Volkswagen golf 5 User manual

3
General
Lifting the vehicle using vehicle hoist and workshop
trolle
y
j
ack
Safety precautions
Warning!
Before driving on to a hoist ensure there is
sufficient clearance between low lying vehicle
components and hoist.
Before driving a vehicle onto a lifting platform it
must be ensured that the vehicle weight does
not exceed the permissible lifting capacity of the
platform.
Vehicle may only be lifted at points indicated in
illustration in order to avoid damaging vehicle
floor pan and to prevent vehicle from tipping.
Never start engine and engage a gear with
vehicle lifted so long as even one wheel has
contact with the floor. There is a risk of an
accident if this is not observed!
If work is to be performed under vehicle it must
be supported by suitable stands.
Lifting points for lifting platform and trolley jack:
Front:
Page 1 / 10Volkswagen Golf 5 - Description of work

- Place support plate, in area of side member marking -
arrow A - , on vertical stiffener of floor plate -arrowB-.
Warning!
Make sure that side member stiffener contacts support
p
late of liftin
g
p
latform at center.
Rear:
- Place support plate, in area of side member marking -
arrow A - , on vertical stiffener of floor plate -arrowB-.
Warning!
Make sure that side member stiffener contacts support
p
late of liftin
g
p
latform at center.
Data stickers
Appl
y
sticker "First service"
(
at the deliver
y
inspection
)
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Appy sticker "Your next service events" 01-3, Data
stickers
"First service" sticker
- Apply sticker on drivers side door jamb (B-pillar); the
sticker is located on an instruction which is attached at
front in the vehicle wallet. Destroy the instruction after
attaching the sticker!
Appl
y
sticker "Next service"
- Service sticker "Next service" : Enter a cross at the
position for oil change service or inspection service (next
service due) and enter date / odometer reading
- Apply sticker on drivers side door beam (B-pillar).
A
pp
l
y
in
g
"Data sticker" in service schedule
- Apply the upper of the two data stickers -arrow-.
1 - Planning week
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2 - PR Number
Dia
g
nostic unit, connectin
g
S
p
ecial tools, testers and auxiliar
y
items re
q
uired
Vehicle Diagnosis, Testing and Information System
VAS 5051 A
Vehicle Diagnosis, Testing and Information System
VAS 5051B
Vehicle diagnosis service syst. VAS 5052 or later
testers
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Diagnostic system VAS 5053
Diagnostic cable VAS 5051/6A
Warning!
During a test drive you must always secure
testing and measuring equipment on the back
seat.
Drivers must NEVER operate these tools while
driving.
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- Perform the following work procedure:
- Connect diagnosis cable connector to data link
connector.
- Turn on the tester.
- Switch ignition on.
Now follow information given on screen to start the desired
functions.
V
ehicle Identification Number
(
VIN
)
Com
p
onent location en
g
ine com
p
artment
Vehicle Identification Number (VIN) is located on extension
of longitudinal member -arrow-.
Meaning of Vehicle Identification Number (VIN):
000 234
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WVW ZZZ 1K1
1) Z4 8
Manufacturer
code Filler characters Model Filler characters Model year 2004 Production location Serial
number
1) Rabbit/GTI 2006
V
ehicle data sticke
r
The vehicle data sticker - arrow - is located in rear of
vehicle on the left in the spare wheel well under foam
storage tray. The vehicle data sticker can also be found in
the service schedule for the customer.
Sticker contains the following vehicle data:
1 - Production control number
2 - Vehicle Identification Number (VIN)
3 - Model identification number
4 - Model explanation/engine output
5 - Engine and transmission code letters
6 - Paint number/interior equipment identification number
7 - Optional extras identification numbers
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Information on time or distance dependent service
Service Identification
- Check via the vehicle data plate in luggage compartment,
whether the vehicle is equipped with PR number "QG0" or
with PR Number "QG2" . The PR number determines the
service intervals 01-3, Service intervals .
Vehicle data plate is applied at left next to spare wheel
well, component location, see 01-3, Vehicle data
sticker .
Vehicles marked with the following PR-number:
"QG2" indicates time or distance de
p
endent service.
"QG0" means time or distance de
p
endent service.
En
g
ine oils
Approved engine oil norms for vehicles
For information regarding approved oil types please
refer to:  Additional Information, Fluid Capacity
Charts for a
pp
ro
p
riate model and
y
ear
En
g
ine code and en
g
ine numbe
r
Engine code and engine identification are found in:
Gasoline engines:
Repair Manual, 2.0 Liter 4-Cyl. 4V Turbo Engine
Mechanical, Fuel Injection Ignition, Engine Code(s): BPY,
Repair Group 00, Technical data, engine number
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On vehicle data sticker 01-3, Vehicle data
sticker .
Service intervals
Service intervals
So that each service is performed at the correct point in
time and is not forgotten, a sticker on the door beam or
service reminder indicator in the instrument cluster display
serves to remind customer of the service event.
Information about the sticker can be obtained 01-3, Data
stickers .
V
ehicles with PR-number QG0, QG2
Oil change service Page
- Oil change service at 5,000 miles (8,000 km)
(whichever occurs first)
(according to service interval display)
01-2, Oil change service
Inspection service (oil change service inspection service) every 10,000
miles (15,000 km) or after 1 year Page
- Oil change service every 10,000 miles (15,000 km) or after 1
year
(whichever occurs first)
(according to service interval display)
01-2, Oil change
service
T
y
pe plate
Note:
Vehicles for certain countries have no type plate.
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4-door vehicles
Type plate - arrow 1 - can be seen after opening left front
door, in lower area of B-pillar.
Sticker contains the following vehicle data:
A - Vehicle Identification Number (VIN)
B - Axle loads
C - Model identification number
2-door vehicles
Type plate is visible after opening right door on door beam
at bottom.
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4
Descri
p
tion of work
(p
art 1 of 2
)
Ball
j
oints, visual inspection
- Check ball joint boots - arrow - for leaks and damage.
Automatic transmission, check ATF level, 09G -
transmission
- Work procedure:
.
Repair Manual, Automatic transmission 09G, Repair
Group 37, ATF level, checking and topping of
Batter
y
, check batter
y
terminals for secure seatin
g
S
p
ecial tools, testers and auxiliar
y
items re
q
uired
Torque wrench V.A.G 1331
Note:
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tion of work
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art 1 of 2
)

Tight battery connections assure trouble-free battery
function and long service life.
Perform the following work procedure:
- Operate lock - arrow - , fold up and remove cover
toward front.
- Check battery terminal clamps are seated securely on
the battery terminals by moving the battery Ground (GND)
wire - 1 - and the battery positive wire - 2 - back and forth
by hand.
Warning!
If the battery clamp is not seated securely on the
p
ositive terminal, disconnect battery Ground (GND)
clamp on battery negative terminal first, to prevent
p
ossible accidents.
If the battery clamp on positive terminal is not seated
securely:
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tion of work
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art 1 of 2
)

- First disconnect battery clamp - 1 - at battery negative
pole.
- Tighten battery clamp - 2 - on battery positive terminal to
9 Nm.
- Re-connect battery clamp - 1 - on battery negative
terminal and tighten to 9 Nm.
If the battery clamp on negative terminal is not seated
securely:
- Tighten ground connection - 1 - on battery to 9 Nm.
- Reinstall cover.
Note:
Once the battery is reconnected:
.
Repair Manual, Electrical Equipment, Repair Group 27,
Batter
y
, check
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p
tion of work
(p
art 1 of 2
)

Battery: Checking
Repair Manual, Electrical Equipment, Repair Group 27,
Check tires, condition, tire tread, filling pressure, tread
depth
Checking condition of tires, 01-4, Tire condition,
checking .
Checking tire wear pattern, 01-4, Checking tire wear
pattern .
Depth of tire tread (including spare wheel): Checking,
01-4, Depth of tire tread (including spare wheel), check .
General notes, 01-4, General notes .
Check tire inflation pressure using tire inflation device VAS
5216 and correct it if necessary, Rabbit/GTI 2006 ,
01-4, Tire pressures, Rabbit/GTI 2006 .
S
p
ecial tools, testers and auxiliar
y
items re
q
uired
Tire filling unit VAS 5216
Tire condition, checking
Warning!
If damage is discovered, the tire must be examined to
determine whether a new one must be installed.
Tests durin
g
deliver
y
ins
p
ection:
- Check tires (tread and side walls) for damage and
remove foreign material for example nails and glass
splinters if necessary.
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tion of work
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art 1 of 2
)

Tests durin
g
ins
p
ection service
- Check tires (tread and side walls) for damage and
remove foreign material for example nails and glass
splinters if necessary.
- Check tires for scuffing, one sided wear, porous side
walls, cuts and fractures.
Checking tire wear pattern
The wear pattern of the front wheels can be used to assess
whether a check of the track and camber is necessary:
Feathered edges of the treads may indicate faulty
toe adjustment.
One-sided tread wear is mainly attributed to
incorrect camber.
When wear of this nature is noticed determine cause by
performing alignment checks (repair measure).
Depth of tire tread (including spare wheel), check
- Check tire tread depth
Minimum depth: 1.6 mm
Note:
This value may vary for individual countries due to
different legislative regulations.
The minimum tread depth is reached when the tires
have worn down level with the 1.6 mm high tread
wear indicators - arrows - positioned at intervals
around the tire.
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)

If the tread depth is approaching the legal minimum
permissible depth, the customer must be informed.
General notes
Warning!
For reasons of safety only tires of same type and
tread pattern should be fitted on a vehicle!
Note:
Tire inflation pressure table applies to normal tires,
for all tire sizes installed at factory.
Observe that the inflation pressure specifications
refer to the air pressure of cold tires. Do not reduce
increased pressures on warm tires.
Tires pressures for the relevant model are on a
sticker attached to the inside of fuel tank flap.
Adapt tire pressure corresponding to load.
The spare wheel receives the highest tire pressure
designated for the vehicle.
Note that a basic setting should be performed after
every change in pressure in vehicles with tire
pressure control indicator 01-5, Tire pressure
control indicator, performing basic setting .
Winter tires
Note:
Important information on the recommended winter
tires can be found in
.
Repair Manual, Suspension, Wheels, Brakes, Steering ,
Repair Group 00, Wheels and Tires Guide
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tion of work
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art 1 of 2
)

For winter tires, tire inflation pressure must be
increased approx. 0.2 bar.
Tire pressures, Rabbit/GTI 2006
Gasoline en
g
ine
Displacement / output
2.0L / 147 kW
Tire sizes half load full load
front (bar) rear (bar) front (bar) rear (bar)
205/55 R 16 91 W 2.4 2.4 2.6 3.0
225/45 R 17 91 W, Y 2.4 2.4 2.6 3.0
225/40 R 18 92 Y (XL) 2.4 2.4 2.6 3.0
Spare wheel (collapsible spare wheel)
4.2 4.2 4.2 4.2
Brake and clutch s
y
stems, chan
g
in
g
fluid
Notes on application and safety, 01-4, Notes on
application and safety precaution .
Specification of brake fluid, 01-4, Specification of brake
fluid .
Work procedure, changing brake fluid, 01-4, Work
procedure, changing brake fluid .
Notes on application and safety precaution
Note:
From model year 2006, a new brake fluid is
introduced.
The new brake fluid can also be used for older
vehicles.
New brake fluid can be mixed with previous brake
fluid.
For vehicles from model year 2006, "only" new brake
fluid must be used.
Warnin
g!
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art 1 of 2
)

Brake fluid must never come into contact with
fluids containing mineral oils (oil, gas, cleaning
solutions). Oils containing minerals damage
seals and sleeves on brake systems.
Brake fluid is poisonous. Due to its caustic
nature, it must also never be brought into
contact with paint.
Brake fluid is hygroscopic, which means that it
absorbs moisture from the air. Always store
brake fluid in air-tight containers.
Wash off brake fluid spillage using plenty of
water.
Do not reuse, (used) extracted brake fluid.
Observe waste disposal regulations!
Specification of brake fluid
Permissible specifications of brake fluid for vehicles
u
p
to model
y
ear 2005:
Brake fluid corresponding to US standard FMVSS
116 DOT 4 (previous brake fluid).
Brake fluid corresponding to VW standard, VW 501
14 (new brake fluid).
Permissible specifications of brake fluid for vehicles
from model
y
ear 2006:
Brake fluid corresponding to VW standard, VW 501
14 (new brake fluid).
Work procedure, changing brake fluid
S
p
ecial tools, testers and auxiliar
y
items re
q
uired
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tion of work
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art 1 of 2
)

Brake charger/bleeder unit VAS 5234
Brake pedal depressor V.A.G 1869/2
- Unscrew brake fluid reservoir cap -1-.
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tion of work
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art 1 of 2
)

- Extract as much brake fluid as possible using intake hose
Brake charger/bleeding unit VAS 5234 .
Note:
The strainer in the brake fluid reservoir must not be
removed.
Warning!
Extracted brake fluid must not be re
-
used
!
- Screw adapter - 1 - onto brake fluid reservoir.
Observe operating instructions for VAS 5234 !
- Install brake pedal depressor V.A.G 1869/2 between
drivers seat and brake pedal and apply tension.
- Connect charger hose of brake charger/bleeder unit VAS
5234 to adapter.
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p
tion of work
(p
art 1 of 2
)