SERVICE VOLKSWAGEN E-GOLF 2019 Service Manual

WARNING
Failure to heed warning lights and instrument cluster text messages can cause the vehicle to break down in traffic and result in a collision and serious personal injury.
x Never ignore warning lights or text WARNINGS.
x Always stop the vehicle as soon as it is safe to do so.
WARNING
Driving with bad brakes can cause a collision and serious personal injury.
x If the brake warning light "2!+% or H does not go out, or lights up when driving, either the brake fluid level in the reservoir is too low or there is a fault in the brake system. Stop the
vehicle as soon as you can do so safely and get expert assistance ⇒ Brake fluid.
x If the brake warning light "2!+% or H lights up at the same time as the ABS warning light !"3 or J, the ABS may not be working properly. This could cause the rear wheels to lock up rela-tively quickly during braking. Rear wheel brake lock-up can cause loss of vehicle control.
x If you believe the vehicle is safe to drive, drive slowly and very carefully to the nearest authorized Volkswagen dealer, authorized Volkswagen Service Facility, or other qualified workshop and have the brake system inspected. Avoid sudden hard braking and steering.
x If the ABS indicator light !"3 or J does not go out, or if it lights up while driving, the ABS system is not working properly. The vehicle can then be stopped only with the standard brakes (without ABS). You will not have the protection ABS provides. Contact your author-ized Volkswagen dealer or an authorized Volkswagen Service Facility as soon as possible.
x If the brake pads are worn or you notice changes in the way the vehicle brakes, immedi-ately contact an authorized Volkswagen dealer or authorized Volkswagen Service Facility to have the brake pads checked and, if necessary, replaced.
NOTICE
Failure to heed warning lights or text WARNINGS can result in vehicle damage.
Warning messages when leaving the vehicle

mance by applying more pressure to the brake pedal. But, during the break-in period, the stopping distance for hard braking and emergency braking will be longer until the brakes are fully broken in. Avoid hard braking and situations that might require hard braking (such as following other vehicles too closely) – especially during the break-in period.
Brake pad wear depends mostly on operating conditions and the way the vehicle is driven. If you do a lot of city and short-distance driving and/or have a sporty driving style, you should have the brake pads checked by an authorized Volkswagen dealer or authorized Volkswagen Service Facility more often than the regular service intervals.
Wet brakes (for example, after driving through water or washing the vehicle or after heavy rainfall) will not brake as well. Stopping distances will be longer when brake discs are wet or, in winter, even icy. Wet or icy brakes must be dried as soon as possible by carefully applying the brakes a couple of times while traveling at a relatively high speed. Make sure nobody is behind you and that you do not endan-
ger yourself or others ⇒ .
Brakes coated with road salt also react slower and need longer stopping distances. If there is salt on the roads and you are not braking regularly, brake carefully and gently from time to time to remove any
salt coating from the brake discs and pads ⇒ .
Brake disc corrosion (rust) and dirt buildup on the brake pads are more likely to occur if the vehicle is not driven much or is driven only for short distances with little braking. If the brakes have not been used and there is some rust on the discs, clean the brake discs and pads once in a while by carefully braking a couple of times while driving at relatively high speed to help clean the brake discs and pads.
Make sure nobody is behind you and that you do not endanger yourself or others ⇒ .
Brake system malfunction
If you brake and find that the vehicle doesn't brake nearly as well as it used to (sudden increase in stopping distance), a brake circuit may have failed. The brake warning light H or "2!+% will light up and a message may appear in the instrument cluster display. If you believe the vehicle is safe to drive, immediately take it to the nearest authorized Volkswagen dealer or authorized Volkswagen Service Facility for repair. Drive slowly and very carefully, allow for the longer stopping distance, and be ready to push longer and harder on the brake pedal to slow the vehicle down.
Electro-mechanical brake booster
The electro-mechanical brake booster works only when the electric motor is activated. It increases the force on the brakes above and beyond the pressure put on the brake pedal by the driver.
If the electro-mechanical brake booster is not working, you will have to push the brake pedal harder to
make up for the lack of booster assistance and the resulting longer stopping distance ⇒ .
WARNING
New brake pads do not provide maximum braking performance.
x New brake pads do not have the best stopping power for the first 185 miles (300 km) and must be “broken in.” You can compensate for the slightly reduced braking force by putting more pressure on the brake pedal.
x Drive with extra care while the new brake pads are being broken in. This reduces the risk of collisions and serious personal injuries due to a loss of control over the vehicle.
x Never follow other vehicles too closely or put yourself into other situations that might require sudden, hard braking, especially when the brake pads have not been broken in.

WARNING
Overheated brakes will reduce the vehicle's stopping power and increase stopping distances considerably.
x When driving downhill, the brakes have to work especially hard and heat up quickly.
x Before driving downhill, especially on hills that are long or steep, always reduce speed and use the recuperation mode. This will let the vehicle use electric motor braking and re-duce the load on the brakes. Otherwise, the brake system could overheat and possibly fail. Only use the brakes when you need them to slow the vehicle down more or to stop.
x A damaged front bumper or a non-standard spoiler can reduce airflow to the brakes and make them overheat.
WARNING
Wet brakes or brakes coated with ice or road salt react slower and need longer stopping dis-tances.
x Carefully apply the brakes to test them.
x Always dry brakes and clean off ice and salt coatings with a few cautious brake applica-tions when visibility, weather, road and traffic conditions permit.
WARNING
Driving when the electro-mechanical brake booster is not working increases stopping dis-tances and can cause accidents and serious personal injuries.
x Never let the vehicle coast when the electric motor is switched off.
x If the electro-mechanical brake booster is not working, a lot more pedal force is needed to slow down and stop.
NOTICE
x Never “ride” the brakes by keeping your foot on the brake pedal when you do not want to brake. Constant pressure on the brake pedal can make the brakes overheat. Riding the brakes will substantially reduce braking performance, increase stopping distance, and can cause complete brake system failure.
x Before driving downhill, especially on hills that are long or steep, always reduce speed and use the recuperation mode. This will let the vehicle use electric motor braking and reduce the load on the brakes. Otherwise, the brake system could overheat and possibly fail. Only use the brakes when you need them to slow the vehicle down more or to stop.
When the front brakes are serviced, you should have the rear brake pads inspected at the same time. The wear of all brake pads should be visually checked regularly. The best way to check for brake pad wear is to have your authorized Volkswagen dealer or authorized Volkswagen Service Facility visually inspect the pads through the openings in the wheel rims or from underneath the vehicle. If necessary, the wheels can be taken off for a more thorough inspection.
Braking assistance systems

The brake fluid level drops slightly when the vehicle is being used as the brake pads wear and the brakes are automatically adjusted.
Changing brake fluid
Brake fluid must be changed according to the service schedule in your ⇒ Booklet Warranty and
Maintenance. Have the brake fluid checked by an authorized Volkswagen dealer or an authorized Volkswagen Service Facility. Refill only with new brake fluid that meets the standards listed above.
WARNING
Brake failure and reduced brake performance can be caused by not having enough brake fluid in the reservoir or by old or incorrect brake fluid.
x Check the brake system and brake fluid level regularly.
x Always change the brake fluid according to the service schedule in your
⇒ Booklet Warranty and Maintenance.
x Hard braking with old brake fluid may cause vapor lock. Vapor lock reduces braking per-formance, increases stopping distances and can even cause total brake failure.
x Always make sure that only the correct brake fluid is used. Only use brake fluid that ex-pressly conforms to VW Standard 501 14 or, if it is not available, only use a high-quality brake fluid that conforms to U.S. Standard FMVSS 116 DOT 4 requirements.
x Using another brake fluid, or one that is not of high quality, can impair the function of the brake system and reduce its effectiveness. If the container does not say that the brake fluid complies with VW Standard 501 14, or U.S. Standard FMVSS 116 DOT 4, do not use it.
x The brake fluid must be new.
WARNING
Brake fluid is poisonous.
x To reduce the risk of poisoning, never use food, beverage or other non-original containers to store brake fluid. Someone might be misled by the original label on the container, or by the shape of the container, and drink the brake fluid. This could occur even if you relabel the container as “brake fluid.”
x Only store brake fluid in the closed, original container and keep it out of the reach of chil-dren.
NOTICE
Brake fluid will damage vehicle paint, plastic parts, and tires. Wipe any brake fluid off vehicle paint and other vehicle parts immediately.
Brake fluid can pollute the environment. Brake fluid that has leaked out must be collected and disposed of properly, following all applicable environmental regulations.

DANGER
High-voltage systems in the electric motor compartment and in other places on the vehicle can cause electrical shocks or even electrocution, severe burns, other serious injuries, and even death!
x Always assume that the high-voltage battery is fully charged and that all high-voltage components are live.
x Touching damaged orange high-voltage cables, the high-voltage battery or other parts of the high-voltage electrical system can cause fatal electric shock.
x The high-voltage system may also be active even when the ignition is switched off!
x Electrolyte fluid in the high-voltage battery will cause severe chemical burns. If electrolyte fluid contacts skin, thoroughly flush affected area with clean water for at least 15 minutes and then wash affected area with soap and water; medical attention is recommended.
x Never attempt to carry out any work on the high-voltage network, the high-voltage cables or the high-voltage battery.
x Never open, maintain or repair components or parts of the high-voltage network, and nev-er disconnect them from the network.
x Never damage, change or remove the orange high-voltage cables or disconnect them from the high-voltage network.
x Never open, modify or remove the cover of the high-voltage battery.
x Any work on the high-voltage system, or on systems which could be indirectly affected by it, must only be carried out by properly trained and qualified experts.
x Work in the vicinity of high-voltage components and high-voltage cables with machinery, sharp-edged tools or heat sources, for example, welding, soldering, hot air or thermal adhe-sives, may only be performed after the high-voltage components have been disconnected. Only properly qualified and trained specialist staff may work on the high voltage compo-nents.
x The Volkswagen standards and guidelines must be adhered to when carrying out any work on the high-voltage network or the high-voltage battery.
x During such work, keep the vehicle key safe and far enough away from the vehicle to pre-vent any risk of the ignition being accidentally switched on and the electrical system activat-ed (particularly in vehicles with Keyless Access).
x Any gasses emitted by or escaping from the high-voltage battery may be toxic or flamma-ble.
x Damage to the vehicle or to the high-voltage battery could lead to a leak of toxic gases, either immediately or at a later time. These emitted gases could also potentially cause a fire. If damage has been incurred, it is vital to then open the vehicle windows to allow any emitted gases to disperse. Do not inhale these gases.
x Never touch or inhale any liquids or gasses leaking from the high-voltage battery, espe-cially if the battery has been damaged.
x Remember to inform any attending emergency services that the vehicle is equipped with a high-voltage battery.
Warning and indicator lights

The vehicle’s high-voltage battery is included in the New Vehicle Limited Warranty. The terms and
conditions of this warranty can be found in the Warranty & Maintenance booklet ⇒ Chapter Warranty
and Maintenance.
All batteries age with use and over time. There are things you should know about the care of the high voltage battery that will help it keep giving you good service and reliability over time. Please read and keep the following information in mind while you enjoy the performance and economy of your vehicle.
x Be sure to charge the high voltage battery before leaving the vehicle parked and unused for a longer period of time. Ideally the high-voltage battery should have a charge level between 40 % and 60 % when parked for a long time.
x If the battery charge level is below 3%, never park the vehicle for more than 21 days without charg-ing the high-voltage battery. The

the battery fluid coming in contact with skin and eyes. If skin or eyes come into contact with bat-tery fluid, rinse the affected areas with clean flowing water for at least 15 minutes and see a doctor immediately.
(3) The high-voltage battery can burn. The high-voltage battery should never be exposed to fire, sparks or naked flames. Always handle the high-voltage battery with care to prevent damage and fluid leaks.
(4) Always keep children away from the high-voltage battery.
(5) You will find further information and warnings in the Owner's Manual and in the workshop manual.
(6) Never remove the cover from the high-voltage battery nor disassemble the high-voltage battery.
(7) Have maintenance work on the high-voltage battery performed only by properly qualified and
trained specialist staff ⇒ . Never make try to modify the high-voltage battery. The opened high-voltage battery should not come into contact with water or other liquids. Liquids can cause short-circuits, electric shocks and burns.
WARNING
Working on the high-voltage battery can cause severe chemical burns, explosions or life-endangering electric shocks.
x Any necessary work should only be carried out by an authorized Volkswagen dealer or an authorized Volkswagen Service Facility .
WARNING
Damage to the high-voltage battery can cause liquids and gases to leak. Harmful substances can then leak and cause injuries. The emitted gases could also potentially cause a fire.
x Do not touch any fluid that leaks out from the high-voltage battery as it can cause chemi-cal burns.
x Call the fire department in the event of a fire. Inform the fire department that the vehicle has an electric drive and high-voltage components.
x Leave the hazard area.
x If you think that the high-voltage battery has been damaged, have the high-voltage battery checked by properly qualified and trained specialist staff.
Charge level display

Fig. 133 In the instrument cluster: Charge level display for high-voltage battery

Charging at J1772 public AC charging stations or with the Wallbox (AC charging)
Charging the high-voltage battery at an AC charging station or with the Wallbox: The high-voltage battery is charged at a rate of up to 7.2 kW. The charging process for a completely discharged high-voltage battery lasts about 4 hours.
The charging connector has to be connected to the upper part of the charging socket (3). Leave the lower part covered.
The Wallbox is available as an accessory. An authorized Volkswagen dealer can provide you with information on the Wallbox.
Make sure that the Wallbox is installed by a qualified expert and that your house’s electrical system is also checked before installation.
It is not possible to feed energy back into the power grid.
Supplementary charging cable
Connect the charging connector on the supplied charging cable to a properly functioning 110 Volt Ground Fault Circuit (GFI) outlet with a 15 amp fuse. The outlet must be properly protected from
water, moisture, and other fluids ⇒ 
Charging for the first time and charging after long standing periods
If the high-voltage battery is charged for the first time or charged after the vehicle has been standing for a long period, it is possible that the maximum charging level of the high-voltage battery cannot be reached. This is for technical reasons and does not necessarily mean a vehicle malfunction. If the maximum charge level is not reached even after several charging procedures, have the high-voltage battery checked by an authorized Volkswagen dealer or authorized Volkswagen service facility.
If the vehicle is not used for a long period, the high-voltage battery must be charged after 4 months at
the latest ⇒ .
WARNING
If you are not familiar with the socket or the electrical installation or it has not been checked by qualified experts, never use it for charging. Even very low charging currents can cause serious damage and in particular fires if the socket or electrical installation is in bad condi-tion. If necessary, get expert assistance from a qualified electrical installation specialist.
NOTICE
Frequently charging the vehicle with a high charging power, particularly with a direct current (DC charging), can lead to a permanent reduction of the charging capacity of the high-voltage battery. If possible, charge the vehicle with low charging power, like with a home-charging station or with the supplementary charging cable.
NOTICE
Not using the vehicle for long periods can cause damage to the high-voltage battery. Charge the high-voltage battery after 4 months at the latest.
The vehicle can be charged on charging stations that comply with the J1772 standard.

Control module display ⇒ fig. 136:
No. Display Meaning Proper re-
sponse
(4) Lights up
is connected to a
110 Volt outlet,
but an error was
detected by the
control module.
The high-voltage
battery is not
being charged.
cable checked
by a qualified
electrical special-
ist. Go to an
authorized
Volkswagen
dealer or
Volkswagen
service facility for
assistance.
(2) (4) Lights up
The vehicle’s
system detected
an error in the
connected
charging cable.
The high-voltage
battery is not
being charged.
Disconnect the
charging cable
from the 110 Volt
outlet and the
vehicle and plug
it back in. Should
the error occur
again, get expert
assistance from
a qualified elec-
trical installation
specialist.
(1) (2) Lights up An overheating - Let the charg-

Control module display ⇒ fig. 136:
No. Display Meaning Proper re-
sponse
(4) Flashes
of the charging
cable was de-
tected. The high-
voltage battery is
not being
charged. An
overheating can
be caused by:
- A damaged 110
Volt outlet
- Ambient tem-
perature above
113 °F (45 °C)
- A damaged
charging cable
ing cable cool
down.
- Should the
error occur
again, have
charging cable
checked by a
qualified electri-
cal specialist. Go
to an authorized
Volkswagen
dealer or
Volkswagen
service facility for
assistance.
(1) Lights up
The system de-
tected fluctua-
tions in the volt-
age. The high-
voltage battery is
not being
charged
- The charging
process will con-
tinue automati-
cally once the
voltage is stable
again.
- If necessary try
connecting the
cable to another
110 Volt outlet.
- Should the
error occur
again, get expert
assistance from
a qualified elec-
trical installation
specialist.
(4) Flashes
(2) Flashes Excess voltage - Disconnect the