapter into anti-theft wheel bolt onto stop. – Slide the wheel bolt wrench onto adapter onto stop. – Retighten the wheel securing bolts to correct torque setting.

  • Page 119: Radio/Radio Navigation System: Enter Pin Of Anti-Theft Coding And Store Local Radio Stations To Station Buttons

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Procedure – Connect vehicle diagnostic tester ⇒ page 32 – Switch on ignition. – Touch the field or button on the screen for “GUIDED FUNC‐ TIONS”. – Confirm with button.

  • Page 120: Tyre Pressure Monitoring: Perform Basic Setting

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 For technical reasons it is possible that several cross references are not directed to the correct chapter. In this case select the pro‐ cedure manually in the information.
  • Page 121 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Press button -1- and button -2- simultaneously and for longer than 2 seconds in the centre console. If ESP is not fitted, press button. The start of basic setting will be confirmed by an acoustic signal.

  • Page 122: Tyre Repair Set: Check Bottle For Damage And If Used; Check And Enter Date Of Tyre Sealant

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.36 Tyre repair set: Check bottle for damage and if used; check and enter date of tyre sealant The tyre repair set is located in the spare wheel well -arrow- The tyre repair set consists of the compressor and a tyre filler bottle with sealant.

  • Page 123: Headlight Adjustment: Check

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.38 Headlight adjustment: Check ♦ Checking headlight adjustment ⇒ page 119 ♦ Headlights with gas discharge bulbs, perform basic setting ⇒ page 122 ♦ Adjusting headlights ⇒ page 122 ♦...
  • Page 124 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Note For certain export markets a manually regulated headlight ♦ range control is not offered, thus the -0- position is discontin‐ ued. For NAR vehicles the side adjustment of headlight is not per‐...
  • Page 125 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Checking headlight adjustment: Note With dipped beam switched on, the horizontal bright/dark ♦ boundary must not exceed the dividing line -1-. The light beam of the main beam must lie on the centre mark ♦...

  • Page 126: Adjusting Headlights

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.38.2 Headlights with gas discharge bulbs, perform basic setting – Connect vehicle diagnostic tester ⇒ page 32 – Switch on ignition. – Press “Guided fault finding”. Enter vehicle data, all control units will be read.
  • Page 127 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ “Bi-xenon” headlights “Bi-xenon” means that both the dipped beam and the main beam are generated from a “single” gas discharge lamp. Therefore on “bi-xenon” headlights the main beam is automati‐...
  • Page 128 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ First adjust the height adjustment bolt -A- for dipped beam and main beam, to bright/dark boundary of test area in display of tester. ♦ Then adjust the lateral adjustment bolt -B- for dipped beam and main beam, to bright/dark boundary of test area in display of tester.
  • Page 129 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – To adjust the headlight range turn adjustment screw -arrow-. A lateral adjustment is not possible. Fog light in bumper, right (Golf GT) Location of adjustment screw on left-hand fog light is a mirror im‐...

  • Page 130: Service Interval Display: Reset

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Remove bolt -1-. – Unclip retaining lugs -2- and pull cover off lower part of bump‐ Note In some cases the retaining lugs are very tight. Therefore, pull cover very carefully to prevent that the retaining lugs break off.

  • Page 131: Service Interval Display: Recode

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Engine code – Confirm vehicle identification. – Select one after the other: ♦ “Dash panel insert” -ARROW-. ♦ “Resetting the service interval display”. – Perform adaption according to the information of “GUIDED FUNCTIONS”.
  • Page 132 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Type ♦ Model year ♦ Engine code – Confirm vehicle identification. If the vehicle identification has been performed correctly, confirm with button. > – Select one after the other: ♦...

  • Page 133: Sunroof: Check Function, Clean And Grease Guide Rails

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.41 Sunroof: Check function, clean and grease guide rails Carry out the following procedure: – Check function of sunroof. – Clean guide rails -arrows- and lubricate with Lithium grease - G 052 147 A2- .
  • Page 134 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – To press out dirt, guide cleaning and fitting tool -VAS 6620- onto drain valves by pushing and pulling it slowly. – Drains -arrows- are located on the left and right side, inside the plenum chamber.

  • Page 135: Window Wash/Wipe System And Headlight Washer System: Check Function

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.43 Window wash/wipe system and head‐ light washer system: Check function Check anti-freeze concentration of Windscreen Clear -G 052 164- , replenish with fluid ⇒ page 131 Window wash/wipe system: Check spray jet settings and adjust if necessary ⇒...
  • Page 136 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Starting immediately, use only Windscreen Clear -G 052 164- all- year-round when replenishing the window wash/wipe system. Note Windscreen Clear -G 052 164- protects the spray jets, fluid ♦...
  • Page 137 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Setting tool -T10127- equipped with needle 3125/5 A Spray jets for windscreen washer system: The washer jets are preset. However, small height differences can be compensated for.
  • Page 138 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.43.3 Headlight washer system: Check spray jet settings, adjust if necessary, Golf 2004▸ Headlight washer system: Check spray jet settings, adjust if nec‐ essary, Golf Plus 2005▸ ⇒ page 135 Note If the spray field is uneven due to soiling in the spray jet, re‐...
  • Page 139 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 The spray jets -arrows- are extended. – Carry out the following procedure: – Align spray direction of respective jet to upper edge of head‐ light -item B- and -item C- using adjusting tool -T10167- .
  • Page 140 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Adjusting tool -T10167- The jet adjustment dimensions are for the left-hand headlight (right-hand headlight mirror image) Checking jet setting – Switch on dipped headlight. – Operate windscreen washer system.

  • Page 141: Wiper Blade Protection: Remove

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.44 Wiper blade protection: Remove Currently there are three versions to separate the wiper blade protection from the wiper blade or to exchange a transport wiper arm. Version 1 On this wiper arm the blade protector is secured on the blade with two securing clips -arrows-.
  • Page 142 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 This transport wiper arm is fitted without wind deflector. Perform the following procedure: – Set wipers in service position. This can be done by switching the ignition on and off once with bonnet closed. Then operate wiper lever and the wipers will stop in service position.

  • Page 143: Wiper Blades: Check Park Position

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Set wipers in service position. This can be done by switching the ignition on and off once with bonnet closed. Then operate wiper lever and the wipers will stop in service position.

  • Page 144: Track Rod Ends: Check Play, Security And Boots

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.45.3 Rear window wiper blades: Check park position – Switch rear window wiper on and off and let it move into park position. – Check that the distance of wiper blade ends to the lower edge of window is as follows.

  • Page 145: Door Arrester: Grease

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Setting weekday using buttons on windscreen wiper lever – Setting in the menu is performed respectively with buttons on the steering wheel. 4.48 Door arrester: Grease Carry out the following procedure: –...
  • Page 146 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Indicated on display: – Press the button on display for “Collection services”. Indicated on display: – Press the button on display for “Switch off transportation mode”. Ending output Indicated on display: –...

  • Page 147: Transportation Devices: Remove Blocking Pieces From Front Axle Springs

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.50 Transportation devices: Remove block‐ ing pieces from front axle springs Blocking pieces are fitted to front axle springs of vehicles with sports running gear. These vehicles are identified by a warning tag on the mirror -arrow-.

  • Page 148: Clock And Date: Set To Correct Time

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.52 Clock and date: Set to correct time Set clock with buttons below rev. counter The setting buttons are located on the left below the rev. counter. – Press the left button -1- to set the hours. Press the button only briefly to advance the time one hour.

  • Page 149: Toothed Belt And Toothed Belt Tensioning Roller: Renew (Tdi Unit Injector)

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.53 Toothed belt and toothed belt tensioning roller: Renew (TDI unit injector) Note Generally it is not necessary to renew the toothed belt before the actual change interval is reached. Especially cracks on the belt side are not relevant for service life and cannot be covered by goodwill or warranty processing.

  • Page 150: Spark Plugs: Renew

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.56 Spark plugs: Renew Renewing spark plugs: 1.4 l injection engine ⇒ page 149 Renewing spark plugs: 1.4 l TSI engines ⇒ page 156 Renewing spark plugs: 1.6 l injection engine and Flex Fuel engine ⇒...
  • Page 151 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Puller -T10094 A- ♦ Puller -T10095- ♦ Assembly tool -T10029- ♦ Puller -T10112- 4. Descriptions of work...
  • Page 152 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Assembly tool -T10118- 4.56.1 Renewing spark plugs: 3.2 l injection en‐ gine Removing – Pull off ignition coil connector with final output stages -arrows-. – Position assembly tool -T10118- at connector locking device -arrow- and carefully pull off connector.
  • Page 153 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Before removing ignition coils with output stage observe fitting position to the connectors -arrows-. The flat side of the connector must align with the flat side of igni‐...
  • Page 154 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 The spark plugs are located under ignition coils with output stages -arrow-. Note Note installation position of ignition coils with output stages. – Pull ignition coils with output stages off spark plugs using the puller -T10094 A- .
  • Page 155 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.56.3 Renewing spark plugs: 2.0 l FSI, TFSI and TSI Removing: Carry out the following procedure: – Remove engine covers ⇒ page 89 Note To pull off spark plugs, fit puller -T40039- on top, thick rib ♦...
  • Page 156 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Unscrew spark plugs using spark plug socket and extension -3122 B- . Note Spark plug designation and specified torque: “Power unit” ⇒ ♦ Power unit; Rep. Gr. 28 ; Test data, spark plugs “Test data, spark plugs”.
  • Page 157 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.56.4 Renewing spark plugs, 2.5 l petrol injec‐ tion engines Removing: Note To pull off spark plugs, fit puller -T40039- on top, thick rib ♦ -arrow- of ignition coils with output stages.
  • Page 158 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Unscrew spark plugs using spark plug socket and extension -3122 B- . Installing – Screw in new spark plugs using spark plug wrench -3122 B- and tighten to 20 Nm.
  • Page 159 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Screw in new spark plugs using spark plug socket and exten‐ sion -3122 B- . – Fit spark plug connectors using puller -T10112- . – Fit connectors of injectors.
  • Page 160 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Place puller -T10094 A- on ignition coil with output stage. – Slide connector on ignition coil with output stage until it audibly engages. – Push ignition coil with output stage -arrow- into cylinder head.
  • Page 161 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Seat puller -T10094 A- on ignition coil with output stage. – Pull out ignition coil with output stage and connected wires and carefully place to side. – Unscrew spark plugs using spark plug socket and extension - VAS 3122B- .
  • Page 162 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 4.56.8 Renewing spark plugs: 1.4 l TFSI en‐ gines Removing: – Remove engine cover ⇒ page 89 – Disengage clamps of cable guide -arrows-. – Remove hoses -1- and -2-.

  • Page 163: Front And Rear Final Drive: Check Oil Level

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Push ignition coil with output stage in direction of -arrow- into cylinder head. – Route cables properly in cable guide. – Secure cable guide clips -arrows-. – Connect hoses -1- and -2-.

  • Page 164: Exhaust Emissions Test

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Exhaust emissions test In this chapter you will obtain information on the following sub‐ jects: Exhaust emissions test for petrol engines ⇒ page 160 Exhaust emissions test for diesel engines without OBD ⇒...
  • Page 165 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Note It is only possible to carry out an exhaust emissions test when ♦ all units of the emissions testing station -VAS 6300- are con‐ nected properly and combined with each other according to operating instructions.
  • Page 166 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Continue exhaust emissions test according to instructions on display. – If the EET specification selection is displayed, select respec‐ tive “EET specification selection” -arrow-. ♦ If exhaust emissions test is performed initially, either select “Standard values”,...
  • Page 167 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Select “with OBD”, -arrow-. Specified data input for EET: Note If specifications are not available as bar code, they are to be ♦ entered manually. All test conditions and data required for exhaust emissions ♦...
  • Page 168 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Visual check: – Follow instructions on display. – Perform visual check. – If visual check is OK press “OK” button. -arrow-. Note When "not OK" button is pressed a check will be carried out The visual check is displayed with the request to connect the di‐...
  • Page 169 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Follow instructions on display, see -arrow C- and -arrow A-. ♦ Start engine. ♦ Perform visual check of MI lamp. – Insert emission probe in exhaust tail pipe.
  • Page 170 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Measurement at increased idling speed: It is automatically switched to display for measuring increased idling speed. – Follow instructions on display. Measurement starts when the engine speed has reached the re‐...

  • Page 171: Exhaust Emissions Test For Diesel Engines Without Obd

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Evaluation: When the exhaust emissions test has been performed, the log is shown on display. The test result is displayed. Now remarks concerning the exhaust emissions test can be en‐...
  • Page 172 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 ♦ Adapter cable -VAS 5087/3- Note All test conditions and data required for exhaust emissions ♦ test: ⇒ Data sheets for exhaust emission test If possible, the test should be completed outdoors following a ♦...
  • Page 173 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Using adapter cable -VAS 5087/3- , connect “Output” of en‐ gine speed adapter -VAS 5087- to pick-up clamp input of diesel tester -V.A.G 1743- . – Turn switch for number of cylinders to respective number of cylinders.
  • Page 174 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 WARNING If the governed speed (maximum speed) is exceeded, lift off accelerator pedal immediately and perform repair measures. – If the values are not within specified range, a repair measure must be made.

  • Page 175: Exhaust Emissions Test For Diesel Engines With Obd

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Exhaust emissions test for diesel en‐ gines with OBD Caution • Observe “SAFETY AND DAMAGE AVOIDANCE PRE‐ CAUTIONS” in the operating instructions for VAS 6300. Note The following description refers to vehicles fitted with “On‐...
  • Page 176 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Initial screen: – Select button “Exhaust emissions test”, -arrow-. An overview is displayed to select the respective EET type. – Select “EET diesel” -arrow-. The display for warm-up phase appears.
  • Page 177 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Continue exhaust emissions test according to instructions on display. – If the EET specification selection is displayed, select respec‐ tive “EET specification selection” -arrow-. ♦ If exhaust emissions test is performed initially, select “Stand‐...
  • Page 178 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Select “Diesel OBD” -arrow-. Specified data input for EET: There are different ways to enter the specified data: ♦ 1. Manual input ♦ 2. Bar code input of EET data sheet ♦...
  • Page 179 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 All data required are shown on display -1-. – Press button -arrow- to continue procedure. → Visual check: – Follow instructions on display. – Perform visual check. – If visual check is OK press “OK” button. -arrow-.
  • Page 180 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – If lamp lights up, press button “Lamp On” -arrow C-. Note If the MI lamp does not light up during visual check, the result of the exhaust emissions test is “Failed”.
  • Page 181 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 It is automatically switched to display for measuring rev limit. Measurement starts when the engine speed has reached the re‐ quired level. – Operate throttle until the measurement is carried out. To do this, immediately depress accelerator pedal.
  • Page 182 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Follow instructions on display -arrow B-. – Depress accelerator pedal fully when prompted and hold until the prompt for idling is shown on display. Free acceleration - phase 3: –...
  • Page 183 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 – Press button “Close” -arrow B- to close the menu “Print pre‐ view ”. – Follow instructions on display. – Take emission probe out of exhaust tail pipe.

  • Page 184: Glossary

    Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Glossary These explanations only apply to “Maintenance Manual”. They are not necessarily generally valid! Term Explanation Anti-lock brake system: the ABS is a regulating system in the brake system, that pre‐...
  • Page 185 Golf 2004 ➤ , Golf Plus 2005 ➤ Maintenance - Edition 11.2009 Term Explanation Society of automotive engineers: association which creates proposals and guidelines for implementing legal requirements (e.g. standards) Naturally aspirated diesel engine Naturally aspirated diesel engine - direct injection...

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