Volkswagen Golf 2013 Service Download

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Pro

rig

r i

olk

n AG

olk

AG do

ot g

uar

ante

or a

ith

tio

rig

ht b

olk

Valid for all authorised wheel/tyre combinations. ⇒ Wheels and

Tyres Guide - Standard; Rep. gr. 44

Part number -5G0 010 841 D-

Golf

Half payload

kPa/bar/psi

Full payload

kPa/bar/psi

Tyre size

front

rear

front

rear

205/55 R16

240/2.4/35

260/2.6/38

300/3.0/44

205/50 R17
225/45 R17
225/40 R18
225/35 R19

260/2.6/38

280/2.8/41

310/3.1/45

T125/70 R16

415/4.2/61

T125/70 R18

Part number -5G0 010 841 H-

Golf

Half payload

kPa/bar/psi

Full payload

kPa/bar/psi

Tyre size

front

rear

front

rear

All

210/2.1/30

230/2.3/33

280/2.8/41

Emergency spare

tyre

415/4.2/61

Valid for all authorised wheel/tyre combinations. ⇒ Wheels and

Tyres Guide - Standard; Rep. gr. 44

Part number -5G0 010 841 Q-

Golf

Half payload

kPa/bar

Full payload

kPa/bar

Tyre size

front

rear

front

rear

195/65 R15 91H

200/2.0

230/2.3

280/2.8

205/55 R16 91V

225/45 R17 91W

225/40 R18 92Y

T125/70 R16 96M

415/4.2

T125/70 R18 99M

Spare wheel

Part number -5G0 010 841 R-

Golf

Half payload

kPa/bar

Full payload

kPa/bar

Tyre size

front

rear

front

rear

205/55 R16 91V

210/2.1

230/2.3

280/2.8

225/45 R17 91W

225/40 R18 92Y
225/35 R19 88Y

230/2.3

250/2.5

290/2.9

Golf 2013 ➤

Maintenance - Edition 10.2012

4. Descriptions of work

Summary of Contents for Golf 2013

Page 1: ...e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Maintenance Golf 2013 Edition 10 2012 Service Service Department Technical Information ...

Page 2: ...t b y V o l k s w a g e n A G Maintenance Heading 1 Engine list 2 Service work 3 General 4 Descriptions of work 5 Exhaust emissions test 6 Glossary 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...

Page 3: ...rming visual check for leaks and damage 39 4 9 Thickness of brake pads linings and condition of brake discs front and rear Checking 40 4 10 Brake fluid level Checking 42 4 11 6 speed dual clutch gearbox 0D9 Changing gear oil and oil filter 43 4 12 Checking diesel particulate filter 44 4 13 Window regulators Checking positioning open and close functions 44 4 14 Protective bellows Visual check 45 4 ...

Page 4: ... 4 38 Track rod ends Checking clearance security and boots 91 4 39 Dust and pollen filter Cleaning housing and renewing filter element 91 4 40 Transportation mode Switching off 92 4 41 Transportation devices Removing blocking pieces from front axle springs 92 4 42 Clock and date Set to correct time 94 4 43 Underbody Visual check for damage to underbody sealant underbody panels routing of lines plu...

Page 5: ...000 Torque Nm at rpm 250 1500 3500 175 1400 3500 160 1400 3200 200 1400 4000 Bore mm 74 5 71 0 71 0 74 5 Stroke mm 80 0 75 6 75 6 80 0 Compression ratio 10 5 10 5 10 5 10 0 Injection ignition Motronic MED17 5 21 TSI Turbocharg er Motronic MED17 5 21 TSI Turbocharger Motronic MED17 5 21 TSI Turbocharger Motronic MED17 5 21 TSI Turbocharg er RON unleaded at least 95 in exceptional circumstances at l...

Page 6: ...rque Nm at rpm 250 1500 2750 320 1750 3000 320 1750 3000 340 1750 3000 Bore mm 79 5 81 0 81 00 81 0 Stroke mm 80 5 95 5 95 5 95 5 Compression ratio 16 2 16 2 16 2 16 2 Injection ignition TDI common rail TDI common rail TDI common rail TDI common rail Diesel particulate filter yes yes yes yes Camshaft drive Toothed belt Toothed belt Toothed belt Toothed belt Vehicles with diesel particulate filter ...

Page 7: ... year PR number Service 2013 QI6 Flexible service 2013 QI1 QI2 QI3 QI4 QI7 Fixed service 2 1 2 Flexible service The flexible service enables long service intervals depending on individual driving style and the conditions under which the vehicle is used Note For the flexible service a special LongLife engine oil is required page 5 Vehicles with production control number QI6 are set up for flex ible...

Page 8: ...h panel insert Engine oil level sensor Brake pad wear indicator if fitted 2 1 4 Service interval display Introduction of extended servicing intervals ESI page 4 Flexible service interval display only vehicles with a flexible serv ice page 4 Fixed service interval display only vehicles with a fixed service page 5 Service type for service due page 5 Service initial warning page 5 Retrieving service ...

Page 9: ...rs after a few seconds or if en gine is running Service initial warning If a service is due Service initial warning appears on dash panel insert display when ignition is switched on On vehicles with text messages on dash panel insert display the following appears Service in km or days The service information disappears after a few seconds or if en gine is running The service initial warning is dis...

Page 10: ...he service intervals with regard to the entries in the service sched ule 2 2 1 Service tables Service intervals page 6 VW engine oil standards page 7 Filter change intervals page 7 Toothed belt change intervals page 8 Spark plug change intervals page 8 Other time or distance dependent additional work page 9 Service intervals GOLF 5G1 2013 Service intervals From to PR No Service Intervals Indicated...

Page 11: ...ulate filter 507 00 1 4 cylinder TDI common rail without diesel particu late filter 507 00 1 4 cylinder TDI common rail without diesel partic ulate filter 505 01 1 Combination product 504 00 507 00 Note Vehicles with diesel particulate filter fitted ex factory can be identified by production control number 7MJ or 7MM on the ve hicle data sticker Filter change intervals GOLF 5G1 FILTER CHANGE INTER...

Page 12: ...iesel en gines oper ated in countries with high levels of dust All TDI com mon rail CLHA CRBB CRBC CRLB CRVA Since introduction Every 210 000 km page 94 Every 210 000 km Petrol engines 1 2 l TSI 1 4 l TSI CJZA CJZB CHPA CMBA CPTA CPVA Since introduction No prescribed change in terval toothed belt drive with test interval see other time or distance dependent additional work page 9 Spark plug change...

Page 13: ...ery 30 000 km there after page 44 Camshaft drive toothed belt Check Only valid for vehicles without prescribed change interval At 240 000 km then every 30 000 km there after page 95 Coolant pump toothed belt Check Only valid for vehicles without prescribed change interval At 240 000 km then every 30 000 km there after page 96 Exhaust emissions test EET Perform test For vehicles used for commercial...

Page 14: ...Maintenance tables Inspection QI2 QI4 Every 15 000 km or 1 year 1 Maintenance tables Inspection with expanded scope Only applicable in addition to regular inspection Every 30 000 km or 2 years 1 Maintenance tables Dust and pollen filter cabin filter Renew Every 15 000 km or 1 year 1 page 91 Spark plugs Renew Applies only for 1 2 l and 1 4 l TSI engines Every 30 000 km or 2 years 1 page 97 Diesel f...

Page 15: ...otes WARNING Before driving onto a lifting platform ensure that there is sufficient clearance between low lying components and lifting platform Before driving a vehicle onto a lifting platform it must be ensured that the vehicle weight does not exceed the per missible lifting capacity of the platform Lift vehicle only at points indicated in figure to avoid dam aging vehicle underbody or tipping ve...

Page 16: ...de member reinforcement seats centrally on support plate of hoist mounting Rear lifting point Position support plate in area of side member marking at ver tical reinforcement of floor pan arrow WARNING Ensure that side member reinforcement seats centrally on support plate of hoist mounting 3 2 Sticker Attach vehicle data sticker in customer service schedule page 12 3 2 1 Attaching vehicle data sti...

Page 17: ... also applies to components which were changed before the regular change interval Note When using Genuine parts kits it must be taken into account whether it is technically necessary to change all the compo nents included in the genuine parts kits If more components are renewed than is technically necessa ry inform the customer before repair 3 4 Vehicle diagnosis testing and informa tion system Co...

Page 18: ...r VAS 5054 2 Note Ensure that the selected vehicle diagnostic tester is only used with the respective diagnosis cable WARNING Always secure testing and measuring equipment on the rear seat during a road test Only a passenger may operate these devices during a drive Carry out the following procedure Connect diagnosis cable connector to diagnostic connection Switch on vehicle diagnostic tester Switc...

Page 19: ...umber chassis number arrow is lo cated on the left hand side of the vehicle in the windscreen near the wiper mounting It is visible from outside 3 5 2 Vehicle identification number on exten sion of longitudinal member The vehicle identification number is located on the extension of longitudinal member arrow 3 5 3 Significance of vehicle identification number WVW ZZZ AU Z D W 000 234 Manufacturer c...

Page 20: ... data The leg end can be found below the sticker 3 7 Severe operating conditions If the vehicle is used under severe operating conditions some work will have to be performed before the next service is due or at shorter service intervals Severe operating conditions Regular short trips or stop and go operation in urban traffic High percentage of cold starts Vehicle is used in areas with winter tempe...

Page 21: ...rbaijan Guinea Martinique Suriname Ethiopia Guinea Bissau Mauritania Swaziland Australia Guyana Mauritius Syria Bahrain Honduras Mexico Tajikistan Bangladesh Hong Kong Mongolia Tanzania Barbados India Mozambique Thailand Belize Indonesia Myanmar Burma Togo Benin Dahomey Iraq Namibia Chad Bhutan Iran Nepal Subcontinent of In dia Tunisia Bolivia Israel Nicaragua Turkey Botswana Yemen Niger Turkmenis...

Page 22: ...b y V o l k s w a g e n A G 3 10 Type plate Note Vehicles for certain export countries have no type plate 4 door vehicles The type plate arrow is visible in lower area of B pillar when the left front door is opened The type plate includes the following vehicle data A Vehicle identification number B Variable indications e g axle loads gross vehicle weight rat ing gross combination weight C Model id...

Page 23: ...i s n o t p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Golf 2013 Maintenance Edition 10 2012 4 Descriptions of work 19 ...

Page 24: ...ge 43 Diesel fuel filter Renew page 52 Checking diesel particulate filter page 44 Window regulators Check positioning open and close functions page 44 The fault memory of all systems must be read with vehicle diag nostic tester possible faults must be corrected according to repair guidelines page 99 Protective bellows Visual check page 45 Haldex coupling Change oil page 46 Interior and exterior bo...

Page 25: ...t adjustment check gas discharge headlights with DLA adjust if necessary page 84 Service interval display Reset page 89 Service interval display Recode page 90 Track rod ends Check clearance security and boots page 91 Dust and pollen filter Clean housing and renew filter element page 91 Transportation mode Switch off page 92 Transportation devices Remove blocking pieces from springs on front axle ...

Page 26: ... vulcanised rubber mounting must not show any cracks or porous areas 4 2 Automatic headlight control and static cornering light Perform functional check Note The automatic headlight control was formerly called driving light assist Vehicle must be in natural daylight Switch on ignition Turn light switch 4 to position Auto 2 The headlights may not light in brightness The rain and light sensor is loc...

Page 27: ...t The static cornering light is integrated in the headlights Start engine Switch on dipped beam or automatic headlight control Switch on turn signal Check cornering light Repeat procedure on other side 4 3 Front passenger front airbag Checking key switch and ON OFF function Note The PASSENGER AIRBAG ON OFF switch is located in the dashboard on the front passenger side Front passenger front airbag ...

Page 28: ...on ignition Warning lamp PASSENGER AIRBAG OFF arrow goes out after self test passenger airbag activated Switch off ignition 4 4 Battery Checking battery terminal clamps for secure seating Special tools and workshop equipment required Torque wrench V A G 1331 Note A securely seated battery terminal clamp ensures trouble free function and long service life of the battery When securing terminal clamp...

Page 29: ...al 6 Bolt for securing bracket 15 Carry out following procedures after connecting battery Procedure Vehicle electrics Electrical system Rep gr 27 Discon necting and connecting battery For technical reasons it is possible that some links do not make reference to the correct chapter In this case select the procedure manually in the information 4 5 Battery Checking with battery tester al ways refer t...

Page 30: ...termined always check to see if a new tyre should be fitted Tests at delivery inspection Check tyre side walls and treads for damage and foreign bod ies such as for example nails or glass splinters Tests at service Check tyre side walls and treads for damage and foreign bod ies such as for example nails or glass splinters Check tyres for cupping one sided wear porous side walls cuts and punctures ...

Page 31: ...pth is approaching the minimum allowed depth inform the customer 4 6 4 General notes WARNING For safety reasons only tyres of same type and tread pat tern should be fitted on a vehicle Approved wheel and tyre combinations e g Running gear Rep gr 44 On vehicles with four wheel drive tyres of the same type and tread pattern must be used Otherwise the self locking centre differential may be damaged N...

Page 32: ...eral cross references are not directed to the correct chapter In this case select the pro cedure manually in the information 4 6 5 Tyre pressures Golf Note During delivery inspection check that tyre inflation pressure sticker is fitted If the sticker is missing order a new sticker through ETKA The mandatory tyre pressures for the respective model can also be found on a sticker attached to the insi...

Page 33: ... 70 R181 1 Spare wheel Part number 5G0 010 841 C Golf Part number 5G0 010 841 L Half payload kPa bar psi Full payload kPa bar psi Tyre size front rear front rear All 1 220 2 2 32 220 2 2 32 240 2 4 35 280 2 8 41 Emergency spare tyre 415 4 2 61 1 Valid for all authorised wheel tyre combinations Wheels and Tyres Guide Standard Rep gr 44 Part number 5G0 010 841 D Golf Part number 5G0 010 841 M Half p...

Page 34: ...81 1 Spare wheel Part number 5G0 010 841 S Golf Half payload kPa bar Full payload kPa bar Tyre size front rear front rear 205 55 R16 91V 200 2 0 200 2 0 230 2 3 280 2 8 225 45 R17 91W 205 50 R17 93V 220 2 2 220 2 2 240 2 4 290 2 9 225 40 R18 92Y T125 70 R16 96M1 415 4 2 T125 70 R18 99M1 1 Spare wheel Part number 5G0 010 842 Golf Half payload kPa bar Full payload kPa bar Tyre size front rear front ...

Page 35: ...e Standard Rep gr 44 Part number 5G0 010 851 K Golf Part number 5G0 010 851 L Half payload kPa bar psi Full payload kPa bar psi Tyre size front rear front rear 195 65 R15 210 2 1 30 210 2 1 30 230 2 3 33 280 2 8 41 205 55 R16 205 50 R17 225 45 R17 225 40 R18 225 35 R19 230 2 3 33 230 2 3 33 250 2 5 36 290 2 9 42 Emergency spare tyre 415 4 2 61 Part number 5G0 010 841 B Golf Part number 5G0 010 841...

Page 36: ...225 35 R19 260 2 6 38 260 2 6 38 280 2 8 41 310 3 1 45 T125 70 R16 415 4 2 61 T125 70 R18 Part number 5G0 010 841 H Golf Half payload kPa bar psi Full payload kPa bar psi Tyre size front rear front rear All 1 210 2 1 30 210 2 1 30 230 2 3 33 280 2 8 41 Emergency spare tyre 415 4 2 61 1 Valid for all authorised wheel tyre combinations Wheels and Tyres Guide Standard Rep gr 44 Part number 5G0 010 84...

Page 37: ...Pa bar Full payload kPa bar Tyre size front rear front rear 205 55 R16 91V 250 2 5 250 2 5 270 2 7 300 3 0 225 45 R17 91W 225 40 R18 92Y 225 35 R19 88Y 280 2 8 280 2 8 300 3 0 330 3 3 1 Spare wheel Part number 5G0 010 842 A Golf Half payload kPa bar Full payload kPa bar Tyre size front rear front rear 205 55 R16 91V 240 2 4 240 2 4 260 2 6 300 3 0 225 45 R17 91W 225 40 R18 92Y 225 35 R19 88Y 260 2...

Page 38: ...ad kPa bar Tyre size front rear front rear 205 55 R16 91V 250 2 5 250 2 5 270 2 7 300 3 0 225 45 R17 91W 225 40 R18 92Y 225 35 R19 88Y 270 2 7 270 2 7 290 2 9 320 3 2 T125 70 R16 96M1 415 4 2 T125 70 R18 99M1 1 Spare wheel 4 7 Brake and clutch system Changing brake fluid WARNING Brake fluid must under no circumstances come into con tact with fluids containing mineral oils oil petrol cleaning solut...

Page 39: ...s w a g e n A G Brake filling and bleeding equipment VAS 5234 Brake bleeding tool VAS 6564 Depending on vehicle equipment the tool set for brake bleed ing VAS 6564 can be used for bleeding front and rear brakes without the need to remove the wheels Extracting brake fluid Note The strainer in brake fluid reservoir must not be removed Ensure that no brake fluid runs through the strainer after com pl...

Page 40: ... t C o p y r i g h t b y V o l k s w a g e n A G Extract as much brake fluid as possible using suction hose from brake filling and bleeding equipment VAS 5234 WARNING Do not reuse extracted brake fluid Bleeding brake system Bolt adapter 1 to brake fluid reservoir Connect filler hose 2 from brake filling and bleeding equip ment VAS 5234 to adapter 1 Set the correct pressure at the brake filling and...

Page 41: ... valve so that no air can enter the brake system There must always be sufficient brake fluid in the brake res ervoir so that no air can enter the brake system through the reservoir Start with front right brake caliper on RHD vehicles Open bleeder valve and let appropriate quantity of brake fluid run out see table Close bleeder valve Torque Running gear Brake systems Rep gr 47 Repairing front brake...

Page 42: ...nly for vehicles with manual gearbox Remove complete air filter housing if it prevents access to bleeder valve arrow illustration below Rep gr 23 Air filter Removing and installing air filter housing Or Rep gr 24 Air filter Removing and installing air filter housing Remove dust cap from bleeder valve arrow Connect bleeder hose to bleeder valve and to pressure hose of fluid collector bottle If nece...

Page 43: ...luid Sequence bleeder valves Brake fluid quantity which must flow out of bleeder valves LHD vehicles RHD vehicles Brake caliper Front left 0 20 litre 0 4 litre Front right 0 20 litre 0 4 litre Wheel brake cylinder brake caliper Rear left 0 30 litre 0 6 litre Rear right 0 30 litre 0 6 litre Clutch slave cylinder 0 15 litre 0 15 litre Total capacity for automatic gearbox approx 1 00 litres approx 2 ...

Page 44: ...ating leaks and corrosion WARNING Faults found must always be rectified repair measure 4 9 Thickness of brake pads linings and condition of brake discs front and rear Checking Front disc brake pads Check thickness page 40 Rear disc brake pads Check thickness page 41 Condition of brake discs Check page 42 Special tools and workshop equipment required Torque wrench V A G 1332 Electric hand torch and...

Page 45: ...enewed repair meas ure Inform customer Note When replacing brake pads always check brake discs as well for wear Checking and if necessary replacing the brake discs is a repair measure Check brake disc for wear Procedure Running gear Brake systems Rep gr 46 Brakes mech anism Repairing front brakes Note For technical reasons it is possible that several cross references are not directed to the correc...

Page 46: ...check brake discs as well for wear Checking and if necessary replacing the brake discs is a repair measure Check brake disc for wear Procedure Running gear Brake systems Rep gr 46 Brake mecha nism Repairing rear brake Note For technical reasons it is possible that some links do not make reference to the correct chapter In this case select the procedure manually in the information 4 9 3 Condition o...

Page 47: ...h away spilt brake fluid using plenty of water Observe disposal regulations Brake fluid level at delivery inspection At delivery inspection the fluid level must be at MAX marking Note In order that brake fluid does not overflow the reservoir MAX marking 1 must not be exceeded Brake fluid level at inspection service The fluid level must always be judged in conjunction with lining pad wear When vehi...

Page 48: ...on the screen If the display is not as shown in the procedure Operating in structions for vehicle diagnostic tester Press field to confirm Select one after the other Brand Type Model year Engine codes Confirm vehicle identification Select vehicle system Engine Select Checking ash mass of diesel particulate filter Follow instructions on display End test Switch off ignition and separate diagnosis co...

Page 49: ...ing 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 Switch on ignition Close all doors and windows completely Pull window regulator buttons up and hold for at least one second in this position Release buttons pull up and hold again The one touch opening and closing f...

Page 50: ...plugs of both systems are often interchanged due to the in tegrated housing construction of Haldex coupling and final drive Caution must be exercised during maintenance and servicing as incorrect fitting can cause the Haldex coupling and the final drive to fail The Haldex coupling and the final drive are one system with separate oil systems 1 plug for Haldex oil filler hole 2 drain plug for Haldex...

Page 51: ...drain plug Parts catalogue with new seal The drain plug is fitted with a secure seal Specified torque 30 Nm Remove oil filler plug 1 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 The vehicle can be lowered as soon as the hose above the rear left wheel leads away from the vehicle Bolt oil ...

Page 52: ... this connect vehicle diagnostic tester page 13 Select one after the other Guided fault finding Running gear 22 Four wheel drive with Haldex coupling Rep Gr 01 39 01 On board diagnostic capable system 22 Transfer box control unit J646 22 Functions Read measured values If the oil temperature is not between 20 40 C adherence to prescribed temperature range must be ensured by running gear box warm or...

Page 53: ...damper on belt pulley using a socket Check poly V belt 1 for Substructure cracks cracks core ruptures cross sectional breaks Layer separation top layer cord strands Base break up Fraying of cord strands Flank wear material wear frayed flanks brittle flanks glassy flanks surface cracks Traces of oil and grease Caution If faults are found it is absolutely necessary to renew the poly V belt This will...

Page 54: ...damage to the engine The correct coolant solution ratio helps prevent damage from freezing and corrosion as well as scaling Such additives also raise the boiling point of the coolant For this reason the cool ing system must be filled all year round with coolant additives Because of its high boiling point the coolant improves engine reliability under heavy loads particularly in countries with trop ...

Page 55: ...addi tives G12 G12 Plus G12 Plus Plus and G11 The scale 2 is only calibrated for coolant additive G13 If frost protection is too low drain coolant and add coolant ad ditive page 51 Note Observe disposal regulations Check coolant additive concentration after road test again 4 18 2 Checking coolant level replenish cool ant if necessary Check coolant level in coolant expansion tank with engine cold D...

Page 56: ...d the fuel can reach a temperature of up to 100 C Allow the fuel to cool down before disconnecting the lines risk of scalding Wear protective gloves Wear protective goggles Risk of injury due to highly pressurised fuel To release pressure in fuel system place clean cloth around connection and carefully undo connection Special tools and workshop equipment required Protective gloves Eye protection N...

Page 57: ...i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Note Disregard the remaining items Installing Insert filter element 2 centrally into fuel filter housing 1 Screw in bolts for filter housing 4 and tighten them to speci fied torque Torque setting Nm Bolts for filter housing 5 Golf...

Page 58: ...lling air filter element common rail engines page 55 4 20 1 Removing and installing air filter ele ment 1 2 l and 1 4 l TSI engines Removing Pull air hose 2 off upper part of air filter 1 Release hose clips 3 and 4 Pull air filter housing 1 off ball head pins upwards Pull air hoses ducts off air filter housing 1 Remove air filter element 1 and place down turned through 180 Unscrew bolts 1 on under...

Page 59: ... using bolts 1 Fit air hoses ducts to air filter housing 1 Fit hose clips 3 and 4 Position air filter housing 1 centrally on ball head pins and press on Fit air hose 2 on upper part of air filter housing 1 Torque setting Nm Securing bolts 1 5 4 20 2 Removing and installing air filter ele ment common rail engines Removing Unscrew securing bolts arrows from upper part of air filter housing and lift ...

Page 60: ... e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Insert air filter element 16 centrally into mounting in lower part of air filter housing 18 Carefully fit upper part of air filter housing 8 onto lower part of air filter housing 18 without applying excessive force Screw in securing bolts 7 and tighten them to specified tor que Note Disregard...

Page 61: ...ilter housing for dirt and clogging Remove salt residues dirt and leaves from upper and lower part of air filter housing using a vacuum cleaner if necessary Note When using compressed air to blow out the air filter housing ob serve the following in order to avoid functional impairments cover the critical air carrying engine components with a clean cloth 4 21 Engine and components in engine com par...

Page 62: ... a tool Position engine cover panel paying attention to oil filler neck and dipstick Press engine cover panel into rubber grommets first on the left side and then on the right side 4 23 Removing and installing engine com partment cover noise insulation bot tom Procedure Removal of engine cover bottom noise insulation can be found in Workshop Manual under General body repairs exterior General body ...

Page 63: ...nes with turbocharger page 59 Draining engine oil page 59 Renewing oil filter 1 2 l and 1 4 l TSI engines page 61 Renewing oil filter common rail diesel engines page 61 Replenishing engine oil page 63 4 25 1 Notes on engines with turbocharger After the engine oil has been changed and the oil filter has been renewed observe the following when starting the engine for the first time The engine must o...

Page 64: ...ed the oil drain plug must always be renewed This prevents leaks Observe disposal regulations Remove oil drain plug Let engine oil drain Note Observe disposal regulations Screw in oil drain plug together with seal hand tight and then tighten to specified torque Torque setting Nm Oil drain plug 30 Replenish engine oil specification page 5 Engine oil capacity Power unit Rep gr 17 Removing and instal...

Page 65: ... oil filter strap 2171 1 Torque wrench V A G 1331 Removing oil filter Remove engine compartment cover noise insulation bot tom page 58 Loosen oil filter element arrow using Hazet oil filter strap 2171 1 or oil filter tool 3417 and remove oil filter Installing oil filter Clean sealing surface for oil filter on engine Moisten rubber seal of oil filter element with engine oil Screw in oil filter elem...

Page 66: ...ng it in direction of arrow Unscrew oil drain plug 1 from screw cap 3 and drain engine oil Removing oil filter Remove screw cap 3 using 32 mm hexagon socket insert Renewing oil filter element Pull out oil filter element 5 Insert O ring 2 in groove of oil drain plug for screw cap 1 Screw in oil drain plug and tighten it to specified torque Moisten new O ring 4 with engine oil and renew oil filter e...

Page 67: ...p Pull dipstick out again and read oil level A Oil must not be replenished B Oil can be replenished up to A marking C Oil must be replenished Oil level must then be at least in upper third of measuring area B If oil level is above A marking drain or extract excess oil in order to avoid damage to catalytic converter If oil level is below marking C replenish oil to marking A Oil specification page 5...

Page 68: ...cleaned in advance using lint free cloth or applicator and wet and dry vacuum cleaner VAS 5128 Lubricate inside and outside of guide rails on both sides high lighted in green with lubricating paste Apply lubricating paste to approx first 10 cm of guide rail from both sides in area of arrows Ensure that no other components or the inside of the vehicle are soiled Note Should the blocking element of ...

Page 69: ...es using a vacuum cleaner with a suitable nozzle Caution Use a suitable nozzle for the wind deflector so that the net is not damaged Ensure that no dirt enters the inside of the vehicle while this work is being carried out 4 27 Performing road test driving behaviour noises air conditioner etc Which of the following can be checked depends on vehicle equip ment and local conditions urban country Che...

Page 70: ...ce Wheels drive shafts propshaft Wheel bearings Noises Engine Hot starting behaviour 4 28 Wheel securing bolts Tightening to specified torque Pulling off wheel hub trim page 66 Pulling off wheel trim page 67 Pulling off wheel bolt caps page 67 Loosening tightening anti theft wheel bolts page 67 Tightening wheel bolts page 68 Installing wheel centre cover wheel bolt cover caps and wheel cover page ...

Page 71: ...ls do not lever wheel bolt caps off with screwdriver only use the special tool for this purpose puller hook in vehicle tool kit Note Before loosening or tightening the wheel bolts remove the cover caps The puller hook to remove the cover caps is located with the ve hicle tool kit Place the puller hook through opening in cover cap Pull off cap using the puller hook Loosening tightening anti theft w...

Page 72: ...k s w a g e n A G Adapter set for tamper proof wheel bolts T10313 Torque wrench V A G 1332 Slide adapter 2 as far as stop onto anti theft wheel bolt 1 Slide the wheel bolt wrench onto adapter 2 onto stop Tightening wheel bolts Tighten the wheel bolts diagonally and alternately to the fol lowing torque setting 120 Nm WARNING Never use an impact screwdriver to tighten the wheel bolts Installing whee...

Page 73: ... indicator must only be per formed after the tyre pressure has been corrected to the prescribed values If no pressure loss and tyre damage are found after a tyre pressure warning the incorrect warning can be rectified by calibrating The tyre pressure indicator compares the speed and thus the rolling circumference and vibrations of the individual wheels via the ABS sensors If the tyre pressure chan...

Page 74: ...nt system Press infotainment CAR button Press Setup function button Press Tyres function button Press Set function button Press Confirm function button 4 30 Checking tyre mobility set Note Depending vehicle equipment the vehicles are equipped with a tyre mobility set It also contains a filling bottle with tyre sealant The tyre mobility set can be found in the tool bag 3 on the right side in luggag...

Page 75: ...m Check spray jet settings page 73 Windscreen wiper blades Check park position page 74 4 31 1 Checking anti freeze protection of fluid topping up fluid Special tools and workshop equipment required Refractometer T10007 A Read precise value for the following tests at bright dark boundary Using a pipette place a drop of water on the glass to improve the readability of the bright dark boundary The br...

Page 76: ...reezing Otherwise the complicated spray jet system can become blocked by the crystallised washer fluid which affects the spray pattern of the spray jet Windscreen Clear G 052 164 ensures that the fan type spray jets remain fully functional also at low tempera tures Replenish Windscreen Clear G 052 164 also in the warmer periods of the year The powerful cleanser removes wax and oil residue from the...

Page 77: ...can be compensated for If both spray fields are not at same height adjust spray direc tion upwards or downwards as follows 1 Cowl panel in front of windscreen 2 Adjuster Torx size 8 3 Fan jet 4 Bonnet Adjust the spray jet 3 by turning the adjuster 2 using a Torx screwdriver Clockwise lower Anti clockwise higher Rear window spray jet setting Adjust spray jet using adjusting tool T10127 so that the ...

Page 78: ...eviates from specifications carry out repair measures Note The same test pattern is also applicable for vehicles with halogen headlights 4 31 4 Windscreen wiper blades Checking park position Procedure Vehicle electrics Electrical system Rep gr 92 Window wash wipe system e g windscreen wiper system Adjusting wiper blade park position Note For technical reasons it is possible that some links do not ...

Page 79: ...oving wiper blade protection version 2 page 76 3 Transport wiper blade Identification the transport wiper blade is fitted without wind deflector and must be replaced by the standard wiper blade Renewing wiper blade protection version 3 transport wiper blade page 76 4 32 1 Removing wiper blade protection ver sion 1 Switch ignition on and off briefly with bonnet closed When engine is switched off mo...

Page 80: ...otection ver sion 2 Switch ignition on and off briefly with bonnet closed When engine is switched off move wiper lever down to touch wipe function within 10 seconds The wipers move in service position Lift the wiper arm away from windscreen Caution When doing this do not touch the wiper blade to prevent dam age Pull protective strip off wiper blade upwards as shown in il lustration Carefully place...

Page 81: ...his do not touch the wiper blade to prevent dam age Carefully place wiper arm back onto windscreen Switch ignition on and briefly operate the wiper lever to move the wipers back to park position Switch ignition off again 4 33 Headlight adjustment checking halogen headlights and fog lights adjusting if necessary Test prerequisites page 77 Checking headlight adjustment using test screen without 15 s...

Page 82: ...ination information in is stamped in trim above headlight Headlight adjustment must be performed according to this infor mation Percentage given is based on a projection distance of 10 metres For example inclination of 1 0 converts to approx 10 cm For vehicles in the North American market an inclination of 0 7 is to be set Note For certain export markets halogen headlights with manually regulated ...

Page 83: ... Checking headlight adjustment using test screen without 15 setting line Headlights Check the following Whether with the dipped beam switched on the horizontal bright dark boundary contacts the dividing line 1 of the test area and Whether the breaking point 2 between the horizontal part of the bright dark boundary on the left and the rising part on the right lies on the vertical line of the centra...

Page 84: ...adlights move evenly when manually operated headlight range control is functioning Set the appropriate inclination on the headlight adjustment unit The inclination for headlights with halogen bulbs is 1 0 Note Percentage given is based on a projection distance of 10 metres Adjusting left headlight The adjustment bolts for the right headlight are a mirror image Height adjustment screw hexagon socke...

Page 85: ...st screen without 15 setting line page 82 Gas discharge headlights without Dynamic Light Assist dynamic main beam regulation adjusting page 83 4 34 1 Checking and adjusting prerequisites Tyre pressure OK Headlight lenses must not be damaged or dirty Reflectors and bulbs OK Vehicle must be loaded The vehicle must be rolled forward or backward several me tres or front and rear springs must be bounce...

Page 86: ...t 90 full then load as follows Read fuel level in fuel tank on fuel gauge Determine additional weight from following table and place weight in luggage com partment Fuel gauge table Fuel level of fuel gauge Petrol and diesel engines additional weight in kg To 1 4 30 To 1 2 20 To 3 4 10 Full 0 Example When the fuel tank is half full an additional weight of 20 kg must be placed in the luggage compart...

Page 87: ...tical line passing through the centre mark Note To simplify the determination of the breaking point 2 cover and uncover left from driver perspective half of the headlight a few times Then check dipped beam again 4 34 3 Gas discharge headlights without Dy namic Light Assist dynamic high beam regulation adjusting Overview of gas discharge headlights without Dynamic Light As sist dynamic main beam re...

Page 88: ... the right headlight are a mirror image 4 35 Headlight adjustment checking gas dis charge headlights with DLA adjusting if necessary DLA Dynamic Light Assist dynamic high beam regulation Identifying vehicles with Dynamic Light Assist page 87 Checking and adjusting prerequisites page 84 Checking headlight adjustment using test screen without 15 setting line page 85 Gas discharge headlights with Dyn...

Page 89: ...ed unladen weight The unladen weight is the weight of vehicle ready for operation with a full fuel tank at least 90 including weight of all equip ment normally carried e g spare wheel tools jack fire extin guisher etc If the fuel tank is not at least 90 full then load as follows Read fuel level in fuel tank on fuel gauge Determine additional weight from following table and place weight in luggage ...

Page 90: ...dynamic main beam Note For dynamic main beam test pattern headlights need to be reset to basic settings using vehicle diagnostic tester The basic settings can only be reset using vehicle diagnostic tester After resetting DLA main beam distribution is actuated automatically Pay special attention to correct alignment of the adjustment sighting device on the headlight adjuster Only when this has been...

Page 91: ...ern for the right headlight is a mirror image Test pattern with dipped headlights Testing may also be carried out with dipped headlights switched on Nevertheless said dynamic main beam test pattern is prefer red For checking dipped headlight it is not necessary to use the ve hicle diagnostic tester Headlight adjustment on the other hand can only be carried out using the test pattern with dynamic m...

Page 92: ...light M1 or bulb for right parking light M3 based on LED technology 2 Bulb for left cornering light L148 or bulb for right cornering light L149 3 Bulb for front left turn signal M5 or bulb for front right left turn signal M7 4 Left gas discharge bulb L13 or right gas discharge bulb L14 5 LEDs for daytime driving light and dimmed for parking light Carrying out basic setting of headlight range contr...

Page 93: ... of the headlight any more during the check Readjusting the vertical setting is permissible Check headlight setting Adjust height setting of headlight if necessary Press GoTo End buttons to exit Guided functions Note Adjustment of the right headlight is carried out in the same sequence The adjustment bolts for the right headlight are a mirror image 4 36 Service interval display Resetting Resetting...

Page 94: ...to be reset Select Dash panel insert Carry out adaptation according to the information of Guided functions Select Identify control unit Select Guided functions Select the respective service which is to be reset Carry out adaptation according to the information of Guided functions 4 36 2 Resetting service interval display with out vehicle diagnostic tester With function button on dash panel insert ...

Page 95: ...s Select Change flexible fixed intervals Carry out adaptation according to the information of Guided functions 4 38 Track rod ends Checking clearance security and boots Carry out the following procedure With vehicle raised wheels hanging free check clearance by moving track rods and wheels Clearance Zero clearance Check mountings Check that boots arrow are not damaged and are seated correctly 4 39...

Page 96: ...e which can re duce the battery capacity when being misused Examples are radios electronically operated flaps and attach ments and anti theft alarm systems which can produce faults during transportation Procedure Connect vehicle diagnostic tester page 13 Switch on ignition Select Vehicle self diagnosis If the display is not as shown in the procedure Operating in structions for vehicle diagnostic t...

Page 97: ... f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Vehicles with blocking pieces fitted to the suspension struts have a label hanging from the mirror arrow Removing blocking pieces on piston rod Relieve weight on coil springs by raising vehicle with a hoist Slide suspension strut protective sleeve arrow upwards Push blocking pieces arrows off piston rod Sl...

Page 98: ...y Press button 1 until the desired minute value is displayed Keep the button pressed for fast run Setting time and date in Infotainment system Switch on ignition Switch on Infotainment system Press infotainment CAR button Press Setup function button In the menu scroll to the Service function button Press Time and date function button Press Time function button and set current time Press Date funct...

Page 99: ...cribed toothed belt change interval can be found in service tables page 5 4 45 1 Checking toothed belt condition Procedure Release hoses from retainer 3 and lay them to one side Remove bolt 2 Release clips arrows and remove upper toothed belt guard 1 Turn crankshaft by the bolt of the crankshaft toothed belt in the direction of the engine and check the entire toothed belt for the following Cracks ...

Page 100: ... c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 4 46 Coolant pump toothed belt Checking Procedure Loosen hose clips 1 2 and remove air pipe Free air hose from air pipe Disconnect electrical connector 1 Release catches arrows and remove air pipe Press release tabs and disconnect hose 1 for activated char coal filter Unscrew bolts arrows and remove crankcase breather hose Note If one or b...

Page 101: ...f the engine and check the entire toothed belt for the following Cracks cross sectional breaks cracks coating arrow Side contact Fraying of cord strands Cracks in teeth base arrow Layer separation toothed belt body draw strands Surface cracks synthetic coating Traces of oil and grease Note If faults are found always renew toothed belt This will avoid pos sible breakdowns or operating problems The ...

Page 102: ...hose clips 1 and 2 and remove air pipe Disconnect electrical connector 2 Remove bolt 1 and remove respective pencil type ignition coil Repeat the procedure for all other pencil type ignition coils Note Observe installation position of ignition coils with output stages Ensure that the cables are not kinked or damaged Unscrew spark plugs using spark plug socket and extension VAS 3122B Installing Scr...

Page 103: ...eading fault memory of all systems with vehicle diagnostic tester correct ing possible faults according to repair guidelines Procedure Connecting diagnosis tester page 13 Select Vehicle self diagnosis Select self diagnostic system Read equipment configuration list Repair all faults according to repair guidelines Caution The vehicle must always be delivered to the customer with event memory cleared...

Page 104: ...e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G All event memories are read again Now it is confirmed on display that all sporadic faults have been cleared The diagnosis log can be sent automatically online The vehicle system test is completed Golf 2013 Maintenanc...

Page 105: ...ific legal regulations The exhaust emissions test described below has been created according to the legal regulations valid in Germany Emissions test intervals Vehicles with regulated catalytic converter or vehicles with diesel engine 3 years after initial registration and then every 2 years Vehicles for commercial passenger transport e g taxis every 12 months 5 1 Exhaust emissions test for petrol...

Page 106: ...5055 Note It is only possible to carry out an exhaust emissions test when all units of the emissions testing station are connected prop erly and combined with each other according to the operating instructions All work to be performed is displayed by the emissions testing station Test prerequisites All test conditions and data required for exhaust emissions test are found on EET data sheet for the...

Page 107: ... VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G An overview is displayed to select the respective EET type Select EET petrol arrow The display for warm up phase appears Golf 2013 Maintenance Edition 10 2012 5 Exhaust emissions ...

Page 108: ...input menu is displayed Enter the following data Registration number Key numbers Vehicle identification number Type of fuel Odometer reading The following vehicle data can be found in the vehicle registration certificate part 1 Registration number e g WOB HH 1234 Emission key No field 14 1 code for field 14 Vehicle manufacturer Field 2 Field 2 1 code for field 2 Vehicle identification number field...

Page 109: ...idling speed 7 Idling speed 8 Select regulating probe type either Step type probe or Broad band probe item 1 9 Lambda probe value When all data have been entered properly press Continue button arrow Specified data input for EET as bar code If specified data for EET are available as bar code read bar code of EET data sheet with bar code reader All data required are shown on display Press button arr...

Page 110: ... i g h t b y V o l k s w a g e n A G Follow instructions on display Switch off ignition Connect diagnosis cable connector to EOBD connection Switch on ignition Perform visual check of exhaust emissions warning lamp If lamp lights up press button Lamp On arrow C Follow instructions on display see arrow C and arrow A Start engine Visual check of exhaust emissions warning lamp Insert emission probe i...

Page 111: ...zero a regulating probe test is not performed If not all displayed values are set to zero a regulating probe test will be performed later Confirm condition of exhaust emissions warning lamp condi tion arrow B Catalytic converter conditioning It is automatically switched to warm up phase of catalytic con verter Follow instructions on display Measurement starts when the engine speed has reached the ...

Page 112: ... button and the test can be repeated Maintain engine speed in required engine speed range The remaining time to perform measurement is displayed arrow A Measuring idling speed and CO content It is automatically switched to display for measuring the idling speed and CO content Measurement starts when the engine speed has reached the re quired level The remaining time to perform measurement is displ...

Page 113: ... test is classed as passed select arrow B EET sticker issued in drop down menu and date Then confirm with Yes see arrow C After confirming the 2 TEST CERTIFICATES are printed out automatically If a further test certificate is required press arrow A Print button Follow instructions on display Take emission probe out of exhaust tail pipe Then press button arrow B The exhaust emissions test is comple...

Page 114: ...relief VAS 5055 2 Remote diagnosis head VAS 5054 A Diagnosis interface VAS 5055 Note It is only possible to carry out an exhaust emissions test when all units of the emissions testing station are connected prop erly and combined with each other according to the operating instructions All work to be performed is displayed by the emissions testing station Test prerequisites All test conditions and d...

Page 115: ...eorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 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 Golf 2013 Maintenance Edition...

Page 116: ...performed initially select Stand ard values Or Last vehicle when an exhaust emissions test is to be car ried out again Select Continue item 1 on display Vehicle data input The vehicle data input menu is displayed Enter the following data Registration number Key numbers Vehicle identification number Type of fuel Odometer reading The following vehicle data can be found in the vehicle registration ce...

Page 117: ...omatically transmitted via the network to the respective mask Manual specified data input for EET Note All test conditions and data required for exhaust emissions test see Data sheets for exhaust emissions test for respective en gine Perform manual data input according to instructions on dis play Enter displayed values on EET data sheet in column Test values for exhaust emissions test on display a...

Page 118: ... are shown on display 1 Press button arrow to continue the process Visual check Follow instructions on display Perform visual check of all exhaust emissions relevant com ponents Check if exhaust system is fitted and complete and check for leaks and damage If visual check is OK press OK button arrow Note When the not OK button is pressed a check will be carried out Connecting diagnostic connector I...

Page 119: ...ing Start engine and confirm engine running on display with Yes Perform visual check of exhaust emissions warning lamp The lamp must not light or flash Confirm exhaust emissions warning lamp condition arrow It is automatically switched to test for readiness of operation It is checked here if all tests for readiness of operation supported by the control unit have been performed Conditioning In the ...

Page 120: ...re reset using the button and the test can be repeated Maintain engine speed in required engine speed range The remaining time to perform measurement is displayed arrow Measuring rev limit 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 immediate...

Page 121: ...display arrow A and arrow C Maintain idling speed in engine speed range indicated arrow D The remaining time to perform measurement is displayed arrow B Note The emissions probe must be in the exhaust tail pipe If the speed deviates from engine speed range indicated the measurement starts again Measurement can be skipped using button i e the exhaust emissions test has failed Free acceleration phas...

Page 122: ... this case the operator assesses if the value is OK The values are not OK and the measurement is terminated skipped by pressing the button arrow C If the measured values are OK after 3 throttle bursts in succes sion i e all fields are coloured white the exhaust emissions test is completed Evaluation When the exhaust emissions test has been performed the log is shown on display The test result is d...

Page 123: ...enAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Then press button arrow B The exhaust emissions test is completed a new exhaust emis sions test can be performed Golf 2013 Maintenance Edition 10 2012 5 Exhaust emissions test...

Page 124: ...the automotive industry in the USA Germany the European Union and other countries The AdBlue urea solution is not mixed with diesel fuel but is carried in a separate tank in the vehicle ATF level Filling level of ATF in gearbox CO Carbon monoxide is produced when fuels containing carbon are not combusted com pletely Common rail CR Refers to a common high pressure injection line rail which supplies...

Page 125: ... interval display in dash panel insert Engine oil level sensor Brake pad wear indicator QG2 The LongLife service is not factory activated This means vehicles have a non flexible service interval display time and distance dependent service intervals and are fitted with the following components Non flexible service interval display in dash panel insert Engine oil level sensor Brake pad wear indicato...

Page 126: ... i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Term Explanation TSI From model year 2008 the designation TFSI is replaced by TSI Therefore the designation TSI is given to TSI turbocharger and TSI twincharger TSI turbocharger charging only with turbocharger TSI twincharger charging with turbocharger and compressor TDI Turbo diesel engine direct injection DP Distrib...

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Volkswagen Golf 2013, Service

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