brake VOLKSWAGEN E-GOLF 2019 Service Manual

WARNING
Hot steam and hot electric motor coolant can cause serious burns.
x Never open the hood if you see steam or coolant escaping from the electric motor com-partment. Always wait until you no longer see or hear steam or coolant escaping from the electric motor.
x Always let the electric motor cool down completely before carefully opening the hood. Hot components will burn skin on contact.
x When the electric motor has cooled down and you are ready to open the hood:
– Firmly apply the parking brake and shift the transmission into Park (P) (automatic) or Neutral (manual only).
– Take the vehicle key out of the ignition.
– On vehicles with Keyless Access, make sure that the remote control vehicle key is out of range of the vehicle and that the vehicle cannot be started by depressing the starter
button ⇒  Starter button.
– Always keep children and others away from the electric motor compartment and never leave them unsupervised.
x The electric motor coolant system is under pressure when the electric motor is hot. Never unscrew the coolant expansion tank cap when the electric motor is hot. Hot coolant can spray out and cause severe burns and other serious injuries.
– Turn the cap slowly and very carefully in a counterclockwise direction while applying light downward pressure on the top of the cap.
– Always protect your face, hands, and arms from hot escaping coolant or steam by covering the cap with a large, thick rag.
x Never spill fluids on the electric motor when refilling. Spilling fluids onto hot parts of the electric motor can cause a fire. Under some conditions, the ethylene glycol in electric motor coolant can catch fire.
NOTICE
x Use distilled water only when adding coolant! All other types of water contain chemical compounds that can cause extensive corrosion damage to the electric motor. This can even lead to electric motor failure. If you have added non-distilled water, take the vehicle immediate-ly to an authorized Volkswagen dealer or an authorized Volkswagen Service Facility to have the coolant system drained, flushed, and refilled completely with the proper coolant.
x Refill electric motor coolant only up to the top edge of the marked fill range ⇒ fig. 154. Ex-cess electric motor coolant may be forced out of the electric motor cooling system when it gets hot and cause damage.
x In the case of significant electric motor coolant loss, refill electric motor coolant only when the electric motor is completely cooled down. Significant electric motor coolant loss is a sign of leaks in the cooling system. Have the electric motor cooling system checked immediately by an authorized Volkswagen dealer or an authorized Volkswagen Service Facility. Otherwise the electric motor may be damaged!
x Do not refill electric motor coolant if there is no coolant in the expansion tank. Air could enter the cooling system. Do not drive the vehicle! Get expert assistance. Failure to do so can result in electric motor damage.
x When changing or topping off operating fluids, make sure that you pour the fluids into the correct reservoirs. Serious malfunctions and electric motor damage can result if you pour operating fluids into the wrong reservoir.

WARNING
After the vehicle has been washed, the wet brakes or, in winter, brake discs or pads coated with ice, react slower and need longer stopping distances.
x Always dry the brakes and clean off any ice coatings with a few careful applications of the brake. Make sure not to endanger other motorists or cyclists or disobey legal requirements.
CAUTION
Sharp edges under the vehicle can cut exposed skin.
x Always protect your hands and arms from cuts on sharp metal edges when cleaning the underbody, the inside of the wheel housings, etc.
NOTICE
x The water temperature must not be more than +140 °F (+60 °C).
x To help prevent damage to the paint, do not wash the vehicle in direct sunlight.
x Do not use insect sponges, abrasive kitchen sponges or similar things to clean the vehicle. These can damage the paint finish.
x Never clean headlights with a dry cloth or sponge. Always use a wet cloth or sponge. For best results use soapy water.
x When washing or rinsing the vehicle in cold weather, do not let water get into the lock cylinders or point the hose at gaps around the doors, hood, or rear hatch. The water could freeze on the locks and seals and make it difficult to open the vehicle!
x When outside temperatures are low, wipe the rubber seals and their contact surfaces dry to help prevent freezing.
NOTICE
To help prevent vehicle damage in a car wash:
x Compare the vehicle track width with the dimensions of the guide rails in the car wash to help prevent damage to wheel rims and tires!
x Switch off the rain sensor before driving the vehicle through a car wash ⇒ page 127, Rain sensor.
x Make sure there is enough clearance for the height and width of the vehicle.
x To help prevent paint damage to the electric motor hood, place wiper blades against the windshield after they have dried. Do not let them snap back into place.
x Fold the outside mirrors toward the vehicle body.
x Lock the rear hatch to help prevent unintentional opening in the car wash.
Washing with a power washer

Make sure there is enough distance to soft materials such as rubber hoses or insulating material as well as the sensors of the Park Distance Control system (if equipped). The Park Distance Control
system sensors can be found in the rear and, if applicable, front bumper ⇒ .
Make sure there is enough distance to soft materials such as rubber hoses or insulating material.
Never use concentrated jet nozzles or so-called dirt blasters ⇒ .
Never use a power washer to clean the electric motor compartment ⇒  Cleaning the electric motor compartment.
WARNING
Improper use of power washers can cause serious invisible permanent damage leading to tire failure and loss of vehicle control. This can cause accidents and severe personal injury.
x Keep sufficient distance between water jet and tires. Never wash tires with a nozzle that sprays the water out in a direct stream regardless of the distance to the tire and even for a very short time.
x Never use “dirt blasters” to clean tires. Even spraying from a relatively long distance for a very short time can do visible or invisible damage to tires.
WARNING
After the vehicle has been washed, the wet brakes or, in winter, brake discs or pads coated with ice, react slower and need longer stopping distances.
x Always dry the brakes and clean off any ice coatings with a few careful applications of the brake. Make sure not to endanger other motorists or cyclists or disobey legal requirements.
NOTICE
x Water temperature should not be more than +140 °F (+60 °C).
x To help prevent damage to the paint, do not wash the vehicle in direct sunlight.
x In order for Park Distance Control to work correctly, the sensors in the rear bumper must be kept clean and clear of snow and ice.
x When using a power washer or steam cleaner, only spray the sensors directly for a short period of time and always keep the nozzle at least 4 inches (10 cm) from the sensor.
x Do not clean icy or snow-covered windows with a power washer.
x When washing or rinsing the vehicle in cold weather, do not let water get into the lock cylinders or point the hose at gaps around the doors, hood, or rear hatch. The water could freeze on the locks and seals and make it difficult to open the vehicle!
Cleaning windows and outside mirrors

x Slip the cover up and over the selector lever ⇒ .
Emergency release for the selector lever (version A)
x With the screwdriver from the vehicle tool kit, carefully push the release lever ⇒ fig. 166 A in the direction of the arrow and hold it in this position.
x Press the release button in the selector lever handle and shift the selector lever to Neutral (N).
x Carefully press the selector gate cover back in place, making sure that the electrical wiring stays in the correct position and is not pinched or damaged.
Emergency release for the selector lever (version B)
x Push the colored release lever ⇒ fig. 166 B in the direction of the arrow and hold it in this position.
x Press the release button in the selector lever handle and shift the selector lever to Neutral (N).
x Carefully press the selector gate cover back in place, making sure that the electrical wiring stays in the correct position and is not pinched or damaged.
WARNING
Never shift the transmission out of Park (P) without first firmly applying the parking brake. Otherwise, the vehicle can start to roll unexpectedly, especially on hills or inclines, and cause an accident and serious injuries.
NOTICE
Even with the selector lever is in Neutral (N), the automatic transmission will be damaged if the vehicle is towed (or you let it coast) for an extended period or at high speed with the electric motor shut off.
Emergency release for the charging connector

WARNING
Changing a wheel, especially on the side of the road, can be dangerous. To help reduce the risk of serious personal injury:
x Always stop the vehicle as soon as it is safe to do so. Move the vehicle a safe distance off the road where it is safe to change the wheel.
x Always make sure that all passengers, especially children, are in a safe place outside the vehicle and away from the vehicle and traffic (such as behind a guard rail).
x Turn on the emergency flashers and set up another warning device about 25 yards (25 meters) behind the vehicle to warn approaching traffic.
x Change a wheel by yourself only if you are familiar with the necessary steps. Otherwise, get expert assistance.
x Always switch the electric motor off, firmly apply the parking brake, and shift the trans-mission into Park (P) (automatic transmission) or any gear (manual only) to help prevent the vehicle from moving suddenly and slipping off the jack.
x Always make sure that the ground is level and firm. If necessary, place the jack on a large and sturdy board or on a similar ground support.
x Always block the wheel diagonally opposite the wheel being changed with chocks or other similar things.
x Always use proper and undamaged tools when changing a wheel.
x Once a wheel is lifted off the ground, having the transmission in Park (P) or in gear will not prevent sudden vehicle movement.
x Always use a jack that has been approved by the manufacturer for your vehicle. Never use other jacks, even if they have been approved for use on other Volkswagen models.
x To reduce the risk of losing control, crashes, and serious personal injuries, never loosen the screws on rims with threaded rim rings.
x After changing a wheel, have the wheel bolt tightening torque checked with an accurate torque wrench.
x After changing a wheel or tire, reset the Tire Pressure Monitoring System ⇒  Tire Pressure Monitoring System (TPMS).
Preparations for changing a wheel

WARNING
Using the tire mobility set on the side of the road can be dangerous. To help reduce the risk of serious personal injury:
x Always stop the vehicle as soon as it is safe to do so and move the vehicle a safe distance off the road where it is safe to use the tire mobility set.
x Always make sure that the ground is level and firm.
x All passengers and especially children must stay a safe distance away from you while you are working and keep out of the area you are working in.
x Turn on the emergency flashers and set up another warning device about 25 yards (25 meters) behind the vehicle to warn approaching traffic.
x Use the tire mobility set only if you are familiar with the necessary steps. Otherwise, con-tact an authorized Volkswagen dealer or Volkswagen service facility for assistance.
x Use the tire mobility set only in emergencies and only until you can get professional help.
x Immediately replace a tire repaired with the tire mobility set.
x Sealant is harmful and must immediately be removed in case of skin contact.
x Always store the tire mobility set out of reach of children.
x Never use a vehicle jack, even if the jack is approved for use with your vehicle.
x Always apply the parking brake and shift the automatic transmission into Park (P) to help prevent the vehicle from moving suddenly.
WARNING
Improper use of the tire mobility set can cause a temporary tire to fail and lead to loss of vehicle control and serious personal injuries.
x Always remember that a tire filled with sealant does not handle as well as an undamaged tire without sealant.
x Never drive faster than 50 mph (80 km/h) with a sealed tire.
x Never use the tire mobility set if the outside temperature is below –4 °F (–20 °C).
x Never drive with a tire that has cuts or punctures, especially when they are larger than 3/16 in (4 mm).
x Use the tire mobility set only for emergencies until you can get professional help.
x If the tire cannot be inflated to at least 36 psi (250 kPa), do not drive the vehicle. Contact an authorized Volkswagen dealer or Volkswagen service facility for assistance.
x If the tire inflation pressure drops below 26 psi (180 kPa) after driving for 10 minutes, do not drive the vehicle any farther. Contact your an authorized Volkswagen dealer or Volkswagen service facility for assistance.
x Always replace a tire repaired with the tire mobility set immediately. Do not drive a tire that has been repaired with the tire mobility set longer or farther than is absolutely necessary.
x Avoid full throttle acceleration, hard braking, and fast cornering.
x Drive at slow speed for 10 minutes. Then get out and check the air pressure and condition of the sealed tire.
Obey all legal requirements when disposing of used or expired sealant.
Replacement tire inflation cylinders for the tire mobility set are available if you have used the one supplied with the vehicle. Please contact an authorized Volkswagen dealer or Volkswagen service facility for assistance.

Checklist
Carry out the following steps in the order listed before starting to inflate a tire ⇒ :
1. If you have a flat tire, move it as far away from traffic as possible. Park the vehicle on a flat, level surface at a safe spot.
2. Firmly apply the parking brake to help prevent the vehicle from moving
3. Move the selector lever into Park (P)
4. Switch off the electric motor and remove the key from the ignition switch
5. Have all passengers exit and go to a safe place, such as behind the guard rail.
6. Switch on emergency flashers and use a warning triangle or other device to warn oncoming traffic. Observe all legal requirements.
7. Check whether a repair with the tire mobility set is possible
8. If the luggage compartment is loaded: Remove the luggage.
9. Remove the tire mobility set from the luggage compartment.
10. Affix the label ⇒ fig. 177 (2) from the tire mobility set on the instrument panel in the driver's field of vision.
11. The foreign object (screw or nail, for example) should not be removed from the tire!
WARNING
Disregarding the safety-related checklist may lead to accidents and serious injuries.
x Always review and follow the checklist. Follow accepted safety practices and use common sense.
Sealing and inflating the tire

WARNING
Improper use of jumper cables when jump-starting a vehicle with a dead battery can cause the battery to explode, leading to serious personal injury. To help reduce the risk of battery explosion:
x All work on the batteries or the electrical system in your vehicle can cause serious acid burns, fires, or electrical shocks. Always read and heed the following WARNINGS and safety
precautions before working on the batteries or the electrical system ⇒  12 Volt vehicle bat-tery.
x Always make sure that the battery providing starting assistance (the booster battery) has the same voltage as the dead battery (12 V) and about the same amperage capacity (see bat-tery label).
x Never jump-start a vehicle with a thawed or frozen vehicle battery. The battery can ex-plode. A dead battery can freeze at temperatures around +32 °F (0 °C).
x A battery that is frozen or was frozen, but has since thawed, must be replaced.
x When the vehicle battery is jump-started, it gives off hydrogen gas, which is highly explo-sive! Always keep fire, sparks, open flame, and smoking materials far away from vehicle bat-teries. Never use a mobile telephone while connecting or disconnecting jumper cables.
x Jump-start batteries only in well-ventilated areas. Batteries give off highly explosive hy-drogen gas during jump-starting.
x Always route the jumper cables so that they cannot get caught in any moving parts in the electric motor compartment.
x Never short out the battery terminals by connecting the positive (+) and negative (-) termi-nals with each other.
x Never connect the negative cable from the other vehicle directly to the negative terminal of the dead battery, as this may cause the hydrogen gas given off by the dead battery to ex-plode.
x Never attach the negative cable from the vehicle providing starting assistance to any part of the brake hoses or brake lines.
x Never allow the non-insulated parts of the battery clamps to touch.
x Never allow the jumper cable attached to the positive battery terminal to contact metal parts of the vehicle.
x Always follow the instructions of the jumper cable manufacturer.
NOTICE
To help prevent extensive damage to the vehicle electrical system, read and heed the follow-ing:
x Connecting jumper cables improperly can cause a short circuit and do expensive damage to the vehicle's electrical system.
x Do not let the vehicles touch each other while the jumper cables are connected. If they do, electrical current may flow between the vehicles when the positive (+) terminals are connected, causing electrical system damage.

WARNING
Improper use of jumper cables when jump-starting a vehicle with a dead battery can cause the battery to explode, leading to serious personal injury. To help reduce the risk of battery explosion:
x All work on the batteries or the electrical system in your vehicle can cause serious acid burns, fires, or electrical shocks. Always read and heed the following WARNINGS and safety
precautions before working on the batteries or the electrical system ⇒  12 Volt vehicle bat-tery.
x Always wear proper eye protection. Never lean over the vehicle battery.
x Attach the jumper cables in the correct order: first the positive cable, then the negative cable.
x Never connect the negative cable from the vehicle providing starting assistance to parts of the brake hoses or brake lines.
x Never allow the non-insulated parts of the battery clamps to touch.
x Never allow the jumper cable attached to the positive battery terminal to contact metal parts of the vehicle.
x Check the battery acid level indicator window on the vehicle battery. Use a flashlight, never a match, cigarette lighter, or other open flame. If you cannot see the color of the win-dow clearly, or if it is light yellow or colorless, do not jump-start the vehicle. Get expert assis-tance.
x Avoid electrostatic discharge in the vicinity of the vehicle battery. Sparks may cause the hydrogen gas escaping from the vehicle battery to ignite.
x Never jump-start a vehicle with a battery that is damaged or frozen or that was frozen and has thawed. The battery can explode. Replace the battery instead.
x Always follow the instructions of the jumper cable manufacturer.
x Always make sure that the battery providing starting assistance has the same voltage as the dead battery (12 V) and about the same capacity (see battery label).
x Batteries give off explosive hydrogen gas. Always keep fire, sparks, open flame and smok-ing materials away from batteries.
x Never connect the negative cable from the other vehicle directly to the negative terminal of the dead battery. The hydrogen gas from the battery is explosive.
x Never short out the battery terminals by connecting the positive (+) and negative (-) termi-nals with each other.

WARNING
Towing a vehicle changes the way it handles and brakes. To help reduce the risk of an acci-dent and serious personal injury, note the following:
x The driver of the vehicle that is being towed:
– Since the brake booster also does not work when the electric motor is stopped, you will need to press harder on the brake pedal to slow down or stop. Always be alert so as not to rear-end the towing vehicle.
– Will have to use considerably more force to turn the steering wheel because the power steering is not working.
x The driver of the vehicle that is doing the towing:
– Must accelerate gradually and gently and avoid jerking movements.
– Must not brake hard or steer sharply.
– Must brake earlier and more gently than in normal driving.
NOTICE
x Be careful not to damage the paint when installing and removing the towing eye and the cover for the threaded hole behind the bumper.
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