Service TrainingSelf-study Programme 318The Golf 2004The Golf 2004 continues the success story of the Golf, which so far has been almost 30 years in the making. It stands out by virtue of its aesthetics and comfort, and through the use of modern technologies. The loving attention to detail, the spacious interior, the powerful and safetyconscious "inner values" under the bonnet and within the member structure set the Golf 2004 apart as a trendsetter.The product characteristics of the Golf 2004:● ● ● ● ● ● ● ●Dynamic, elegant design Excellent quality Superior handling dynamics Comprehensive safety Innovative drivetrain technology Efficient economy Spacious interior Target-group-oriented product rangeS318_032There are special Self-study Programmes on the following topics:● ● ● ●SSP 308: SSP 317: SSP 319: SSP 321:The Direct Shift Gearbox 02E The Electromechanical Power-Assisted Steering with Double Pinion The Golf 2004 - Electrical System The 2004 Golf Running GearNEWImportant NoteThis self-study programme shows the design and function of new developments! The contents will not be updated.For current inspection, adjustment and repair instructions, please refer to the relevant service literature.2ContentsBrief overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Occupant safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Engine gearbox combinations . . . . . . . . . . . . . . . . . 30Power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Power transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . 46Running gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Heating and air conditioning. . . . . . . . . . . . . . . . . . . 56Radio and navigation. . . . . . . . . . . . . . . . . . . . . . . . . 78Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .803Brief overviewThe Golf 2004The Golf 2004 sets new standards for the A-class in many areas, e.g.: design, handling dynamics, drivetrain technology, spaciousness, safety, quality.●High-end radio and sound system●Various stowage options, e.g. in the overhead console●Electromechanical power assisted steering●2.0 l/103 kW TDI engine with 4-valve technology●Clear glass headlights4The Golf 2004 stands for the group values... ...innovation, value retention and a partnership approach.●2C-Climatronic (2-zone air conditioning)●Rear lights with LED technologyFurther highlights:●Intelligent wiper system with "droplet wipe function": a repeat wipe cycle is executed five seconds after the last wipe-wash cycle Optional Coming Home and Leaving Home function Optional ParkPilot (rear distance warning)●●S318_0705Brief overviewTechnical dataThe figure shows the dimensions of the Golf 2004 as a 4-door saloon with front-wheel drive.2578 420414851539 17591528S318_056Dimensions and weightsLength Width Height Wheelbase Roof load Trailer load, braked Tank capacity 4204 mm 1759 mm 1485 mm 2578 mm 75 kg from 1200 to 1700 kg 55 l Front track width Rear track width Max. permissible weight Unladen weight Luggage capacity Coefficient drag value 1539 mm 1528 mm from 1740 to 2010 kg* from 1154 to 1431 kg* 350 l 0.32 cd *varies depending on model6Interior dimensions31246 85 7S318_059Dimensions1 Front headroom from 965 to 987 mm* from 978 to 979 mm* 1736 mm from 1390 to 1391 mm* from 1446 to 1448 mm* 6 Shoulder room rear 7 Elbow room rear 8 Luggage capacity with rear seat back folded forward from 1348 to 1386 mm* from 1437 to 1479 mm* 1305 l2 Headroom 2nd seat row 3 Cabin length 4 Shoulder room front 5 Elbow room front*varies depending on model7BodyThe body structureStatic and dynamic rigidity The Golf 2004 sets new standards for static and dynamic rigidity. However, this rigidity has not been achieved to the detriment of body weight, but by systematic application of lightweight design principles. This fact is reflected clearly in the vehicle's 'lightweight factor'.The lightweight factor L Formula: L= MRK CT . AMRK = bodyshell mass CT = torsional rigidity A = wheel contact surface As the formula shows, the lightweight factor is the ratio of vehicle mass to the product of vehicle size and rigidity. The lesser the vehicle's mass and the greater its size and rigidity in relation to this, the better. Therefore, the lower the value, the higher the lightweight factor L. The lightweight factor of the Golf has been improved continuously over generations. The 1974 Golf had a lightweight factor of L=6.2; in the 1998 Golf, it was L=4.0, and in the 2004 Golf it is now only L=2.5.S318_010 Key: red =side impact zone yellow =occupant cell blue =frame structure8B-pillarThe B-pillar The B-pillar has a 3-layered structure. By using hot formed panels, it provides a high degree of safety for the vehicle's occupants in the event of a side-impact collision.S318_066Outer body side panelInner body side panel (tailored blank)The hot formed panels Hot formed panels are used for the B-pillar and in the adjacent portion of the body in the direction of the A-pillar. These components derive their strength from specific heat treatment before and during the in-tool shaping process. Hot formed panels have a higher strength and lower weight than regular panels.Hot formed panelsS318_0999BodyThe add-on partsDeformable foamThe front bumper The risk of injury for pedestrians was reduced by integrating an elastic impact-absorbing element into the front bumper behind the front spoiler. This deformable foam element allows a defined compression of the front end in the event of a collision.S318_289S318_068The headlights The headlights on the Golf 2004 feature clear glass technology. The lamps are connected to the reflector by a "one-touch" fastener system. The turn signals are located below the dipped and main beam headlights in order to improve visibility for other road users. In the Medium and High versions, a combination of the BiXenon module and a main beam reflector with H7 lamps is possible as an optional extra.10The exterior mirror LED turn signals are integrated in the exterior mirrors.S318_151The rear lights The 2004 Golf has two-part rear lights.S318_259The doors concept A completely new doors concept based on a door outer panel with mounting rails and a door inner section will be introduced to the Golf.S318_06211BodyThe glazingThe windows on the Golf are in green-tinted glass, and will also be available in blue-tinted glass at a later date. Deep tinted glass on the windows behind the B-pillar is optional. The thickness of the window glass corresponds to its function: the windscreen is 4.4 mm thick, the front side windows are 3.5 mm thick and the other windows are 3.15 mm thick. All fixed windows are bonded directly.The windscreen The windscreen is also available with an infrared-reflective metal vapour deposition coating. This metal vapour deposition coating reflects to a large extent the infrared portion (heat radiation component) of the sunlight, whereas conventional heat reflective glass shields only a far smaller proportion of the solar radiation by absorption.Sealing lipCeramic coating as third sun visorCutout for the sensors (optional extras)Area Drip mouldingArea Drip moulding Windscreen stampS318_003Area below under the bonnet lidSash for plenum chamber coverCutout for plate with VINThe windscreen may only be set down on its side. Otherwise, the sash at the bottom and/or the sealing lip at the top can become damaged.12The rear window In the production process, windows are fitted with different types of aerial depending on model. As a replacement part, the rear window is basically fitted with Diversity aerials. If no Diversity system is being used in the vehicle, the unnecessary aerial terminal must be removed, otherwise rattling noises can occur. In the case of the Diversity aerial, there are two aerial terminals on the window. The signals are simultaneously relayed from these terminals to the radio and respectively to the Diversity switching box (with the radio navigation system MFD 2). Use of both aerial signals significantly reduces interference with reception.Aerial terminalHeater element with additional printed conductors for optimising the rear window aerialsAerial terminalS318_005Heater element terminal Wiper hole with sealHeater element terminalThe rear window may only be fitted if the rear lid has been installed and set. For detailed instructions for fitting the rear window, please refer to the current workshop manuals.13BodyThe bonnet lidThe bowden cable for opening the bonnet lid is located in an access-protected position in the engine compartment. There is a disconnection point behind the left headlight. This means that the bowden cable need no longer be removed from the vehicle interior, but can easily be disconnected to carry out work on the front end.S318_046Disconnection point closedS318_251Disconnection point openS318_253Bowden cable disconnectedS318_25514The rear lidThe rear lid has a new locking mechanism. The VW badge swivels upward under gentle pressure - which is applied to the top third of the badge with the thumb - to become a neat handle for opening the rear lid. After that, the badge glides gently backs into its original position by means of a silicone brake.S318_048S318_283After the body has been painted, the lock unit can be installed. It is functional straight away - without the need for adjustment work. To make this possible, a diecast zinc ring was beaded into the body.The emergency release mechanism There is a removable cover in the rear lid trim. After this cover has been removed, the locking linkage can be accessed to allow emergency release of the rear lid.15BodyThe new doors conceptThe doors in the Golf 2004 consist of a door outer panel with two mounting rails and a door inner section for mounting the fittings. The door outer panel is bonded onto the mounting rails. The mounting rails are in turn bolted onto the door inner section.Door inner sectionCover stripMounting railCover stripMounting rail Door outer panelS318_257Side impact barThis provides the following advantages: - The technology in the doors is easily accessed and checked after the door outer panel has been removed. - In the event of damage, the door outer panel can be separately detached for removing dents or for replacement purposes.16The mounting rails The door outer panel is made for accurate fit and is bonded once only onto mounting rails, which are bolted into the door inner section.S318_203Mounting rails Door outer panelThe door fittings Detaching the door outer panel provides easy access to the side impact bars, the door handle bearing bracket, the door lock and the side airbag crash sensor, as well as the window regulator module on the door inner section.Bearing bracket for door handleDoor lock Window regulator module Side impact barsS318_205Side airbag crash sensor, driver side G17917BodyThe door assembly The door inner section serves as the supporting structure. The mounting rails are bolted onto the door inner section along the two vertical edges beneath the top shoulder. The door outer panel is bonded onto the mounting rails. For this purpose, the door outer panel must firstly be adapted "dry" to the mounting rails installed in the door inner section using spacer elements and wedges. The door outer panel is aligned along the x-axis using the spacer elements and along the z-axis using the spacer wedges. Fixing stops are used to fit the panels along the y-axis. The shut line is set using pins attached to the spacer elements.S318_223The door outer panel is aligned along the x-axis using the spacer element.x-axisDoor outer panel Spacer elementS318_245S318_221For detailed instructions for assembling the door, please refer to the current workshop manuals. The spacer elements, fixing stops and spacer wedges are supplied with tool no. T10237.18The adapted door outer panel is fixed in place using double-sided adhesive tape and the fixing stops. It can now be detached complete with the supports and stops. Adhesive can now be applied to the mounting rails, and the outer body panel can be securely bonded in place. In addition, the door outer panel and door inner section are bolted directly in the sill and top shoulder areas. If so required, the door outer panel can now be detached by unscrewing the mounting rails and undoing the direct bolted connection.Door outer panel Adhesive tape Fixing stopy-axisThe door outer panel is aligned along the y-axis by means of fixing stops.S318_225S318_247S318_249S318_227Door outer panel z-axisThe door outer panel is aligned along the z-axis using spacer wedges.Spacer wedge19BodyThe seat conceptThe front seats The front seats have as standard equipment an active head restraint system. A mechanical 2-way lumbar support or an electrical 4-way lumbar support and an under-seat drawer are available as optional equipment. The figure shows a seat with electrical 4-way lumbar support.Active head restraint system 4-way lumbar supportS318_060The front passenger seat has an optional through-loading facility. This allows long items of cargo to be transported easily using the full length of the vehicle interior. An Isofix anchoring is optionally available for the front passenger seat.S318_101The front seats in the 2-door version are equipped with the "Easy-Entry" system with manual memory function.S318_05720The rear bench seat The seat cushion is continuous across the width of the car. The backrest is split 60/40 and can be folded down. The backrests can be locked using a rotary latch lock. There is attached to the backrest a red indicator which signals the status of the backrests so it can be determined at first glance whether the backrests are locked or not.Red indicator: this seat is not locked.S318_207A through-loading facility is optionally available for the rear bench seat. The armrest and a flap located behind it can be folded forward to allow long items (e.g. skis, golf bag) to protrude from the luggage compartment.S318_209S318_211The load-through flap is locked.Red indicator: the load-through flap is not locked.21BodyThe stowage space conceptThere is a multiplicity of storage compartments and spaces in the interior of the Golf 2004.The front storage compartments/spaces Three compartments are provided as standard in the dash panel. If the vehicle is equipped with an air conditioning system, the storage compartment on the front passenger side is cooled.S318_103The storage compartments/spaces in the overhead console There is an open compartment in the overhead console of the Golf 2004. A spectacles compartment, as shown in the figure, is optionally available.S318_10522The storage compartments/spaces in the centre consoleIn the basic trim, there are two open compartments as well as a cup holder for the driver, front passenger and one rear passenger in the centre console.S318_089The Golf is optionally available with an airconditioned combi-box in the centre armrest, as well as foldaway cup holders for the rear seats.Rear centre ventS318_081Manually adjustable outletFold-up coverTemperature-controllable compartment in the centre armrest Folded-out cup holderS318_15523BodyThe storage compartments/spaces in the doors Located in the door panel trims are storage compartments, as well as a cup holder for 1.5 litre bottles.S318_135The stowage net on the rear shelf An optional extra is a stowage net which attaches to the underside of the rear shelf and in which small objects can be safely stowed away.S318_13324The storage compartments/spaces in the luggage compartment A sliding cover integrated in the side luggage compartment trim accommodates small objects. When the sliding cover is removed, items such as a golf bag can be easily stowed parallel to the rear bench seat.S318_239The storage compartments/spaces in the spare wheel well The Golf 2004 is optionally available with an emergency wheel or a full-size spare wheel. In those vehicles which are equipped with a full-size spare wheel, the cavities below the hub cap serve as additional stowage spaces.S318_10725Occupant safetyIntroductionFor protection of the occupants in the Golf 2004, the following components have been fitted. Standard equipment: driver and front passenger airbags, side airbags in the front seats, head airbags for cockpit and rear occupants, 3-point seat belts on all seats, belt tensioners and belt force limiters for the front seats, - active head restraint system on the front seats. Optional equipment: - side airbags for rear passengers in combination with belt tensioners and belt force limiters on the outer and rear seats (in the 4-door version). The figure shows a Golf 2004 with airbag and belt systems in full specification.Airbag control unit J234S318_153The new pressure sensors in the front doors register sudden changes in pressure caused by deformation during a sideimpact collision.S318_125In the front end of the vehicle there are two longitudinal acceleration sensors in the form of Early Crash Sensors which recognise an impact and its severity and transmit the data to the airbag control unit.At market launch, the Early Crash Sensors will only be available for the North American market.S318_07726The front airbags are designed for single-stage deployment. The front passenger airbag can be deactivated by means of a key switch in the storage compartment on the front passenger side. In the curtain airbags, which cover a window area extending from the A-pillar to the C-pillar, a gas distributor tube ensures uniform inflation of the airbags in the event of a crash.Isofix anchorages are located on the rear outer seats. An Isofix anchorage can be ordered for the front passenger seat as an optional extra.Head airbag with gas distributor tubeS318_153In the rear wheel housing trims there are lateral acceleration sensors which recognise a side-impact collision.Three-point seat belt with belt tensioner and belt force limiterThree-point seat belt with retractor in the backrest27Occupant safetyThe rear side airbagsIn the 4-door version, side airbags are optionally available for the outer rear seats. They are installed in the side bolsters. Rear side airbags will be introduced to this class for the first time in the 2004 Golf.Airbag moduleRear side cushionS318_016The beltsDriver seat belt in the B-pillar with belt guideThe driver and front passenger belts are equipped with electrically igniting pyrotechnical ball-type tensioners and belt force limiters. The belts for the front seats have belt guides for added comfort. In vehicles equipped with rear side airbags, the rear outer seats also have belt tensioners and belt force limiters. The retractors are attached to the bodyshell for enhanced comfort in the shoulder area. The rear centre seat has a three-point seat belt whose retractor is integrated in the bench seat backrest.S318_21328The side airbag crash sensor, driver side G179, The side airbag crash sensor, front passenger side G180For side impact detection, new pressure sensors are fitted in the place of the conventional acceleration sensors. These new sensors allow more rapid detection of side impacts in the door area.Sealing compoundBlankFunctionAir ducter elementThe side airbag crash sensors for the driver and front passenger sides are located in the front doors between the inner and outer body panels. They react to changes in pressure in the door cavity. The air is directed via an inflow duct to a plate. The components on the plate react to rapid changes in pressure of the kind which arise during a crash.ContactsS318_127HousingSignal application The sensor continuously measures the air pressure. If the sensor detects a rise in air pressure above a predetermined threshold value, it sends a signal to the airbag control unit.Effects of failure If the sensor fails, the airbag warning lamp in the dash panel insert will come on.29Engine-gearbox combinationsThe petrol enginesEngine 0AF 0AG 0A45-speed manual gearbox6-speed manual gearbox5-speed manual gearbox1.4 l/55 kW engine1.4 l/66 kW FSI engine1.6 l/75 kW engine1.6 l/85 kW FSI engine2.0 l/110 kW FSI engine3002S02Q09GDSG 02E6-speed manual gearbox6-speed manual gearbox6-speed automatic gearbox6-speed direct shift gearbox31Engine-gearbox combinationsThe diesel engines0AF 0AG 0A45-speed manual gearbox6-speed manual gearbox5-speed manual gearboxEngine1.9 l/77 kW TDI engine2.0 l/103 kW TDI engineThe 0AF, 0AG, 0A4, 02S and 02Q manual gearboxes are identical to the gearboxes from the Touran. They have been improved for the 2004 Golf in respect of their shift quality and adapted to the installation requirements.3202S02Q09GDSG 02E6-speed manual gearbox6-speed manual gearbox6-speed automatic gearbox6-speed direct shift gearbox33Power unitsThe 1.4 l/55 kW engine with 4-valve technologyThe 1.4 l/55 kW engine is the entry-level engine for the 2004 Golf. It has been adopted from the predecessor model and adapted to the space needs of the 2004 Golf.Special features● ● ● ● ● ●Air filter integrated in the engine cover Returnless fuel system Crankshaft sealing flange with new engine speed sender wheel Electrical exhaust gas recirculation valve Electronic throttle with contactless accelerator pedal position sender Contactless clutch position senderS318_159Technical dataEngine code Type Displacement [cm³] Bore [mm] Stroke [mm] Valves per cylinder Compression ratio Max. output Max. torque Engine management Fuel BCA 4-cylinder in-line engine 1390 76.5 75.6Torque and power development diagram220 200 180 160 Torque [Nm] 140 120 100 80 60 40 20 1000 3000 5000 Speed [rpm] 110 100 90 80 70 60 50 40 30 20 10 7000S318_20110.5:1 55 kW at 5000 rpm 126 Nm at 3800 rpm Bosch Motronic ME 7.5.10 95 RON unleaded fuel (91 RON unleaded fuel can be used alternatively with a slight reduction in performance)Exhaust gas treatmentPre-catalytic converter, main catalytic converter, lambda controlEmissions standardEU 434Performance [kW]4The 1.4 l/66 kW FSI engine with 4-valve technologyThis 1.4 l/66 kW FSI engine is based on the 1.4 l/63 kW FSI engine in the Polo. It is a petrol direct injection engine with timing chain. Its power output has been increased from 63 kW to 66 kW.Special features● ● ● ● ● ● ● ●Timing chain driven camshaft Dual circuit cooling system Self-regulating oil pump Crankshaft sealing flange with integrated engine speed sender wheel Petrol direct injection engine MED 9.5.10 with twin injection Supply on demand fuel system Accelerator pedal module with contactless accelerator pedal position senders Contactless clutch position senderS318_027Technical dataEngine code Type Displacement [cm³] Bore [mm] Stroke [mm] Valves per cylinder Compression ratio Max. output Max. torque Engine management Fuel BKG 4-cylinder in-line engine 1390 76.5 75.6Torque and power development diagram220 200 180 160 Torque [Nm] 140 120 100 80 60 40 20 1000 3000 5000 Speed [rpm] 110 100 90 80 70 60 50 40 30 20 10 7000S318_22912:1 66 kW at 5250 rpm 130 Nm at 3750 rpm Bosch Motronic MED 9.5.10 95 RON unleaded fuel (91 RON unleaded fuel can be used alternatively with a slight reduction in performance)Exhaust gas treatmentPre-catalytic converter, NOx storage-type catalytic converter, lambda controlEmissions standardEU 4Performance [kW]435Power unitsThe 1.6 l/75 kW engine with 2-valve technologyThe 1.6 l/75 kW engine is based on the conventional 1.6 l/75 kW engine from the predecessor Golf with engine code BFQ. In the predecessor Golf, however, the engine was available only in combination with automatic transmission.Special features● ● ● ● ●2-valve roller rocker finger Aluminium engine block Secondary air system Plastic active intake manifold Pressure sensor guided system (previously HFM, hot-film air mass meter)S318_040Technical dataEngine code Type Displacement Bore Stroke Valves per cylinder Compression ratio Max. output Max. torque Engine management Fuel BGU 4-cylinder in-line engine 1595 cm3 81 mm 77.4 mmTorque and power development diagram220 200 180 160 Torque [Nm] 140 120 100 80 60 40 20 1000 3000 5000 Speed [rpm] 110 100 90 80 70 60 50 40 30 20 10 7000 Performance [kW]2 10.5:1 75 kW at 5600 rpm 148 Nm at 3800 rpm Simos 7.1 95 RON unleaded fuel (91 RON unleaded fuel can be used alternatively with a slight reduction in performance)Exhaust gas treatmentPre-catalytic converter probe: linear lambda probe, probe after catalytic converter: nonlinear probeEmissions standardEU 4 S318_23536The 2.0 l/110 kW FSI engine with 4-valve technologyThe 2.0 l/110 kW FSI engine was introduced to the Audi A3 in February 2003. Volkswagen will deploy the engine in the Touran for the first time in October, and thereafter in the Golf in early 2004.Special features● ●● ● ● ● ●Single-piston high-pressure pump Plastic active intake manifold with change-over barrel for homogeneous and heterogeneous charge operation Water-cooled exhaust gas recirculation valve Roller rocker finger with hydraulic support element Two overhead camshafts with continuous inlet camshaft timing adjustment Balancer shaft gear assembly in the oil sump Air-guided combustion processS318_028For further information on the engine, please refer to SSP 322 "The 2.0 l/110 kW Petrol Direct Injection Engine".Technical dataEngine code Type Displacement [mm³] Bore [mm] Stroke [mm] Valves per cylinder Compression ratio Max. output Max. torque Engine management Fuel AXW 4-cylinder in-line engine 1984 82.5 92.8Torque and power development diagram220 200 180 160 Torque [Nm] 140 120 100 80 60 40 20 1000 3000 5000 Speed [rpm] 110 100 90 80 70 60 50 40 30 20 10 7000 Performance [kW]4 11.5:1 110 kW at 6000 rpm 200 Nm at 3500 rpm Bosch Motronic MED 9.5.10 98 RON unleaded fuel (95 RON unleaded fuel can be used alternatively with a slight reduction in performance)Exhaust gas treatmentNOx storage-type catalytic converter and two precatalytic convertersEmissions standardEU 4S318_23337Power unitsThe FSI functional diagram of the 2.0 l/110 kW engineIntake manifold Activated charcoal filter Tank breather valve N204 pressure sender G71 and intake air temperature sender G299Intake air temperature sender G42Throttle valve control unit J338 with throttle valve drive angle senders G187 and G188Motronic control unit J220 Exhaust gas recirculation valve N18 and exhaust gas recirculation potentiometer CAN bus G212Exhaust emissions warning lamp K83 Accelerator pedal module together Data bus diagnosis interface J533 Immobiliser control unit J334 with accelerator pedal position senders G79 and G185Electronic power control fault lamp K132S318_157EPCThe load sensing device utilises the following sensor signals: - ambient pressure (determined by an altitude sender installed in the engine control unit), - intake air temperature (determined by the intake air temperature sender G42 installed upstream of the throttle valve), - throttle valve position,38Single-piston high-pressure pumpFuel pressure sender G247 (high pressure)Inlet camshaft timing adjustment valve N205Fuel pressure sender: low pressure G410Ignition coils 1-4 N70, N127, N291, N292Hall sender G40 Injectors, cylinders 1-4 N30-33 Lambda probe G39 2xPre-catalyst converter 2x Intake manifold flap potentiometer G336 Knock sensors G61, G66Engine speed sender G28 Exhaust gas temperature sender G235 Lambda probe G130 2xCoolant temperature sender G62Fuel pump (presupply pump) G6Storage-type catalytic converter NOxNOx sender G295- pressure and temperature in the intake manifold (determined by the Duo sensor together with intake manifold pressure sender G71 and intake manifold temperature sensor G299), - flap position of exhaust gas recirculation valve N18, - position of the tumble flaps, - inlet camshaft position.39Power unitsThe 1.6 l/85 kW FSI engine with 4-valve technologyThis 1.6 l/85 kW FSI engine has already been introduced to the Touran. It is a petrol direct injection engine with camshaft timing chain.Special features● ● ● ● ● ● ● ● ●Timing chain driven camshaft Continuous variable valve timing Dual circuit cooling system Self-regulating oil pump Crankshaft sealing flange with new engine speed sender wheel Petrol direct injection MED 9.5.10 with twin injection Supply on demand fuel system Accelerator pedal module with contactless accelerator pedal position senders Contactless clutch position senderS318_023Technical dataEngine code Type Displacement [cm³] Bore [mm] Stroke [mm] Valves per cylinder Compression ratio Max. output Max. torque Engine management Fuel BAG 4-cylinder in-line engine 1598 76.5 86.9Torque and power development diagram220 200 180 160 Torque [Nm] 140 120 100 80 60 40 20 1000 3000 5000 Speed [rpm] 110 100 90 80 70 60 50 40 30 20 10 7000 Performance [kW]4 12:1 85 kW at 5800 rpm 155 Nm at 4000 rpm Bosch Motronic MED 9.5.10 98 RON unleaded fuel (95 RON unleaded fuel can be used alternatively with a slight reduction in performance)Exhaust gas treatmentPre-catalytic converter, NOx storage-type catalytic converter, lambda controlEmissions standardEU 4S318_23140The 1.9 l/77 kW TDI engine with 2-valve technologyThis TDI engine is a further development of the 1.9 l/74 kW TDI engine from the Polo. Special features: ● Switchable EGR cooler ● Crankshaft sealing flange with integrated engine speed sender wheel ● Accelerator pedal module with contactless accelerator pedal position senders ● Contactless clutch pedal switch.S318_033Technical dataEngine code Type Displacement Bore Stroke Valves per cylinder Compression ratio Max. output Max. torque Engine management Fuel Exhaust gas treatment Emissions standard BEZ 4-cylinder in-line engine 1896 cm3 79.5 mm 95.5 mm 2 19:1 77 kW at 4000 rpm 250 Nm at 1900 rpm Bosch EDC 16 Diesel, min. 49 CN or biodiesel Exhaust gas recirculation and oxidising catalytic converter EU4Torque and power development diagram400 320 Torque [Nm] 240 160 80 0 100 80 60 40 20 0 Performance [kW]1000 2000 3000 4000 Speed [rpm]S318_19741Power unitsThe 2.0 l/103 kW TDI engine with 4-valve technologyThis TDI engine is a further development of the 1.9 l/96 kW TDI engine. Special features: ● 4-valve technology ● Two camshafts, driven by toothed timing belts ● Increased engine displacement by means of greater cylinder bore ● New unit injectors adapted to the 4-valve technology ● Switchable EGR cooler ● Crankshaft sealing flange with integrated engine speed sender wheel ● Accelerator pedal module with contactless accelerator pedal position senders ● Contactless clutch pedal switch.S318_035For detailed information on 2.0 l/ 103 kW TDI engine please refer to SSP 316, "The 2.0 l TDI Engine".Technical dataEngine code Type Displacement Bore Stroke Valves per cylinder Compression ratio Max. output Max. torque Engine management Fuel Exhaust gas treatment Emissions standard BKD 4-cylinder in-line engine 1968 cm3Torque and power development diagram400 320 Torque [Nm] 240 160 80 0 1000 2000 3000 4000 Speed [rpm]S318_199100 80 60 40 20 0 Performance [kW]81 mm 95.5 mm 4 18:1 103 kW at 4000 rpm 320 Nm at 1750 rpm to 2500 rpm EDC 16 with pump injection system Diesel, at least 49 CN Exhaust gas recirculation and oxidising catalytic converter EU442The advantages of the 4-valve technology Larger inlet and exhaust cross-sections of the valves provide improved volumetric efficiency, as well as higher power output and torque. Wastage on load change is also reduced. The symmetrical layout of the valves and the vertical, centrally located unit injectors allow for good mixture formation. This leads to lower fuel consumption and exhaust gas emissions are reduced as a result.Vertically installed, centrally located Roller rocker arm for unit injector unit injector Inlet camshaftExhaust camshaftRoller rocker finger for valvesStub shafts Inlet portS318_029 Exhaust port Vertically installed valves43Power unitsThe crankshaft sealing flange with integrated engine speed sender wheelA crankshaft sealing flange with an integrated engine speed sender wheel will be used in the diesel engines. This system has already been tried and tested in several petrol engines. The engine speed sender wheel is the only new feature. The crankshaft sealing flange seals off the cylinder block on the flywheel end. The oil seal is made of heat-resistant and nonwearing polytetrafluoroethylene (PTFE) plastic. The engine speed sender is actually a Hall sender. It is mounted in the crankshaft sealing flange housing.Engine speed senderCrankshaft sealing flangeS318_051Engine speed sender wheelThe engine speed sender wheel consists of a steel ring coated with a rubber compound. This rubber compound contains a large number of metal chips which are alternately magnetised to become north and south pole regions. The diesel engines have two large north poles (60-2-2) and the petrol engines have one large north pole (60-2) on the sender wheel; they serve as reference marks for the engine speed sender. The sender wheel is press-fitted onto the crankshaft flange and exactly positioned.S318_049North pole South pole44The pedal clusterThe pedal assembly in the 2004 Golf comprises separately pre-assembled accelerator, brake and clutch control modules. The brake pedal module is made of aluminium and sheet steel. The accelerator pedal and the clutch pedal module are made of plastic. Pedal position recognition is by contactless senders.Brake pedal module Clutch pedal moduleAccelerator pedal moduleS318_038Clutch position sender G476Accelerator pedal position sender G79 and G185Accelerator pedal position sender G79 and G185 Metal plate Accelerator pedalMaster cylinderClutch pedalClutch position sender G476S318_064 S318_054The clutch position sender is a Hall sensor, which signals to the engine control unit that the clutch pedal has been operated. The cruise control system will then be deactivated and the injection quantity in the engines will briefly be reduced in order to prevent engine shudder during the gear change.The two accelerator position senders G79 and G185 are integrated in the upright accelerator pedal module. They are inductive senders, which indicate the exact position of the accelerator pedal the engine control unit. From this data, the engine control unit computes the required injection quantity.For further information on the design and function of the contactless senders, please refer to SSP 316 "2.0l TDI engine with 4-valve Technology" and SSP 321 "The 2004 Golf Running Gear". 45Power transmissionThe 6-speed direct shift gearbox 02EThe 6-speed Direct Shift Gearbox (DSG) combines the advantages of a manual gearbox:● ●high efficiency, as well as robustness and sportinessDSG also provides pure driving enjoyment for manual gearbox drivers by allowing the driver to actively influence the choice of gears and gearshifts and with its lightning-fast, jolt-free gearshifts. At the same time, it surpasses manual gearboxes in terms of fuel economy. The gearbox is distinguished by:with those of an automatic gearbox:●a high level of comfort, particularly when changing gears.DSG meets the high standards of comfort expected by automatic gearbox drivers thanks to its design, which comprises two multi-plate clutches and various automatic shift programs.- Six forward gears and one reverse gear - Normal gearbox program "D", Sport gearbox program "S" as well as Tiptronic selector lever and steering wheel switches, - Mechatronics: electronic and hydraulic control units form a single unit and are accommodated in the gearbox, - Oil cooler and compressed air filter on the gearbox - Maximum torque 350 Nm.Compressed air filter Oil coolerMechatronicsMulti-plate clutchesS318_00246Design of the gearboxThe direct shift gearbox basically consists of two independent part-gearboxes. Each part-gearbox is built to function like a manual gearbox. Each part-gearbox has a dedicated multi-plate clutch. Both multi-plate clutches run in DSG oil and are controlled, opened and closed by the mechatronics, depending on the gear to be selected.Gears 1, 3, 5 and reverse are selected via multi-plate clutch K1. Gears 2, 4 and 6 are selected via multi-plate clutch K2. The figure below shows the principle of the direct shift gearbox.Part-gearbox 2Multi-plate clutch K2 Differential Engine torqueOutput gear Multi-plate clutch K1S318_075Part-gearbox 1Both part-gearboxes transmit the engine's torque to a common output gear, which in turn transfers the torque to the differential.47Power transmissionFunctions of the gearboxKickdown control The kickdown function is activated by the fully depressed accelerator pedal. This information is sent via the CAN data bus to the engine control unit and to the mechatronics. The mechatronics then select the "S" programme for maximum acceleration.Creep control The creep control system enables driving manoeuvres to be executed without use of the accelerator pedal (e.g. parking). If the engine is idling and a drive program is selected, the creep control system triggers the production of a defined amount of slip torque at the multi-plate clutch, which causes the vehicle to move very slowly (creep). A further function of the creep control system is initiated when the vehicle is stationary with the brake applied (e.g. when waiting at a red traffic light). In this case, the multi-plate clutch is opened still further, thus reducing the vehicle's tendency to creep. This has the effect of improving fuel efficiency.Hillholder function If the vehicle rolls back when stationary on a hill with the brake only slightly depressed, the mechatronics increases the pressure in the multi-plate clutch. As a result, the vehicle is held securely in place on the hill.For further information on the direct shift gearbox 02E, please refer to SSP 308 "The direct shift gearbox 02E".48The 6-speed automatic gearbox 09GThe 6-speed automatic gearbox 09G is a compact, lightweight, electronically controlled gearbox for transverse installation. The electro-hydraulic system is based on the 6-speed automatic gearbox 09D.Features of the gearbox are:S318_024-Max. torque of 310 Nm 84 kg in weight Approx. 350 mm in length Torque converter with torque converter lockup clutch - Automatic and Tiptronic operationThe six forward gears and the reverse gear have a simple planetary gear set with a double Ravigneaux planetary gear set. The planetary gear sets are arranged according to the Lepelletier principle.The automatic gearbox control unit controls pressure build-up in the multi-plate clutches and plate brakes via modulating valves. The modulating valves allow a delayed pressure build-up. The result is fast gearbox response and jolt-free gearshifts.49Running gearThe running gearOnce again, the running gear of the 2004 Golf sets new standards in its class. Use has been made of a strut front axle which has in many respects been perfectly optimized. In respect of handling dynamics and driving comfort, the perfectly balanced new four link rear axle points the way to the future. The electromechanical power assisted steering in the Golf provides handling assistance par excellence. It conveys a precise steering feel and harmoniously adapts the steering effort with increasing vehicle speed. In addition to the Golf, the Touran and the Audi A3 currently utilise this running gear platform.●Floor mounted accelerator pedal with contactless accelerator pedal position senders●Optimised suspension-strut-type axle according to the McPherson principle●Direct anti-roll bar connection with a ratio of 1:1●Electromechanical power assisted steering●Brake servo with dual rate characteristic●Electronic stabilisation program based on the MK 60 system by Continental Teves50The Golf can be equipped with a standard running gear, sports running gear or heavy-duty running gear. The running gear packages are distinguished in terms of their springs, dampers, anti-roll bars and the bearing elements. The sports running gear has been lowered 15 mm compared to the responsive and yet comfort-oriented standard running gear. The heavy-duty running gear has been lifted 20 mm compared to the standard running gear.●Four link rear axle●4-motion drive, optional●Tyre pressure monitoring system, optional●Brake assist system●Separately adjustable rear suspension toe and camberS318_008For further information on the Running gear, please refer to SSP 321, "The 2004 Golf Running Gear".51Electrical systemFuse boxes and relay slots in vehicle's electrical systemFitting locations The electrical system of the 2004 Golf is configured decentrally and almost identical to that of the Touran, since both vehicles are based on the same platform. Due to different installation conditions, the fuse boxes and the relay slots are at different locations on board the vehicle. The adjacent diagram shows the various fitting locations.Electrics box on left in engine compartmentBack-up fuse box in the engine compartment on the leftFor further information on the electrical system, please refer to SSP 319 "The 2004 Golf Electrical System".52Relay carrier below the dash panel on the left, above the onboard power supply control unitS318_109Relay carrier in the onboard power supply control unit, below the dash panel on the leftFuse box in the dash panel on the left53Electrical systemThe networking conceptOverview of networked control units To allow data to be transferred between the control units, the control units are internetworked via various data bus systems. The data bus diagnostic interface J533 (gateway) forms the interface to the data bus systems: Drivetrain CAN data bus Convenience CAN data bus Infotainment CAN data bus Combi CAN data bus Diagnosis CAN data busJ533 J334 J285 J220 T16 NOxJ431J503 RJ345J608Control units connected to: Drivetrain CAN data busJ412 J519Convenience CAN data bus Infotainment CAN data busJ525 G397 J255CAN data bus sensor LIN data bus CAN data bus line (high speed and low speed) Communications line LIN data bus lineJ364R78J136J604G273In addition to the CAN data bus, a number of electric components are networked via the LIN data bus.* only with direct shift gearbox54Key:G419D E221 G85 G273 G384 G397 G419 H8 J104 J136 J217 J220 J234 J255 J285 J334 J345 J364 J386 J387 J388 J389 J393 J400 J412 J431 J446 J500 J503 J519 J525 J527 J533 J587 J604 J608 J743* NOx R R78 T16 Ignition/starter switch Operating unit in steering wheel (multi-function steering wheel) Steering angle sender Rear left interior locking switch Vehicle inclination sender Rain and light detector sensor ESP sensor unit Anti-theft alarm system horn ABS with EDL control unit Seat and steering column adjustment control unit with memory Automatic gearbox control unit Motronic control unit Airbag control unit Climatronic control unit (and Climatic) Control unit with display in dash panel insert Immobiliser control unit Trailer detection control unit Additional heater control unit Door control unit, driver side Door control unit, front passenger side Door control unit, rear left Door control unit, rear right Convenience system central control unit Wiper motor control unit Mobile telephone operator electronics control unit Headlight range control, control unit Parking aid control unit Power steering control unit Control unit with display for radio and navigation Onboard power supply control unit Digital sound package control unit Steering column electronics control unit Data bus diagnosis interface Selector lever sensors control unit* Auxiliary air heater control unit Special vehicle control unit Mechatronics for direct shift gearbox NOx sensor radio TV tuner Diagnostic connectionJ743*J217J104J587*J500J234G85E221 D J446J527J400J386J387J393J388J389S318_093H8G384The data protocols have been changed. As a result, the control units cannot be replaced with control units from other vehicle types, e.g. Touareg or Phaeton. 55Heating and air conditioningIntroductionThe 2004 Golf will be equipped with the heating and air conditioning system concept that has already been introduced to the Touran. It comprises three variants: - The 2C-Climatronic heating and air conditioning system (2C = "2 Corner" = zones) - The Climatic heating and air conditioning system - The manual heating and ventilation system.Each variant has a separate operating unit. All operating units are available in four different versions, depending on the vehicle's equipment specification: - with or without instant heat button for auxiliary water heater, - with or without seat heating potentiometer.As usual, all operating elements which are relevant to temperature and ventilation as well as the control unit are combined in the operating units. New are the feedback LEDs on all buttons; they provide the occupants with an overview of all active functions. In the case of the 2C-Climatronic and Climatic systems, an unventilated interior temperature sensor is attached to the operating unit already known from other models. The figure below shows by way of example the operating unit of the 2C-Climatronic system.Driver side seat heating potentiometerFront passenger side seat heating potentiometerFeedback LEDsUnventilated interior temperature sensorS318_073Instant heat button for auxiliary water heater56In the case of the Climatic operating unit, the button "AC" has been renamed "ECON".Unventilated interior temperature sensorFeedback LEDS318_097"AC" has been renamed "ECON".Instant heat button for additional water heaterThe cooling function is deactivated by pressing the "ECON" button; on diesel models, the electrical auxiliary air heater is also deactivated this way.The floating-mounted operating units The operating units are floating-mounted, i.e. they are mounted non-rigidly in the instrument panel and are centred automatically by the trim panel when it is fitted. This ensures uniform shut lines.S318_079Float-mounting57Heating and air conditioningFunctions of the systems in overviewComponentsPollen filter2C-ClimatronicClimaticHeating/ventilationPollen filter with activated charcoal Air recirculation flap with control motor Air flow flap with control motor Temperature flapTwo flaps actuated by control motors actuated by control motor actuated by control motor left and right left one flap actuated by control motor one flap actuated by bowden cableCentral dash panel/footwell flap Defrost flap Left vent temperature sender G150 Right vent temperature sender G151 Vent temperature sender, left footwell G261 Vent temperature sender, right footwell G262 Fresh air intake duct temperature sensor G89 Evaporator out-flow temperature sender G263 High pressure sender G65 Fresh air blower V2 Sunlight penetration photo sensor G134 Unventilated interior temperature sensor Electrical auxiliary air heater* Air recirculation modeactuated by flexible shaftactuated by flexible shaftleft and rightleftwith electronic controlwith Series resistorby pressing the air recirculation buttonwhen driving in reverse in wipe-wash mode of the windscreen washer system= available = not available 58* with all diesel vehicles without additional water heaterThe air conditioner All variants are based on the same basic air conditioner. The fundamental difference between the individual systems is the way in which the air distribution flaps are actuated. The 2C-Climatronic has an additional fresh air flow flap, which is closed at increasing speeds in excess of 100 kph. The result is a constant fresh air intake even at different vehicle speeds. The figure below shows by way of example the air conditioner of the 2C-Climatronic system.The heating and Climatic systems have a fresh air/air recirculating flap. The 2C-Climatronic has a fresh air/air flow flap as well as a separate air recirculating flap.Defroster flap Central flap (dash panel), footwell flaps not visible Vent temperature sender, left footwell G261Air flow flap control motor V71Fresh air/air flow flap Fresh air intake duct temperature sensor G89Defrost flap control motor V107Recirculated air flapAir recirculation flap control motor V154Temperature flap control motor, left V158 Central flap control motor V70 (dash panel/footwell)Vent temperature sender, right footwell G262Temperature flap control motor, right V159Evaporator out-flow temperature sender G263Footwell vent, rear right Temperature flaps, left and right Footwell vent, rear left Rear centre vent (only with centre console with vent, otherwise dummy cover on air conditioner)S318_13159Heating and air conditioningThe air distribution The air distribution is almost identical in all variants and feature the following modifications: All air duct cross-sections have been enlarged compared to the predecessor model. The air duct to the defrost and dash panel vents runs through the dash panel. The front side windows are ventilated through new vents in the A-pillar. For ventilation in the rear passenger compartment, a single air duct leads to each of the left and right footwells. - In the case of the 2C-Climatronic, air ducts integrated in the dash panel lead to the vents on the upper side of the dash panel to provide indirect ventilation.S318_191indirect ventilationVents in the A-pillar Air duct only with centre rear footwell flapAir duct, rear left footwell ventS318_020Air duct, rear right footwell ventA centre console with vent can be ordered as an optional extra for the air conditioning systems and the heating and ventilation system. Air is ducted from the air conditioner to the centre vents along a common air duct. In vehicles without a vent in the centre console, the outlet on the air conditioner is sealed by a dummy cover.Air conditioning systemDummy coverS318_181Air duct, rear footwell vent60The refrigerant circuit The refrigerant circuit with expansion valve in the 2004 Golf is technically identical to the refrigerant circuit in other vehicles with an externally controlled compressor. The drier is bolted onto the capacitor, and an externally controlled compressor is used. The electronic high pressure sender G65 and the evaporator out-flow temperature sender G263 are installed for monitoring and control purposes.Those vehicles which are fitted with an air conditioner have as standard equipment a cooled storage compartment on the front passenger side. The storage compartment is cooled by cold air which is extracted directly at the outlet end of the evaporator and channeled to the storage compartment. Refrigeration output can be adjusted manually using an adjustable outlet.S318_004adjustable nozzleS318_006adjustable nozzleIf the vehicle has a centre console with rear vents, the storage compartment in the centre console also has a temperature control function. In this case, the air is extracted from the air duct leading to the centre console vent. Again, the air supply can be set manually with an adjustable nozzle.S318_14361Heating and air conditioningAir conditioning systemsThe 2C Climatronic Following in the footsteps of the Touran, the 2004 Golf will become the second vehicle in this vehicle class to be equipped with a 2-zone air conditioning system. This means that the temperature on the driver's and front passenger's sides can be set separately to between 16 °C and 29.5 °C. If the "Auto" button is pressed for longer than two seconds, the temperatures in both zones can be adjusted simultaneously from the driver's side. The division into two air-conditioning zones is achieved by using two temperature flaps within the air conditioner. In the case of the 2C-Climatronic, all air conditioner flaps are actuated by six control motors with integrated potentiometer. The 2C-Climatronic can be operated both automatically and manually.S318_036To prevent the windscreen from fogging, the 2C-Climatronic automatically increases the air flow to the windscreen if the compressor is deactivated and the windscreen wipers are activated. To this effect, the defrost flap is opened wider. The 2C-Climatronic also has a function which reduces the output of the fresh air blower depending on vehicle speed. To minimise the airflow noise of the air conditioner after wind and tyre noise have been eliminated, the fresh air blower voltage is adjusted as a function of road speed - without this being noticed by the vehicle occupants. Air distribution is thus reduced. When the cooling function is active, the system compensates for the reduction in air distribution by reducing the air outlet temperature and, if heating mode is active, by increasing the ventilation temperature.62The Climatic system For climate control, the interior of the vehicle is seen as one climate zone. The Climatic air conditioner has a combined fresh air recirculating flap which, like the temperature flap, is driven by a control motor. In the Climatic system, the air distribution flaps are actuated by a flexible shaft. The temperature request is transferred directly to the control unit by a potentiometer integrated in the rotary switch. The desired temperature is achieved by adjusting the temperature flap.S318_034Interface to the air conditionerThe operating units of the Climatic and the manual heating are divided into a rear mechanical part, which is connected to the flexible shaft, and a front electronic part. The heater is additionally attached by a bowden cable. The air conditioner is installed and removed according to the same procedure as in the Touran. In comparison with the Touran, the connection to the flexible shaft on the air conditioner has, for space reasons, been relocated from the left-hand side of the flaps to the right-hand side of the flaps. As a result, the intermediate part of the operating unit had to be adapted to the modified routing of the flexible shaft.Touran 2003:Air conditioner2004 Golf:Intermediate part Operating unitS318_183 S318_18563Heating and air conditioningOverview of the 2C-Climatronic/Climatic systemFresh air intake duct temperature sensor G89* Vent temperature sender, left footwell G261 Vent temperature sender, right footwell G262* Left vent temperature sender G150 Right vent temperature sender G151*High pressure sender G65Evaporator out-flow temperature sender G263Sunlight penetration photo sensor G134*Climatronic control unit J255Defroster flap control motor potentiometer G135* Air recirculation flap control motor potentiometer G143 Central flap control motor potentiometer G112* Air flow flap control motor potentiometer G113* Left temperature flap control motor potentiometer G220 Right temperature flap control motor potentiometer G221*Control unit with display unit in dash panel insert J285Combi CAN data busMotronic control unit J220Drivetrain CAN data bus64Defrost flap control motor V107* Air recirculation flap control motor V154 Temperature flap control motor, left V158 Temperature flap control motor, right V159* Central flap control motor V70* Air flow flap control motor V71*Air conditioning system compressor regulating valve N280Fresh air blower V2 with integrated fresh air blower controller (in the Climatic system, air flow is not controlled electronically, but through series resistors).Steering column electronics control unit J527Auxiliary air heater control unit J604** Convenience CAN data bus Onboard electrical supply control unit J519Infotainment CAN data busData bus diagnosis interface J533S318_083Additional heater control unit J364 (auxiliary water heater)* **only in combination with 2C-Climatronic only in combination with diesel engine with no auxiliary water heater65Heating and air conditioningFunction diagram - air conditioning systemsInput signal Output signal Positive Ground CAN data busG89*G261G262*G263G150G151*G134*J255V70*S318_115G112*V71*G113*V107*G135*Heated driver seat control unit J131 Heated front passenger seat control unit J132G89Fresh air intake duct temperature sensorJ255 Climatronic control unit V70 V71 Central flap control motor (dash panel/footwell) Air flow flap control motor G112 Central flap control motor potentiometer G113 Air flow flap control motor potentiometer V107 Defroster flap control motor G135 Defroster flap control motor potentiometerG261 Vent temperature sender, left footwell G262 Vent temperature sender, right footwell G263 Evaporator out-flow temperature sender G150 Left vent temperature sender G151 Right vent temperature sender G134 Sunlight penetration photo sensor66Term. 75 Term. 30 Term. 15 Term. 31 J533Convenience CAN data bus N280 V2**G65S318_117Unventilated interior temperature sensorV154* **G143V158G220V159*G221*only in combination with 2C-Climatronic The V2 fresh air blower motor with electronic control is only fitted in combination with 2C-Climatronic. Climatic and the heater are controlled through series resistors.In the case of Climatic, the sensors and actuators have in part different designations. For details, please refer to the latest current flow diagrams. N280 Air conditioning system compressor regulating valve G65 V2 High pressure sender Fresh air blower V158 Temperature flap control motor, left G220 Left temperature flap control motor potentiometer V159 Temperature flap control motor, right G221 Right temperature flap control motor potentiometerJ533 Data bus diagnostic interface V154 Air recirculation flap control motor G143 Air recirculation flap control motor potentiometer67Heating and air conditioningThe heating and ventilation systemIn the case of the heating and ventilation system, the temperature is not controlled automatically. The two rotary knobs are only mechanically connected to the air conditioner: The rotary knob for temperature adjustment is connected by a Bowden cable and the rotary knob for air distribution is connected by a flexible shaft, like in the Climatic system. The fresh air recirculating flap is selected manually by a button and actuated by a control motor. All input and output signals are converted to analog signals. The heated rear window activation command is transmitted to the onboard power supply control unit, which switches the heated rear window on depending on the utilization factor of the vehicle electrical system. The feedback signal for activating the LED in the button is generated simultaneously. The process for the additional water heater is similar. The auxiliary water heater is activated by the instant heat button. When the auxiliary water heater starts to operate, the LED in the instant heat button is activated by the feedback signal.The heater and ventilation control unit has its own address word (7D), however it is not CAN-networked.Heater control unit J65Term. 30 Term. 31 Term. 15 Term. 58 d Term. 75 Convenience CAN data bus Onboard power supply control unit J519 and heated rear window Z1 Air recirculation flap control motor V113Auxiliary air heater control unit J604 Heated driver seat control unit J131 and heated front passenger seat control unit J132Fresh air blower V2 with series resistor N24 S318_121Auxiliary heater control unit J364 (auxiliary water heater)68SensorsThe unventilated interior temperature sensor Function The new unventilated interior temperature sensor replaces the dash panel temperature sensor G56 with ventilation motor. It is integrated in the operating unit together with the control unit. The new sensor measures the following values: - surface temperature, - unit temperature and - sunlight penetration. Construction The unventilated interior temperature sensor essentially consists of an "integrated thermo-optical sensor" - an NTC element in combination with a photodiode. This electronic component can measure the temperature and intensity of the solar radiation incident on its surface. As a result, the sensor is able to measure exactly the air temperature in the vehicle interior even if the sensor's surface has heated up considerably. The sensor signals are transmitted via signal lines to the control electronics of the Climatic or 2C-Climatronic. An intelligent software function of the control electronics then evaluates the sensor signals and regulates the temperature of the occupant cell.It has the following advantages over its predecessor: - it is less susceptible to soiling as the sensor housing is protected, so there is less interference with temperature regulation, - there are no components which rotate mechanically, so the sensor is more wearresistant, - there is no ventilation grille in the trim (design advantage), - lower costs.NTC element and photodiodeS318_237Further information: SSP 208 "Air Conditioners in the Motor Vehicle", SSP 271 "The Phaeton Heating and Air Conditioning System" SSP 301 "The Touareg heating/ air conditioning system".S318_141Signal line to the control unit69Heating and air conditioningActuatorsThe fresh air blower with integrated fresh air blower controller V2 In the case of the 2C-Climatronic, a fresh air blower with an integrated electronic control is installed. The fresh air blower is accessible from the front passenger footwell.Housing coverFresh air blower rotorElectronicsS318_195Activation of the fresh air blower controllerClimatronic control unit J255The fresh air blower with integrated electronic fresh air blower controller V2 is addressed by the air conditioner control unit via a pulse-width modulated signal (PWM) and can send back a diagnostic feedback signal. If, for example, a pulse is transmitted in the diagnostic feedback signal, this indicates to the air conditioner control unit that no fault is present. Two pulses signal that the current is limited; three pulses signal that the temperature is too high and can lead to a reduction in output or deactivation of the fresh air blower.Diagnosis PWM Term. 30 Term. 31 Fresh air blower V2 one pulse two pulses three pulses ti tpS318_165 S318_123ti = time segment of one pulse tp = time segment of one periodFor information on other actuators, please refer to SSP 208 "Air Conditioners in the Motor Vehicle", SSP 271 "The Phaeton Heating and Air Conditioning System" and SSP 301 "The Touareg - Heating/air-conditioning system". 70The electrical auxiliary air heaterAn electrical auxiliary air heater is installed in diesel vehicles. The electrical auxiliary air heater is a combination of a PTC heater element with an integrated control unit. It is installed downstream of the heat exchanger and provides additional heating of the vehicle interior after cold-starting the engine. The electrical auxiliary air heater directly heats the air which enters the vehicle interior. It acquires all information needed for operation via the convenience CAN data bus.In the "Heating" version, the heating request is issued via a separate signal line.Auxiliary air heater control unit J604The electrical auxiliary air heater is not installed if the vehicle has an additional water heater, as the latter is used to provide additional heating at low outside temperatures.Auxiliary heating heater element Z35S318_167Activation conditions The electrical auxiliary air heater is activated: - in the case of the 2C-Climatronic and Climatic: automatically via the CAN data bus; in the case of the heating system: if the occupants set the heating output to over 90% at the operating unit (analog signal), - if the water temperature is below 75°C, - if the engine speed is higher than 500 rpm, - if no load management system is active and - if the ECON button is not pressed.The importance of the load management system The onboard power supply control unit controls the load management system, which has a special part to play in operation of the electrical auxiliary air heater. It can deactivate the electrical auxiliary air heater partially or completely. The load management system's status is indicated in the data blocks of the electrical auxiliary air heater. Power output can be reduced in steps of 75%, 50% and 25%.71Heating and air conditioningFunction flowchart of the electrical auxiliary air heaterAuxiliary heating heater element Z35Auxiliary air heater control unit J604Terminal 31Terminal 30Analog signal in case of heating and ventilation system Electrical auxiliary air heaterOnboard electrical supply control unit J519- Deactivation of the auxiliary air heater via the load management system - Status of the auxiliary air heaterConvenience CAN data busClimatronic control unit J255 or air conditioning system control unit J301 (Climatic)- Heating request - Status of the auxiliary air heater - Fault status - Engine speed - Coolant temperature - Alternator utilisation factorData bus diagnostic interface J533Drivetrain CAN data bus Engine speed Coolant temperature Alternator utilisation factorS319_087Engine control unit J...72The auxiliary water heaterThere is a growing demand for engine-independent heaters. Whether in the summer or in the winter, customers seek a pleasant interior climate - without misted-up or iced-up windows. To meet these customer specifications, the Golf can be ordered with the Thermo Top V auxiliary water heater as optional equipment.S318_279Tasks of the auxiliary water heater The auxiliary water heater is used for the following tasks: - as an auxiliary heater for heating the vehicle interior and defrosting the vehicle's windows, - as an auxiliary ventilation system for lowering the interior temperature when the vehicle is parked in sunlight and - as an auxiliary heater for petrol and diesel engines. If a diesel vehicle is equipped with an auxiliary water