brake VOLKSWAGEN GOLF 2004 Repair Manual

3.2 Tips and Advice
The brake fluid be changed every two years.
We recommend that you have the brak e changed b y an authorize d Volkswagen dealer.
S top! Be
fore openin g th e e ngin e hood, always
read and heed all page 39.
Brake fluid
absorbs m oisture. time, it will absorb wate r from the air. the wa ter content in the brak e fluid is too high, the brake sys te m
c
ould corrode. Too much wa te r in the brak e fluid
a lso consid erably reduces the boilin g point of the brake fluid. Very heavy use of th e brak es with
old brake fluid may cause vapor lock . Vapo r lock
reduces braking power, in cre ases stopping tances and can eve n cause total brake failu re.
For this r
eason the brake fluid must be repla ced
every two years.
use brak e fluid the s pecification U S standard 116 4. The brake fluid must be new.
Stop ! Befor e working in the engine compart­ment, always read and h eed all WARNINGS 39. The engine compartment of any motor vehicl e is a potentiall y dangerous area and can cause seriou s persona l injury .
Brake failure can result from old or incorrect brake fluid.
fica tio n
(continued)
A lwa ys check with your authorized swage n deale r to make sure that you arc u sing the correct brake fluid.
The correct brake fluid is also listed on the
labe l on the brak e fluid reservoir.
Always store brake fluid in the closed
To reduce th e risk of poisoning, neve r us e empty food or beverage containers that mi ght mislead someone into drinking from them.
A lwa ys keep bra ke flu id out of the reach of childr en.
Alway s change th e b rake fluid as required in the maintenance bookl et. Heavy braking w ith old brake fluid may cause a vapor lock that reduces braking power, increases ping distances and can even cause tota l brake failure.
Note
Brake fluid can damage the pai nt. Wip e off any
brake fluid from rh c paint immedia tely.
For the sake of environment
B rake fluid
must be drained and disposed of in
th e proper manner obse rv ing env ironmental

For th e sake of e nvironment
Baueries contain toxi c substances including aci d and lead. must b e disposed propriately and not with ordinary garbage.
Tires and
General notes
Tips
After connecti n g a battery and switching on the ig nit ion, the indicator light comes on continuously. It goes out when the ve hicl e is dri ven straigh t for a short distance at 15 mph km/h ).
Tire s may be the least appreciated and most abused parts of a motor vehicle.
Tires may be the lea st appreciated and most abuse d pa rts of a motor ve hicle. Tire s are, eve r, one of the mos t important parts of
safe ly handle,
avoi din g from road h aza rds and inspecting tires for damage including cuts,
sl ash es irregular wea r you can do to help avoid sudden tire fa ilur e including tread separation and blowouts.
Avo iding
damage
lfyou have to drive over stacle, drive very slowly and as close as poss ibl e
Wher e ap pli cabl e W
h
en removed, the wheels or t ires should be stored in cool. dry and p re ferably dark plac e.
tires in ve rtical position if they are not mounted on rims, in ho rizontal posi tion if they
in " 'B reaking in tire s and brake
type tern.
Hidd
en damoge
Da
mage t o tire s rims is often not readily
swage n dealer or qu alified workshop.
Unidir ection al tires
A unidirectio nal tire can b e idemified by arrows on the sidewall, that p oint in the direction the tire is designed to rota te.
p ag e "Unidirectional
Rims with threaded rim ring4l
Light-allo y wheels w ith a bolted rim ring consis t
o f several parts. T hese parts are screwe d to-
57

Tires and
There arc limits to th e amount of load or weig ht that any vehicl e and any tire can carry. A ve hicle that is overloaded will not handle well and is mor e to stop. Overloading can not only
lead l oss of ve hicle control. but ca n al so damage including a blowout
and s udden d eflatio n th at can cause the vehicl e
to crash .
Your safet y
and that of your passengers also de­
pends on making sure th a t l oad limit s arc not ex­ceeded. load in cludes everybody and ev­eryth in g in and on the vehicle. These load limit s are technically refe rred to as th e vehicle' s Gr oss Ratin g
includes the weight of the basic ve­all factory installed accessorie s. a full tank of coolant and other fluids plus max­imum load. The m ax imum load incl udes the number of passengers that the ve hicle is in ­tended to carry lbs. (68 kg) for each pas­senger at designation seating position and the
total wei ght of a ny lu ggage in the ve hicle. yo u the weig ht of the trailer hit ch and the tongue weight of the loaded trailer mus t be included o f the ve hicle load.
T he Gross
Axle is the m aximum load th at can be ap plied at each of the
veh icle's two
has 5 seat ing pos ition s, 2 in the front and 3 in the rear for seating ca­paciry of 5. Eac h seatin g posit ion ha s a sa fe ty bookle t2.1
and
The fact that there is an upper li mit to your ve­
hi cle's Gross Hating means that the total weight of whatever i s bein g carried in the vehicle (in cluding the weight of a trailer hit ch and the tongue weig ht o f the load ed
t railer) is limited. The more passengers in the ve­
hicl e or passengers are heav ier than the standard weig hts assumed mean that less weig ht can be carried lu ggage.
The tire pressure on your Volkswage n also lists the maximum combined weight of all of the occupants and
page fig . 15 .
WARNING
Overloading a ve hicl e can cause loss of vehicle control, a crash or other accident, serious pe r­
sonal injury, nnd even dent h.
more weight than your vehicle was d esig ne d to carry will prevent th e ve hicl e
fr om handling properl y and increase the ri sk of th e loss of ve hicl e control.
The brakes on a ve hicl e that has been over­loaded may not be abl e to sto p the ve hicle
w ithi n a safe di stance.
o n a ve hicle that has been overloaded can
Alway s make sure that the to tal load bein g transported-including the weight of a trail er hitch and the tongu e weight of a loaded trail er -does no t m ake th e ve hicle heavier t11e
ve hicl e's Gross Vehicle Rating .

(continued)
For technical reasons it is not
I f you install wheel t rim discs on the ve­
hicle wheels, make sure that the air flow to the brakes is not blocked. Reduced airflow to the brakes can them to overheat, increasing stop­ping distances and causing collision.
Note
For technical reasons. it is not ge nerally pos­
s ibl e to use th e wheel rim s from other vehicle s.
This can ho ld true for wheels of the same vehicle
ty pe.
Uniform tire
Tr ead wear
Temperature A B
Quality can be found where applicable on the tire sid e wall between tread shoulder an d maximum section pa ge 73, fig.
For example: Tread wear Tra ction M, Te m ­
perature A.
All passe nger car tire s must conform to Federa l
Sa fe ty Hequirement s in addition to these grades.
Tread
wear
T he /read comparative rat ing base d on th e wea r rate of the tire when tested under controll ed co nditi ons on a sp ecifie d go v­
ernment test course.
For exa
mple, a tir e graded would wear one and one half(ll/2) times as well on the govern ­
ment cou rse as a tir e
The relati ve performance of tires depends upon the actual conditions of th eir use , h oweve r, and m ay depart significantl y fro m the norm due to
76 Checking and
extra care. Replace the flat tire
with the tir e matchin g the others on your vehicl e
a s soon as poss ible.
Note
in stall ing new
drive without the va lve ste m cap. The valves and sensors co uld get damaged.
If the sen sors must be re pla ced, then the valve mus t also be replaced th e sa me time.
The sensors mus t be replaced in schedule d bookle t ...
For the sake of environment
Dispose of o ld tires in accordance w ith the local
requirement s.
variations in driving habits, serv ice pra ctices and diff ere n ces in road characteristics and cli­
mate.
Traction
AA, A, B, C
T he
from highes t to lowest, are M, A, Band T hose grades rep resent the tire's abil iry to stop on wet pave ment measured under controlled conditions o n specified gov­ernment tes t s urfa ces of and co ncre te. A
tir e marked may have poor tra ction perfo r­
Temperatur e A, B, C
The lemperruuregrad es arc A (th e highest), B. and C, representing the tire's resistance the
ge neration of heat and its abilit y to diss ipat e heat tested under controlled conditi ons
o n a sp ecified indoor laboratory test wheel.
Susta ined hig h t em pera t
ure cause mate­
rial of th e tir e to degenerat e and reduce tire lif e. and excessive tempera tur e

3.2 Tips and Advice
Wheel bolts must always be tig hte ned to the correct torque.
The design of w heel bolts is mat ched to th e th e
correct wheel bolts with th e rig ht length and rectly shaped bolt heads mu st be use d. Th is sures th at w heels are securely and the
brake system functio ns correct ly.
In cert a in cir cumstances, y ou ma y not usc wheel
bolts from a differe nt vehicl e- ev en if it is th e
sa me mod el page
serio us personal in jury.
keep the wheel bolts the
th reads in the wheel hubs clean so the whee l
bolt s turn easily en ed.
Neve r grease or oi l th e wh eel bolt s and th e
th reads in the wheel hubs. They ca n become
WARN ING (continued)
loose while driving if grea sed or oile d, eve n if
t ightened to th e s pecifi ed torque.
use wheel bolt s belo ng to the
wheel rim installed .
Never usc diff erent wheel s bolts on your vehicle.
Always maintai n th e correc t tig htening torqu e for the w hee l b olts to reduce the ri sk of a wheel loss. If the tightening torque of the
whee l bolts is too low, they can loosen come out w hen th e vehicl e is m ov ing . If t he
tight en ing torque is too high, the wheel bolts and threads can be damaged the w heel
can become loose .
Note
The specifi ed torqu e for th e w hee l bolts is
88 ft/ lb s Nm). Afte r changi ng a whe el. th e
torqu e must b e ch ec ked as soon as po ss ibl e w ith
a torque wre nch - pref erably by an authori zed Volkswage n dealer or qu alified works hop.

3.2 Tips and Advice
WARNING
The spare whee l may be smaller than the origina l tir e. The s maller spare wheel is identi­fied with a sticker and the words
The spare whee l m ust be returned to the
spare whee l well so on as the standard road
wheel can be re pla ced.
Getting started
The spare wheel must always be secured
with the w hee l bolts provided by the factory .
After
r
vehicle in a safe place before changing a wheel.
If yo u have a flat tire or puncture, park
the vehicle as far away fro m the of
traffic as possib le on a firm, even surface
Turn off the e ngin e. Turn on the emer­
gency flasher.
App ly the parkin g brake firm ly and e n ­
gage a
gear or put the selector in
If yo u are towin g a trailer, unhitch it
from yo
ur vehicle.
WARNING
Changin g a wheel, especially on
Alw ays stop the ve hicl e
to change the
Turn on th e e merge ncy fla sh er and se t up an o th er warning device ab o ut 27 ya rds (25 meters) beh ind the vehicl e to warn ap­
proa ching traffic.
Always sure th at th e ground is leve l and firm, if necessary usc sturdy under the ja ck .
When one wh eel is lift ed off the ground putting the se lec to r l ever in
Always apply tl1e par k in g brake firmly and firmly engage gea r or put th e selec tor lever in

Fig . 34 Fuses in fuse box A in the instrument panel
F
use table
The s h ows the fuse locations for th e major
elec trical hand col­umns comainth e location , th e the ampere for the fu se. is po ssible that one electr ical con sumer can
have more tha n one fuse (a lso in separate fuse boxes ).
There is room for replacement fuses in each fuse
box.
There are additiona l fuses in the Have these rep laced by an authorized
brac kets)
8 (5), (5)
Brake -light switch 2 (5) -Cen tral for 12
-Fuel pump 27 (15)

Heated seats 4
(5). 37 46 (5)
windows for 23 front
wind ows for 32 rear
Rea r
window de- 25 (25) fogger
R
ear w indow wiper 41 (15)
R ear 12-vo h socket 26
F1 F2
Backup light left F47 F48
Backup light right F47 F48
Brake light left F48
Warning
Brake light righ t F47
Turn sig na l left F47 F48
Turn signal right F47 F48
F48
Headlight left F47
Headli gh t right F48
Horn F5 (15)
Rad i
ator
Radio Fl9 (15)
Sound syste m
Windshield wipers F31
the wrong fuse and attempti ng to re pair a fuse or usi ng something instead of a fuse can
cause a fir e and serious personal injury.
Alway s read and heed the information and all page a
The check light ill uminates when an ex terior lighting bulb has failed.
The indicato r light lig ht s up in the instrument clus ter when a ve hicle exterior lightin g bulb,
(e.g. le ft high beam) has failed.
th e ve hicle is delivered from the factory with a
t railer h itch and the is correct ly atLached to the trai le r socket, cert ain bulb s on the trail er are also monit ore d .
Bu lb
monitorin g with trailer attach ed The traile r light ing is con stamly monitored for a bulb failu
re.
The ch eck ligh t illumin ates if a b ulb in the rea r light of the trailer has fai led
The following bulbs are mon itored:
failure of all turn signa ls on one si de
Failure o f the rear light on one si de (on som e
model s als o failu re of the license pla te light ).
Failure of both brake li gh ts
What do

(continued)
swagen dealer or a qualified workshop. rious personal injury m ay resu lt from erl y perfo rmed work.
Booklet 3.2 Tips and Advice
Note
Do not touch glass bulb with bare hands.
A bulb can on ly be rep laced by a bulb of the same type. The model identification is either on the bulb base or on the bulb
turn
The rear light contains a light bulb fo r the rear turn signal and a light bulb for the
rea r brake light.
Fig . Removing the toi l ligh t
F ig . 4 1
Toil light: Unlotching bulb holde r
To remov e the tailligh t, yo u need the
screwdr iver from th e
on-board tool kit and
a
x I3mm open ended wrench.
R e moving the
-the headlights off.
-the ign ition off and remove the
key from the ignition lock.
-
the flat blade on th e screw driver
and pry the cover off in direction of th e
arrow
fig. - left illu stration-.
-
the f lat b lade on the sc rewdri ver
and pry the cover off in direction of the
arrow carefully
the open ended wrench (13 mm
A/F), unscrew and remo ve the nut s
the ta illight backward out of the
side panel
of th e veh icle .
What do

If th e e ng ine docs not stan, rum off the aft er ab o ut se cond s a nd try again about seconds.
39. The engine compartment of an y
motor vehicle is a potentiall y dangerous area and can cause seriou s personal injury.
tery explos ion:
Always make sure that the battery viding starting ass istance has the same voltag e as the di scharged battery (12 V) and
appr oximate ly the same capacity (see battery
lab el).
Never jump start a ve hicl e wit h a fro zen
battery. The battery can explode. If a battery i s or h as been frozen, re place it.
Batteries give off exp losive hydrogen gas.
Always keep sparks, open flame and
s moking mate rial s away from batteries.
(continued)
Never short out the battery poles by necting the positive and negative pole s
with each other.
Always follow the jumper cables '
Never connect the negativ e cable from the other vehicle directly to the negativ e terminal of th e di sc harged battery. The hydrogen from the battery is exp los ive.
Never attach the negativ e cabl e from the ve hicl e provid.ing starting assis tanc e to parts of the fuel system or to the brake hoses or brake lines.
Never the non-in sulated parts ofthe battery clamps to touc h. Never allow the jumper cable attached to the positive battery
terminal to contact metal parts of the vehicle.
Always rout e the jumper cables so that
they cannot tangled up w ith moving parts in the engin e compartment.
Note
Install ing jumper cables imp roper ly can
ca use expe nsive damage to the vehicl e's trical system.
Do not let the vehicle s tou ch each othe r. e rwise current could flo w between th e cars as soon as the plus(+) te rminal s arc
What do