Volkswagen Golf 4 - Repair, Service and Maintenance Manual

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VOLKSWAGEN GOLF 4 - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual to vehicles Volkswagen Golf 4.

 
CONTENTS:

2.8 LITER VR6 4V ENGINE MECHANICAL, ENGINE CODE(S): BDF
- Technical data
- Engine, removing and installing
- Engine, disassembling and assembling
- Sealing flanges and dualmass flywheel, removing and installing
- Crankshaft, removing and installing
- Piston and connecting rod, disassembling and assembling
- Cylinder head, servicing
- Valve gear, servicing
- Lubrication system components, servicing
- Cooling system components, servicing
- Components of fuel supply system, servicing
- Evaporative Emissions
- Electronic Power Control (EPC)
- Exhaust system components, servicing
- Secondary air system

2.8 LITER VR6 4V FUEL INJECTION & IGNITION, ENGINE CODE(S): BDF
- On Board Diagnostic (OBD)
- DTC memory
- DTC table: SAE P0 codes
- DTC table: SAE P1 codes
- DTC table: SAE P2 codes
- DTC table: SAE P3 codes
- Output Diagnosis Test Mode (DTM)
- Readiness code
- Readiness code
- Measured value (data) blocks
- Fuel injection system, servicing
- Components, checking
- Functions, checking
- Motronic Engine Control Module (ECM) -J220-
- Additional signals, checking
- Ignition system, servicing

5 & 6 SPD. MANUAL TRANSMISSION 02M
- Transmission identification
- Transmission layout
- Calculating overall ratio "i"
- General repair instructions
- Clutch mechanism, repairing
- Clutch release mechanism, servicing
- Clutch, servicing
- Clutch, servicing
- Gear selector mechanism, servicing
- Transmission, removing and installing
- Transmission gear oil, checking
- Transmission, disassembling and assembling
- Transmission housing, servicing
- Clutch housing, servicing
- Transmission selector mechanism, disassembling and assembling
- Selector forks, disassembling and assembling
- Input shaft, disassembling and assembling
- Input shaft, adjusting
- Output shaft, 1st-4th gear, disassembling and assembling
- Output shaft for 1st-4th gears, adjusting
- Output shaft for 5th, 6th and reverse gear, disassembling and assembling
- Output shaft for 5th, 6th and reverse gear, adjusting
- Oil seals for flanged shafts, replacing
- Differential, disassembling and assembling
- Adjustment overview
- Differential, adjusting

BRAKE SYSTEM ON BOARD DIAGNOSTIC (OBD)
- ABS ITT Mark 20 IE On Board Diagnostic (OBD)
- Electrical/electronic components and locations
- ABS ITT Mk 20 IE On Board Diagnostic (OBD) program
- ABS, ABS/EDL and ABS/EDL/ASR ITT Mark 20 IE, electrical check
- ABS Mark 60 On Board Diagnostic (OBD), vehicles from my 10.00
- Electrical/electronic components and installing locations
- Diagnostic Trouble Codes (DTCs) displayed by warning lights -K47-, -K118- and -K155-
- On Board Diagnostic (OBD), performing
- Electrical check of Mark 60
- Definitions

BRAKE SYSTEM
- Technical data
- Technical data, brakes
- Anti-lock brake system (ABS) and antilock brake system with electronic differential lock (ABS/EDL) ITT Mark 20 IE
- Hydraulic unit, brake booster/master cylinder, overview
- ABS system components for front axle, removing and installing
- Anti-lock brake system (ABS) Mark 60

- VAS 5051 Vehicle Diagnostic, Testing and Information System, connecting and electing functions
- Electrical/electronic components and installing locations (ABS) Mark 6
- Hydraulic unit, brake booster/brake master cylinder Mark 60, assembly overview
- DTCs displayed by (ABS) Mark 60 warning lights -K32-, -K47-, -K118-, and -K155-
- ABS system components for front and rear axles, removing and installing
- ESP system components, removing and installing
- Front brakes
- Rear wheel brakes (disc brakes - front wheel drive), assembly overview
- Rear wheel brakes/disc brakes (allwheel drive), servicing
- Parking brake cables for disc brakes - front wheel drive, removing and installing
- Parking brake cables for disc brakes - all wheel drive, removing and installing
- Parking brake lever, assembly overview
- Brake pedal assembly overview
- Front brake calipers, servicing
- FN 3 front brake calipers, servicing
- Rear brake caliper, servicing
- Brake pressure regulator, assembly overview
- Brake system, bleeding
- Brake booster/brake master cylinder for vehicles with ABS/EDL/ASR/ESP, servicing for vehicles up to my 10.00
- Brake booster/brake master cylinder for vehicles with ABS/EDL/ASR/ESP Mark 60 from m.y. 10.00, assembly overview
- Brake master cylinder, removing and installing
- Brake booster, removing and installing
- Definitions

SUSPENSION, WHEELS, STEERING
- Technical data
- Check list for evaluating the suspension of accident vehicles
- Evaluation of accident vehicles
- Electrical/electronic components and installation locations
- Front suspension, servicing
- Front suspension R32, servicing
- Front drive axle, servicing
- Evaluation of accident vehicles
- Rear axle, servicing
- Wheel bearing, servicing
- Rear axle, servicing (all wheel drive vehicles)
- Trailing arm and transverse links (allwheel drive vehicles), assembly overview
- Subframe with final drive, assembly overview
- Rear drive axle, servicing
- Evaluation of accident vehicles
- Tightening torques for wheel bolts
- Protecting wheel centering seat against corrosion
- Wheels, tires
- Wheel alignment
- Wheels, tires
- Evaluation of accident vehicles
- Connecting VAS 5051 and selecting functions
- Airbag
- Steering column
- Power steering, servicing
- Power steering pump, reservoir and hydraulic lines
- Definitions

BODY COLLISION REPAIR
- Technical data
- Body foam insulation
- Reinforced body sheet metal
- Laser welding

- Galvanized body panels
- Body panel gaps/mating lines
- Body dimensions
- Straightening fixture
- 50 40 55 50 Engine mount bracket, replacing
- 50 52 55 50 Intermediate piece, replacing
- 50 53 55 50 fender connecting plate, replacing
- 50 72 55 50 long member for upper wheel house, replacing
- 50 74 55 00 Front wheel house, partial replacing
- 50 75 55 50 Front inner fender, replacing
- 50 79 55 00 Front long member, replacing
- 50 79 55 02 Front long member, partial replacing
- 50 80 55 00 Long member front section, replacing
- 51 03 55 00 Roof, replacing (Golf)
- 51 03 55 00 Roof, replacing (Jetta)
- 51 03 55 20 Roof, replacing (Jetta wagon)
- 51 07 55 50 Front roof cross member, replacing
- 51 08 55 50 Roof reinforcement, replacing
- 51 09 55 50 Rear roof cross member, replacing (Golf)
- 51 09 55 50 Rear cross member, replacing (Jetta)
- 51 09 55 70 Rear roof crossmember, replacing (Jetta wagon)
- 51 09 55 70 Rear roof crossmember, replacing (Jetta wagon)
- 51 37 55 00 Apillar, inner, replacing
- 51 38 55 50 Apillar, inner, replacing
- 51 41 55 62 B-pillar, replacing (4 door), 51 41 55 52 B-pillar, replacing (Jetta)
- 51 42 55 50 Inner B-pillar, replacing (2-door)
- 51 42 55 60 Inner B-pillar, replacing (4-door), 51 42 55 50 inner B-pillar, replacing (Jetta)
- 51 45 55 00 Outer side member, replacing (2-door)
- 51 45 55 10 Outer side member, replacing (4-door), 51 45 55 00 outer side member, replacing (Jetta)
- 51 49 55 50 Side member reinforcement, replacing
- 51 73 55 50 Floor plate, partial replacement
- 53 05 55 50 Rear cross panel, replacing
- 53 05 55 20 Rear cross panel, exterior, replacing (Jetta wagon)
- 53 05 55 23 Rear cross panel, complete, replacing (Jetta wagon)
- 53 10 55 50 Tail light mount, replacing (Golf)
- 53 05 55 50 Rear center cross panel carrier, replacing (Jetta)
- 53 05 55 50 Rear cross panel, replacing (Jetta)
- 53 16 55 00 End cross panel, replacing (Golf)
- 53 16 55 00 Outer wheel house, replacing (Jetta)
- 53 29 55 70 Reinforcement for C-pillar, replacing (Jetta wagon)
- 53 48 55 50 Rear long member, replacing (Jetta)
- 53 47 55 52 Long member, partial replacement (Jetta)
- 53 55 55 10 Quarter panel, partial replacement (Golf 4-door)
- 53 55 55 00 Quarter panel, partial replacement (Jetta)
- 53 55 55 20 Side panel, partial replacement (Jetta wagon)
- 53 69 55 50 Quarter panel, partial replacement (Golf)
- 53 69 55 50 Wheel house connecting panel, partial replacement (Jetta)
- 53 36 55 50 Connecting panel, replacing (Jetta)
- 53 69 55 70 Rear wheelhousing, outer, replacing - partial section- (Jetta wagon)
- 53 80 55 50 Spare wheel well, replacing (Golf)
- 53 80 55 52 Spare wheel well, partial replacement (Golf)
- 53 80 55 50 Spare wheel well, replacing (Jetta)

BODY EXTERIOR
- Body, front
- Hood
- Rear lid (Golf)
- Rear lid (Jetta)
- Rear lid, (Jetta Wagon)
- Tank flap unit
- Front door
- Central locking system
- Rear doors
- Sunroof
- Sunroof with glass panel (Webasto)
- Sunroof with glass panel (Meritor)
- Front bumper
- Rear bumper
- Flush-bonded windows
- Door windows
- Wheelhousing liner, removing and installing
- Outside rear view mirror
- Roof moldings
- Roof rail
- Trim
- Protective side moldings
- Rear spoiler with integrated stoplight
- Special components of Golf "GTI 337 Edition"/Jetta GLI Sport and Golf R32

BODY INTERIOR
- Seatbelts
- Seatbelts, inspecting
- Inspecting child seat anchors after accident (ISOFIX)
- Airbag
- Crash sensors
- Instrument panel
- Door trim
- Pillar and side trim
- Luggage compartment trim
- Rear lid trim
- Headliner
- Front seats
- Rear seats
- Front seat cushion and cover
- Seat heating elements
- Rear seat upholstery and cover

BODY ON BOARD DIAGNOSTIC (OBD)
- On Board Diagnostic (OBD)
- Airbag system, On Board Diagnostic (OBD)
- Convenience system (vehicles with power windows), On Board Diagnostic (OBD)
- Central locking system (vehicles without power windows), On Board Diagnostic (OBD)
- Driver's side seat adjustment, On Board Diagnostic (OBD)

HEATING AND AIR CONDITIONING
- On Board Diagnostic (OBD) through m.y. 2001
- On Board Diagnostic (OBD) from m.y. 2002
- Climatronic On Board Diagnostic (OBD) through m.y. 2001
- Heating and ventilation system, servicing
- Manual A/C
- Climatronic
- A/C refrigerant system
- A/C refrigerant system, servicing
- A/C refrigerant system, troubleshooting
- A/C refrigerant system, capacities
- Compressor bracket, removing and installing

REFRIGERANT R134A - SERVICING
- General information for A/C system
- General information on refrigerant circuit
- Laws and regulations
- Refrigerant circuit
- Complaints
- Service station, connecting
- Pressures, checking on vehicles
- Components, replacing
- Testing equipment and tools

ELECTRICAL EQUIPMENT ON BOARD DIAGNOSTIC (OBD)
- On Board Diagnostic (OBD) through m.y. 2001
- On Board Diagnostic (OBD) from m.y. 2002
- Instrument cluster through m.y. 1999, On Board Diagnostic (OBD)
- Instrument cluster m.y. 2000 through m.y. 2001, On Board Diagnostic (OBD)
- Data Bus On Board Diagnostic Interface -J533- ("Gateway") m.y. 2000 through m.y. 2001, On Board Diagnostic (OBD)
- Anti-theft immobilizer, On Board Diagnostic (OBD)

ELECTRICAL EQUIPMENT
- Battery
- Battery, checking
- Battery, charging
- Battery, disconnecting and reconnecting
- Battery, removing and installing
- Battery, tightening torques
- Starter
- Starter, tightening torques
- Generator (GEN)
- Generator (GEN) through 04.99
- Generator (GEN) from 05.99
- Generator (GEN) -4- cylinder gasoline engines
- Generator (GEN) -6- cylinder gasoline engines
- Generator (GEN) -4- cylinder TDI engines
- Generator (GEN) -4- cylinder TDI - PD engines
- Generator (GEN), tightening torques
- Cruise Control System (CCS) through m.y. 2001
- Cruise Control System (CCS) from m.y. 2002
- Instrument cluster
- Windshield wiper system
- Windshield wiper system, tightening torques
- Washer system
- Rear window wiper & washer system
- Rear window wiper system, tightening torques
- Washer hoses, repairing
- Headlights - Golf
- Headlights - Jetta
- Side mounted turn signals
- Rear lights
- Rear lights, tightening torques
- License plate lights
- High-mount brake light
- Steering column switches
- Ignition/starter switch and lock cylinder
- Interior lights and switches
- Anti-theft Immobilizer
- Fuse holder and relay carriers
- Fuse holder and relay carriers, tightening torques
- Wiring harnesses and connectors, repairing
- Antenna cables, replacing

COMMUNICATION
- Radio system - "Premium IV" and "Premium V" (including "Monsoon") through 11.01, On Board Diagnostic (OBD)
- Radio system - "Premium VI" (including "Monsoon) from 12.01, On Board Diagnostic (OBD)
- Multi-function steering wheel through 11.01, On Board Diagnostic (OBD)
- Multi-function steering wheel from 12.01, On Board Diagnostic (OBD)
- Communication
- Radio systems
- Radio, "Premium IV"
- Radio, "Premium V" & "Premium V - Monsoon"
- Radio, "Premium VI" & "Premium VI - Monsoon"
- Amplifier system - "Monsoon"
- Speaker system
- Antenna systems
- CD Changer / CD Player
- Multi-function steering wheel
- Telematics
- Mobile telephone and two-way radio operation, notes

MAINTENANCE
- Engine overview
- Service work
- Oil change service
- Delivery inspection
- Maintenance service
- General
- Description of work (part 1 of 2)
- Description of work (part 2 of 2)