Maintenance GolF 2009(1)

Maintenance GolF 2009(1), vw serwisówki erwin

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Service
Vo
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Maintenance
Golf 2009 ➤
Golf Plus 2009 ➤
Edition 11.2013
Service Department. Technical Information
 Service
Maintenance
Heading
1. Engine list
2. Service work
3. General
4. Descriptions of work
5. Exhaust emissions test
6. Work descriptions for Golf “blue-e-motion”
7. Glossary
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2013 Volkswagen AG, Wolfsburg
K0059050520
 Golf 2009 ➤ , Golf Plus 2009 ➤
Maintenance - Edition 11.2013
Contents
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Information reference flexible or fixed service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 Vehicle diagnosis, testing and information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.5 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.6 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.7 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.8 Countries where the diesel has a high sulphur content . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.9 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.10 Countries with high levels of dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.11 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Descriptions of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Removable towing bracket: Check and clean if necessary . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Swivel joints and axle bearings: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.3 Automatic headlight control and static cornering light: Perform functional check . . . . . . . . 41
4.4 Automatic gearbox: Change ATF (09G gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5 Front passenger front airbag: Checking key switch and “ON/OFF function” . . . . . . . . . . . . 43
4.6 Battery: Checking battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . . . . . 44
4.7 Battery: checking using battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . 46
4.8 Status of battery: Read - send diagnosis protocol via online . . . . . . . . . . . . . . . . . . . . . . . . 47
4.9 Checking tyres: Condition, wear pattern, tyre pressure and tread depth . . . . . . . . . . . . . . 47
4.10 Brake and clutch system: Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.11 Brake system and shock absorbers: Performing visual check for leaks and damage . . . . 69
4.12 Thickness of brake pads/linings and condition of brake discs, front and rear: Checking . . 69
4.13 Brake fluid level: Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.14 6-speed dual clutch gearbox (DSG) 02E: Changing DSG oil and filter . . . . . . . . . . . . . . . . 73
4.15 Checking diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.16 Window regulators: Checking positioning (open and close functions) . . . . . . . . . . . . . . . . 74
4.17 Bonnet: Catch hook: Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.18 Protective bellows: Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.19 Haldex coupling: Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.20 Interior and exterior body: Performing visual check for corrosion when doors and flaps are
open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.21 Poly V-belt: Checking condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.22 Cooling system: Checking frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . 82
4.23 Diesel fuel filter: Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.24 Air filter: Cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.25 Multi-purpose additive for petrol fuels: add . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.26 Engine and components in engine compartment (from above and below): Porforming visual
check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.27 Engine cover panel “top”: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.28 Removing and installing engine compartment cover (noise insulation) “bottom” . . . . . . . . 103
4.29 Engine oil level: Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.30 Engine oil: Draining or extracting, renewing oil filter and replenishing engine oil . . . . . . . . 104
4.31 Performing road test (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 115
4.32 Wheel securing bolts: Tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.33 Reading radio code using vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.34 Radio/navigation system: Entering PIN of anti-theft coding and storing local radio stations to
station buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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Contents
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 Golf 2009 ➤ , Golf Plus 2009 ➤
Maintenance - Edition 11.2013
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4.35 Tyre pressure monitoring : Performing basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.36 Checking tyre repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.37 Window wash/wipe system and headlight washer system: Functional check . . . . . . . . . . 122
4.38 Wiper blade protection: Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.39 Headlight adjustment: checking halogen headlights and fog lights, adjusting if necessary
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.40 Headlight adjustment: Check gas discharge headlights and adjust if necessary . . . . . . . . 133
4.41 Sliding sunroof drains: Checking not blocked, cleaning if necessary . . . . . . . . . . . . . . . . 136
4.42 Service interval display: Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.43 Service interval display: Recode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.44 Sliding sunroof: Performing functional check, cleaning and greasing guide rails . . . . . . . . 143
4.45 Track rod ends: Checking clearance, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.46 Auxiliary heater: Setting weekday in menu of dash panel insert . . . . . . . . . . . . . . . . . . . . 144
4.47 Dust and pollen filter: Cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . 145
4.48 Transportation mode: Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.49 Transportation devices: Removing blocking pieces from front axle springs . . . . . . . . . . . . 146
4.50 Door arrester: Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.51 Clock and date: Set to correct time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.52 Underbody: Visual check for damage to underbody sealant, underbody panels, routing of
lines, plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.53 Camshaft drive toothed belt: Renew (diesel engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.54 Camshaft drive toothed belt: Check (4-cylinder petrol engine without change interval) . . . . 149
4.55 Spark plugs: Renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.56 Greasing driving instructor pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.57 Reading fault memory of all systems with vehicle diagnostic tester , correcting possible faults
according to repair guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.58 Gas system test (GAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.59 Additional maintenance for autogas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.60 Renewing autogas tank and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5
Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.1
Exhaust emissions test for petrol engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.2
Exhaust emissions test for diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
6
Work descriptions for Golf “blue-e-motion” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
6.1
Stickers and safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
6.2
Front charging socket: Checking operation of pivoted emblem . . . . . . . . . . . . . . . . . . . . 211
6.3
Removing and installing power electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
6.4
Pairing mobile phone and Premium mobile phone provision via Bluetooth® . . . . . . . . . . 212
6.5
Equipotential bonding wires: Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
6.6
Reading radio code using vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
6.7
Service interval display: Recoding during inspection preceding hand-over to customer . . 213
6.8
Service interval display: Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
7
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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Contents
 Golf 2009 ➤ , Golf Plus 2009 ➤
Maintenance - Edition 11.2013
1 Engine list
(VIGG000663; Edition 11.2013)
This chapter provides information on the following subjects:
Golf 5K1
Petrol engines
⇒ page 1
Diesel engines
⇒ page 3
Electric motor
⇒ page 5
Golf Plus
521
Petrol engines
⇒ page 5
Diesel engines
⇒ page 6
Note
To ease the search for an engine, the engine codes are listed in
alphabetical order.
Petrol engines
Engines:
⇒
Petrol engine
Petrol engine
Petrol engine
Petrol engine
Capacity
I
1.6
1.6
1.4
1.4
Engine code
BSE
BSF
CAVD
CAXA
No. of cylinders/valves per
cylinder
4/2
4/2
4/4
4/4
Output
kW at rpm
75/5600
75/5600
118/5800
90/5000
Torque
Nm at rpm
148/3800
148/3800
240/1750 to 4500 200/1500 to 4000
Bore
∅ mm
81.0
81.0
76.5
76.5
Stroke
mm
77.4
77.4
75.6
75.6
Compression ratio
10.3
10.3
10.0
9.7
Injection/ignition
Simos 7.1
indirect inj.
Simos 7.1
indirect inj.
Motronic MED
17.5.5
TSI twincharger
Motronic MED 17
TSI turbocharger
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RON
unleaded, at
least
95
95
95
95
Camshaft drive
Toothed belt
Toothed belt
Chain
Chain
Engines:
⇒
Petrol engine
Petrol engine
Petrol engine
Petrol engine
Capacity
I
2.0
2.5
2.5
1.2
Engine code
CBFA
CBTA
CBUA
CBZA
No. of cylinders/valves per
cylinder
4/4
5/4
5/4
4/2
Output
kW at rpm 147/5100 to 6000
125/5000
125/5000
63/4800
Torque
Nm at
rpm
280/1700...5000
240/4250
240/4250
160/1500 to 3500
Bore
∅ mm
82.5
82.5
82.5
71
Stroke
mm
92.8
92.8
92.8
75.6
Compression ratio
10.3
10.0
10.0
10.0
Injection/ignition
Motronic MED
17.1
TSI turbocharger
Motronic ME
7.1.1 or
17.5
indirect inj.
Motronic ME
7.1.1 or
17.5
indirect inj.
Simos 10.1
TSI turbocharger
1. Engine list
1
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