Volkswagen Golf 4
WORKSHOP, SERVICE, REPAIR MANUAL
VOLKSWAGEN GOLF 4 - WORKSHOP, SERVICE, REPAIR MANUAL - English Workshop 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)
Volkswagen Golf 4 Workshop Manual
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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