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Construction and operation
Self-Study Programme No. 200
1 Dieses Dokument wurde erstellt mit FrameMaker 4.0.2.
The Self-Study Programme series has been keeping you informed about the construction and operation of Volkswagen and Audi technology for the past 24 years .
• The contents are based on the workshop manuals. • The chapter entitled “Servicing” informs you about changes in our servicing procedures. We hope that the Self-Study Programme will provide you with useful information and assistance in your daily work.
In conjunction with the launch of the new Golf, we have taken the opportunity to revise slightly the layout of our Self-Study Programme.
• In keeping with the times, the style of our Self-Study Programmes is now friendlier and more easily distinguishable. With kind regards of your Self-Study Programme Team K-VK-12
ONE for ALL?
ALL for ONE!
You can find your new Golf in the middle of the Self-Study Programme.
This Self-Study Programme is Please refer to the relevant Service literature for all inspection, not a Workshop Manual. adjustment and repair instructions.
............................................................ 49 Vehicle electrical system Convenience system Headlights Rain sensor Heating........... 18 Fully galvanised body High-strength panels Bumpers Engines .............................................................................................. 4 News Vehicle dimensions Environmental protection...................................................................... recycling Occupant protection..................................................... 57 Heating Manual air-conditioning system Climatronic Service ... 23 Engine-gearbox combination Engine Cruise control Power transmission ..................... anti-theft measures Body ................................. 40 Steering Front axle/rear axle Braking system Wheels/tyres Electrical system ...................................... 38 Manual gearbox Automatic gearbox Running gear ................. air-conditioning system ...................................At a glance An all-new Golf....... 60 Body New special tools 3 ......................................................
.has a Red- prots are cupan dern sysc The o y a mo ted b ing belt tec e lt forc eatur tem f ers and be n tensio . ince 1 F . . firs ction produ the d The egen ond l sec agen olksw of V lue nd-b instr ts umen .An all-new Golf S NEW • EWS N WS • S •NE . fety Sa hting ent lig strum sions e In d-blu e ver y red-an ble in thre c capabilit vaila diagnosti -a self. . im lev igh tr ry-level ve H ent in the de and si rbags t seat ize ai full-s in the fron s airbag ts. 1974 arch 2 NEW nM • NEW S NEW • EWS N d WS • Golfe • NE 974. . .. es backr Body heir how t and s worke inctiv x inner mple co ings. . two rs limite New hts lig head el rsion. S OL the G etive d istinc a repd ith its ed . utatio atic vehic m charis ourth The f tion ra gene GOL F O or ccess the su eetle B to the led off t rol line. with Seat y or mem ar 12-ye ty n warra d derive lights nd ad val he rou The o e original ly distth gh from hts are hi ig headl 4 4 ... w s establish ha hly sign hig n as a le.
. • EWS N WS • S •NE • NEW ent elopm ry dev n. thu resources f lif erable valua efit of gen n the be come. d tralise WOB . im afety The s ecially opt r footwell e p v s been d in the dri act an p e of e sak ent: For th ironm nv the e enConv ysnce s ie tem Safe ence nveni he co as a decen T mh syste layout. HELP GNO NDIA .G relek 01 .S s olf ha ew G f the n nst side im eo ructur ised agai st area.VK 12 olf the G dy of seal and ed bo under by lvanis lly ga kg of PVC he vehicle u The f bout 4 of t a l life saves the usefu ds exten 30%.. tiona desig evolu rd f is the ssless Gol ical standa It cla chn e of the ts a high te erior to th reflec refore sup It the and is ition.Moto SE 3 1 2 6 4 5 9 7 8 Q C 0 HELP PRINT 5 . et comp ew f the n 0% o ble at the 9 Over recycla ful lf is g use Go its lon erving f end o s cons or e.S NEW WS • The n ew m odel like a looks d again an Golf tandnew s sets ards.EIGE tronik V. to tions afety .A.
ns an ng comfor sio ivi r el of d S NEW A eerin g e nti-th asu ft me res res measu ber of en to proA num en tak eft be ive th have effect ore vide m ion. r comfo ear A unni The r ng g nthe ru ion of nts t e nterac The i ar compon f drivg ge od level o nin a go gives fort. ct prote t The s g as teerin wer s ustment of o The p the adj ering ell as nd-aft ste d w re-a dde the fo provide a n colum t. m ing co r. owerf and p onised rn mode n a harm pt. A al manu and CLIM system ditio ir con ning The G olf is gen lkswa Vo ront The f axle ear The r axle 6 6 . heate tween ioning se be Choo air-condit tronic.An all-new Golf • EWS N WS • E oven the pr S•N lf are anual Go in the tic and m • NEW ma S es autorboxes. ed o once Bas ient c l-effic fue i ow em ieve l high levch they a d offer a t. NEW arbox gea e The g WS • E S•N • NEW are sngin The e es ul.
projected surface area + 35 mm cd 0.65 m2 = 0. front 1735 mm 1439 mm + 40 mm Aerodynamic drag = Drag coefficient x Frontal area.Vehicle dimensions the “+ dimensions“ in the drawing are comparative values with the predecessor model Width Height Track width.1 m2 Length Wheelbase 4149 mm 2511 mm + 39 mm + 131 mm Rear track width Through-loading width 1494 mm 1005 mm 1005 mm Tank capacity 55 litres + 34 mm SSP 200/066 + 16 mm 1513 mm 7 .31 x x A m2 2.
8 . plastics. Recycling at a high level In stripping centres the parts removed from scrap cars are sorted into clean material streams according to type and then recycled.1% 16. It employs these technologies throughout the life cycle of its products and beyond.6% 5. In many cases.0% 0.3% 1. progressive technologies available world-wide.2% 64.0% 2 kg 696 kg 1088 kg On the following pages we will explain to you our eco-friendly policy on raw materials using insulating materials as an example.5% 1.1% 4.0% 1. metals and insulating materials can even be made into the original product again.9% 2. The overview below shows what materials are used in the Golf: 34 kg 44 kg 12 kg 174 kg 10 kg 27 kg 14 kg 17 kg 58 kg SSP 200/008 Glass Rubber Insulating materials Plastics Paint Light alloys Electrics/cable Non-ferrous metals Petroleum/oil/grease Miscellaneous Steel/iron Total weight 3.An all-new Golf Environmental protection The Volkswagen Group is making eco-efficient.3% 0.
The raw materials which are made into components are processed and recycled. Wood fibre moulding material meets the requirements of the automobile industry. low emissions.Recycling Principle: • Avoidance comes before reduction • Reduction comes before recovery • Recovery comes before disposal Renewable raw materials are used every vehicle.1 kg flax fibre moulding material used for the wheelhouse trim F l a x f i b r e m o u l d i n g m a t e r i a l is contained in trim panels and covers. However.5 kg flax fibre moulding material used for the tailgate trim 0. high strength and non-splintering properties. The straw left over from the linseed harvest was burnt for many years. The basis of wood fibre moulding materials are the pine woodchips left over from the production of wooden beams and boards in sawmills. Trims and covers made from renewable materials 0. 9 9 . but it does satisfy the high quality standards for trim panels. Recycled insulating materials Cotton fibre fleece in insulating mats and luggage compartment floor coverings For example. 1. approximately 25% of fibre component can be used as a basic material for fibre mouldings. Their recyclability is a major factor. the c o t t o n f i b r e f l e e c e used in insulating mats is a recyclate of garment cuttings.8 kg flax fibre moulding material for seat backrest cover 2. Waste fibre recovery is industry’s contribution to reducing the burden on waste disposal sites. The quality of the fibres need not meet the high standards of the textile industry. Flax fibres are highly workable and have excellent material properties.5 kg wood fibre moulding material in the doors and side panels SSP 200/009 W o o d f i b r e m o u l d i n g m a t e r i a l is used for trim panels. These include: low weight.
An all-new Golf Occupant protection There is more to occupant protection than the airbag. 12 litres SSP 200/12 10 SSP 200/014 . belt tensioner and stable side protection. The front seat belts have two pyrotechnical belt tensioners which operate according to the same principle as the rotary-piston engine. SSP 200/011 A 3-point seat belt and a 3rd head restraint The side airbags for the driver and front passenger. are available for the rear middle seat. The rear seat belts do not have belt tensioners. Achieving such a high standard of safety means paying special attention to detail. 192. The full-size airbags for the driver and front passenger sides are almost twice the size they were before. 64 litres 120 litres SSP 200/013 You can read about the design and function of this seat belt tensioner in Self-Study Programme No. Most of the impact energy is absorbed by the car body.
Lashing eyes The four lashing eyes in the luggage compartment enable luggage to be secured safely. They protect the pelvis and rib areas of occupants during a side impact. SSP 200/016 The child safety seat fastening system SSP 200/015 Welded on the vehicle body are retaining eyelets to which child safety seats equipped with the ISOFIX fastening system can be easily secured. SSP 200/018 SSP 200/017 11 . The paddings are integrated in the door and side trims. The fuel tank is now located in front of the rear axle for added safety in a rear collision.
Encapsulated internal door lock with central locking and SAFE feature SSP 200/076 Immobiliser The door lock is encapsulated and there is a metal reinforcement around the door lock.Lock cylinder freewheel for steering wheel lock .An all-new Golf Anti-theft measures A number of measures have been taken to provide more effective theft protection.Inner-profile key .Lock cylinder freewheel in outer door handle .Slip clutch on steering column Anti-theft alarm Bonnet lock cover . SSP 200/077 SSP 200/078 12 . The bonnet lock cover makes breaking open the bonnet more difficult. Lock cylinder freewheel in tailgate lock . These measures prevent would-be thieves piercing a hole through the bodyshell in this area and levering open the door handle.
The steering column and the bush joined by an interference fit via the corrugated tube. Steering column Bush A corrugated tube is located on the steering column.Anti-theft measures The steering system The striker pin of the ignition lock can no longer be sheared off. Striker pin SSP 200/074 13 . the corrugated tube will be friction-locked between the steering column and bush. A bush with oblong holes is press-fitted on it. This makes it impossible to steer the vehicle. If an attempt is made to turn the steering wheel by applying a force of approx. Corrugated tube Striker pin This is how it works: The striker pin of the ignition lock engages in the oblong holes of the bush when the ignition key is removed from the ignition. SSP 200/073 Bush Steering column Corrugated tube Striker pin Inserting the ignition key in the ignition withdraws the striker pin from the oblong holes of the bush. 150 Nm. It is not possible to steer the vehicle or shear off the locking pin. The vehicle can again be steered since the corrugated tube and the bush now rotate with the steering column.
Lock cylinder Locking plate Freewheel sleeve SSP 200/131 14 . tailgate and ignition lock. It prevents these locks being forced and limits the damage caused by an attempted break-in.An all-new Golf Anti-theft measures The lock cylinder freewheel is integrated in the front doors. The lock-cylinder unit comprises the following components: Lock cylinder Locking plate Clutch Door operating linkage Lock cylinder housing Freewheel sleeve Sliding ring Function of door lock cylinder freewheel shown below using a door lock as an example SSP200/108 When the key is not inserted in the ignition. the locking plates engage in the freewheel sleeve.
In the process. 15 . The door lock is not opened. When the lock cylinder is turned. the locking plates remain in the freewheel sleeve. the lock cylinder is disconnected from the sliding ring. Key SSP 200/132 Door lock Door operating linkage Sliding ring Locking plate Freewheel sleeve Cam inside lock cylinder housing If the wrong ignition key is used or another tool. SSP 200/133 The lock cylinder freewheel and the encapsulated internal door lock minimise damage caused by an attempted break-in.Door lock Door operating linkage Sliding ring Lock cylinder Freewheel sleeve Inserting the matching key in the ignition draws the locking plates into the lock cylinder. The freewheel sleeve and the sliding ring are moved by two cams inside the lock cylinder housing. the freewheel sleeve is also rotated. the lock cylinder in the freewheel sleeve rotates and opens the door lock via the sliding ring and the door operating linkage. The lock cylinder turns without the sliding ring or the door operating linkage. When the ignition key is turned.
Reader coil on ignition lock Engine immobiliser control unit integrated in dash panel insert Ignition key with transponder Engine control unit SSP 200/064 After the ignition is turned on. The immobiliser prevents unauthorised persons from operating the car by intervening in the engine control unit. It is activated when the ignition is turned on. • In addition to the fixed code. This starts a series of secret arithmetic operations in the transponder and the engine immobiliser control unit. The selfvarying code is transmitted to the transponder inside the vehicle ignition key. 16 . The advantage of these secret arithmetic operations is that the calculated self-varying code cannot be decoded. The differences between the 2nd generation immobiliser and the previous generation are as follows: • The immobiliser control unit is integrated in the dash panel insert. If they match. the vehicle is ready to operate. a self-varying code is generated in the engine immobiliser control unit by a random generator. the transponder sends a fixed code to the engine immobiliser control unit. In addition. If these arithmetic operations produce identical results. If this code is correct. the engine immobiliser control unit transmits a self-varying code to the transponder integrated in the vehicle ignition key. the vehicle key is recognised as the correct one. the vehicle ignition keys cannot be copied. a check is performed to see if the self-varying code of the engine immobiliser control unit and the engine control unit match.An all-new Golf Anti-theft measures Immobiliser This is an electronic theft deterrent. As before.
Anti-theft measures Anti-theft alarm This monitors the doors.address word 35 in the central locking control unit or . If the vehicle is broken into in one of the monitored areas. the tailgate and the ignition lock. the vehicle must be locked twice within a period of 5 seconds. Depending on the car’s specification. a signal is sent to the control unit and the alarm is tripped. the selfdiagnosis can be performed using . The function can be integrated in two different control units: In the central locking control unit on vehicles without electric windows In the central control unit for the convenience system on vehicles with electric windows Microswitch in door locks Microswitch in tailgate lock Microswitch in door locks Microswitch in bonnet lock Indicator lamp for central locking/SAFE locking system Ignition lock WOB - Central control unit for convenience system or central locking control unit VK 1 2 Indicator lights SSP 200/112 Signal horn for anti-theft alarm The anti-theft alarm is switched on when the vehicle is locked once with the ignition key. To lock the vehicle without switching the antitheft alarm on. The alarm is reproduced audibly by activating the signal horn for the antitheft alarm and visually by activating all the indicator lights. the bonnet. 17 .address word 46 in the convenience system central module.
10µm thick Does not change shape easily. only body areas of the Golf prone to corrosion were galvanised. Smooth surface Zinc coating approx. for the first time. 8µm thick Changes shape easily. all body parts are either hot-dip galvanised or electrolytically galvanised. All outer skin panels are electrolytically galvanised Rough surface Zinc coating approx. In the past.Body The fully galvanised body The new Golf has a fully galvanised body and therefore offers greater protection against corrosion (12-year anti-corrosion perforation warranty). hot-dip galvanised electrolytically galvanised SSP 200/019 All parts which are externally visible are hot-dip galvanised. 18 . Now.
100µm thick 19 . Vehicle paintwork structure The electrolytic zinc coating provides a good basis for the upper paintwork layers. Sheet steel Zinc coating SSP 200/020 Zinc phosphate coating EC primer dip coating Filler Top coat Clear coat Coating system approx.The paintwork structure The paintwork is specifically structured to increase body corrosion protection even more.
Therefore. only achieve their ultimate strength once the shaping process has been completed. made of a relatively soft material.Body High-strength panels They are specially alloyed thin panels which achieve high strength as a result of subsequent heat treatment. Interior B-pillar Roof cross brace Spare wheel well reinforcement Plenum chamber reinforcement Support brakket for engine support Cover plate for side member SSP 200/021 High-strength panels Thermal post-treatment This is a welcome “side-effect” of the stove enamelling process during which the body is heated to approximately 170°C anyway. A great deal of weight is saved in this way. it is possible to use panels which are thinner than deep-drawn panels yet they are just as strong. 170° C SSP 200/022 20 . The advantage of this effect is that the body panels.
a low-speed rear collision does not cause damage to the body side section. 15 kph. As a result. These measures will reduce repair costs. SSP 200/123 21 .Front bumper In a frontal collision at speeds of up to approx. Side member Cross member Bumpers SSP 200/023 Rear bumper The rear bumper has been enlarged. the bumper together with the cross member absorb enough energy to prevent the side members from being damaged.
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