ESP VOLKSWAGEN GOLF PLUS 2004 Repair Manual

Checking the engine
u
J
Fig. 15 1
information and heed the o n pag e 247.
For a tru e reading of e ng ine oil level, the engine must be at operating temperature. Switch off the engin e and wa it a few minutes for the engine oil to
flow back into the oil pan.
the eng in e hood 242.
The engin e oil filler cap is marked w it h fig . 15 2 . The oil dipstick has a colored handle.
Engin e oil level ranges
Fig. 152 In the engine comportmen t: Engine oil filler cop.
R e insert the dip stick and push it all the way in.
If there is an alignment tab o n the engine oil
th e oil dipstic k out again a nd check the tab le o n page 249.
Afte r read ing th e oil leve l, reinsert the dipstick
in the gu ide tube and push it all the way back in.
fig.l51 Required action according to the respective engin e
Do not refill
T he oil leve l may go into the range,
but not above the range.
lit er). After addin g oil, make sure that the oil
l eve l is
about in the middle of rang e.
Adding engine oil (after checking level)
T o p off gradually w it h sm all amounts of oiL
Unscre w th e cap oft he engine oil filler opening from the cy lind er head cover. If yo u are
not sure where it is , contac t yo ur authorized swage n dea le r or authorized Volkswagen Serv ice Facility .
In the engine comportment
Add oil in sm all amounts-not more than I pint
page 248.
To avo id adding too much oil, wa it a w hile afte r
addin g eac h small qu antity of oil (so that the added oil can reach the oil pa n and the dipstick).
248 249

Engine coo la nt
Introduction
In thi s section you'll find informat ion on the fol­lowing:
Warning
engine coolant and topping off . . . 255
Never do a ny wor k on the coo lant system unless
you
-know exactly ho w to carry out the job,
-have the correct tec hnical informa tion and
th e proper to ols, supplie s, and operating
fluid s, a nd
-are familiar with the necessary safet y
pr eca utions
Traile r page 152
fo r work ing in the e ngine com­partment page 242
Part s, acce ssories , re pair s and modification s
Engin e coo lant is poisonous!
Always keep the coolant in its origi nal con­
t ainer stored in a safe place .
To reduce the risk of poisoning, never store engine coolant in empty food or beverag e con­tainers or in any other containers that might mislead someone into drinking from them.
Always keep engine coolant out of reach of c hildr en.
Alway s make sure there is enough of tJ1e cor­
re ct coo lant additive to provid e proper anti­
fr eeze protection at the cold es t temperatures that can be expected where the vehicle will be used .
At extremely cold temperatures, the coolant could freeze, causing the vehicle to break down.
The heater would also not work, and vehicle oc­
cupants could be without protection at sub­freezing temperatures.
leaking operat ing
fluids and dispose of t h e m properly in acco rdance
w ith applicable environmental laws and regulat ion s .
Warning light and engine coolant temperature gauge
Fig . 153 E ngine coolant temperature gauge in the in­str umen t Engi ne cold;® Normal tempera­ture range;© Warn ing zone.
Core, maintenance
first read and note th e introduct ory information and heed th e on page 252.
normal driving conditi ons, th e needle
s h o uld be in the middl e of th e ga uge. The temper­
ature may go high er w hen th e e ngine is w orking
h ard, espec iall y in hut
When the igni tion is sw itch ed on , seve ra l warnin g and indicator light s co me o n bri efly fo r a function
c h ec k. The y go our after a few seconds.
Th e fo
llow ing table explains w ha t t o do if th e en ­
gine coolant warn ing does no t go out a few secon ds after the engine is s tart ed or light s up or
s tart s fla sh ing while driving.

Temperature
Lights up gauge needle response page252,
fig . 153
off the road and s top as soon as you can do so safely.
the engin e
coolant l eve l and add e ngine coolant if page 255. th e e ngin e coo lant E ng in e coolant tempera-
leve l is correc t o r the p roble m continues Warning zone l
u re too high. afte r addin g coo la nt and driv ing a sh ort tance, do not drive an y farther.
sary 341.
th e engin e coo la nt level after the en-
gine has coole d d own and add en gine
coolant i f page 255. the engine coo la nt leve l is correc t or tl1e problem continues after adding coolant, do
En gin e coolant leve l too not drive a ny farther.
Facility.
These in struction s apply only when the coolant temperature stays in the normal
rang e. immediately if the needle goes
in to
the red warning zone
Eng ine coo lant system the nearest authorized Volk swagen .. malfunction. dealer or authorized Volkswage n
Do not drive at hi gh en g in e s peeds or with heavy en g in e loads until the engine warm s
cause
Engi ne coo lant syste m malfun ction .
the engine compartment 252 253

Charging, replacing, disconnecting and connecting the
first rea d and no te the introductory
o n p age 257.
the vehicle batte ry
Vehicl e batteries should be c harged by your rized Volk swagen deale r or an authorize d
Replacing the ve hicle battery
Th e batt ery in
your vehicl e is s pecially deve loped
f o r it s locati o n, w ith sp eci al dim ensio ns and safe ty
featu res. Befo re buy in g a new battery, ask an th ori ze d Volkswage n deale r o r authorize d swagen Facility w ha t batt eries are suit abl e
w ith r egard to e lectro-m agnetic compatibility, mension s, requir ed m aintenan ce, perfor man ce,
and safety sp ec ifications. H ave th e battery place d by an auth ori ze d Volkswage n deale r o r an authori zed Volk swage n Facility.
use m aint ena nce-free vehicl e ba tt eries m ee tin g standards T L 825
hicle's elec tri cal sys te m , note the following:
off all electrical syste ms and dev ices
and th e ign ition.
Fir st di sconnec t the negative cabl e and th en the positive
the vehicl e battery
to reconnecting the ba tt ery , switch off all elec trical sys te m s and dev ices and the ig niti on .
Con nec t th e positive cable fir st a n d then th e
n ega tive
ta n ce at mph (15-20 km /h).lf the in dica to r ligh ts do not go out, contact an auth orized swage n dealer or a n au th orize d Volkswagen v ice Facility and have the vehicle c hec ked.
If th e battery was discon necte d f or a long tim e, the
n ext scheduled se rvice may no t be correct ly la te d and page 16 The maximum per-
an d nance booklet.
Vehicles with
h icle battery, lock an d unloc k th e ve hicl e from th e outs id e. Th en try to sta rt the ig niti on again. If th e
ig niti on canno t b e switch ed on , ge t expe rt ta n ce.
Automatic electrical
load deactivation
I f t
he ve hicle battery drain is hig h, t he intelligent
o n board electrical sys te m m anage ment cally takes steps to help p reve nt b attery d rain.
The id le speed i s in creased so that the n ato r provides more powe r.
The power to dev ices that co nsume lot of e lec tricity is cut bac k or switched off com ple te ly.
W hen the en gine is s ta rt ed , p owe r supply oft h e
1 2-vo lt socke ts and t he c igare tte lighter is ra ril y int errupted.
T he on
board elec trica l sys tem man age men t
canno t always keep th e battery fro m being drained. For example, th e battery will drain if th e
e n g in e is not running, but th e ig ni tio n i s switc he d
o n for a lo ng tim e or th e parkin g lights a re left o n for a lo ng time.
What drain s th e battery?
Long period s w hen th e engine is no t running, especially w hen th e ig niti on is on.
Fa ilur e to use the proper batte ry with prop er mounting and connecti ons may ca use short seriou s personal injurie s.
Always use only mainten ance- free or leak-pro of batteries with the same
ment battery. Specification s are liste d on the
b attery ho using.
Wh en th e battery is charged, it produces hi ghly explosive hydroge n gas.
Charge ve hicl e batte ries only in w ell-ve nti-
l a te d areas.

Introduct ion
information on th e lowing:
Caring for upholst ery . . . . . . . . . . . . . . . . . . . . . . . . 271
Clean ing upholstery, fabric trim and . 271
Care and
. . . . . . . . . . . . . . . . . . . . . . 27 5
Modern clothing fabr ics su ch as dark den im may
not becompl etelycolorfast. Even w ith normal use ,
d ye from these and other fabri cs can rub on seat uphol stery a nd le ave vis ibl e disco lorations (espec ially on ligh t-colored seat upho ls tery) . This
i s caused by a lack of col orfa stn ess in the clothing
fabri c, not by any fa ult in the sea t upholstery
fabr ic. To help preve nt damage he seat always make sure your clo thing is col orfast.
Volkswag en r ecommends having a qualified cialist re m ove any di scolo ration s from the seat holstery.
More information:
ca re and pag e 262
acc esso ries, repa irs and modification s page303
Vehicle
care product s ca n be dangerous. proper use can cause accidents , burns, soning, or oth er seri ous perso na l in juries.
Alway s sto re vehicle care p roducts onl y in
origin al containers that are secure ly closed.
Care, maintenance
A lways read hee d the in structions and on th e packag e.
To red uce the risk of poisoning, never use
empty food or beverage containers
A lwa ys keep vehicl e ca re produc ts out of the rea ch of c hildr en.
plication . Th ere fore , only usc s uch product
Never use fuel , turpentine, engin e nail
pol is h r emover or other volatile fluids fo r hicl e ca re. They are poisonous and hi ghl y mabl e.
Improper care and cleaning of ve hicle nents ca n compromi se th e vehicle' s sa fe ty tures cause se rio us pe rso na l injury .
Always clean and maintain vehi cle
usc approved or r ecommende d clean ers.
products containin g so lvents ca n
d amage plastics and
To help prevent damage, have stubborn stains remo ved by a professio nal has the necessary
ex pcrlisc ex perience.
thori zecl Volkswage n dealers and auth orized Volk swage n

Caring for upholstery
first read and note the int roductory information and heed the on page
Checklist
note the following when it comes to the care and preser va tion of the
Faste n e rs can damage upho ls te 1y fabric . B efore you get into the veh icle, fasteners that could com e int o wit h fabrics and
Sharp-edged objects and items on and phone cases, zippers, rivets, and rhinestones) can materia l and fabri c trim.1b help prevent damage, do no t let su ch items com e into direct contact with the and fa bric trim .
Dust and dirt pa rticles in pores, folds, and seams ca n have surface damage .
clothing for colo r-fas tness to help prevent upho ls tery discoloration, especially to ore d
Note
Disregarding the upholstery-related checklist may lead to damage or of stery and fabric trim.
note and follow the points
oration remove d by an authorized
first read and not e the information and heed the on
Normal
Befor e using a n y
A soft sponge or a commercially free mic rofiber
Vehicle care and maintenance
su rfaces with a cotto n or or a commercially avai lable lint-free
mi cro fib er
fabri c trim with light generalized soiling can be cleaned with a commercially able cleaner.
and trim with h eavy generalized soiling should b e b y specia li sts.
Stain r
emoval
removing stains, it may be to the area around the stain as the s tai ned spot itself. Thi s is especially true if the rounding a rea is darkened by generalized the trea ted area may be lighter than the untrea ted area.

the leather's co lo r. If necessary, fresh fading spots with a sp ec iall y-co lored le a th er
c ream.
th e leath er with a soft cloth.
Ty pe
of stain Cleaning
Volk swagen recommends u sin g a slight ly
App ly m ild soap so luti on using a damp Dab dry w ith an ab so rbent cloth .
Grease-based
po int pen , m arker, nail
p olish , latex paint , or sh oe
p olish.
[> Dab dry with an absorbent clo th .
[> C lean with sp ec ia l s ta in remover des igned for le ather.
Mild soa p so lution: Two tablespoons of liquid soap in one quart of water.
Note
Neve r treat leather wit h solvents, flo or w ax,
shoe polish, stai n remover or simil ar products.
up spilled liquid s immediately using an ab so rbent cloth, as liquid penetrates lea ther faces within a few seconds.
first read and note th e int roductory information and heed the on p age
Note --------------------~ If the ve hicl e is left in the sun f o r a long time,
cove r the uphols tery to protect th e leather from direct sunli ght and to help p revent fading and co loration.
Sligh t disco lorat io n caused by wear and tear is normal.
Note
Do not cle an leatherett e with solvents, floor wax, shoe poli sh , s tain remover, or s imilar u cts.
These can cause cause the material to become briule and brea.k. Sh arp-edge d objects and items on clothin g and belts (such as belt clips, cell phone cases, zipp ers , riv ets , and rhinestones ) can damage uphol stery mate rial and fabric trim.
If the vehicl e is left in the s un for a long time, cover the upholstery to prot ect the leat herette from direct sunli ght and to h elp prevent fading or
272 273

(contin ued )
tire inflation pressure
regularly when
the tires are cold
and always maintain the pre­
scribed tire pressure .
Low tire
pressure
can cause tires to get too
hot, resulting in
tread separation,
sudden loss of pressure , and
blowouts . This is because tires
with excess ively low pressure
un­
dergo more flexing, which can
cause the tire to overheat and de­
stroy
the tire.
Never exceed the permissible
maximum speed
and load rating
of the tires on your vehicle.
The effectiveness of the driver
assistance systems
and the brak­
ing
support systems depends
on the tire traction.
care and maintenance
To reduce the risk of losing
control,
crashes and serious per­
sonal injuries, never loosen the
bolts on wheels with bolted rim
rings.
Never mount used tires on
your vehicle if you are not sure of
their past use.
Tires age even if they are not
being used and can fail suddenly,
especially
at high speeds,
causing loss of vehicle control,
accidents,
and severe personal
injuries. Tires that are more than
6 years old can be used only in an
emergency and then only with
special care and at low speed.
For technical reasons it is usu-
ally
not possible to use wheel
rims from other vehicles. Even
wh eel rims from
the same model
may not fit properly.
Fac ility if necessa1y.
276

Aggressive fluids and materials
can cause visible and invisibl e
tire
damage that can cause tire
blowouts .
Always keep chemicals, oils,
grease, fuels, braking fluids
and
other aggressive substances
away from tires.
read and note the introductory inform ation and heed the on page 276.
The desig n of the w heel b o lt s is matc h ed to the fac­
tor y-install ed wheels. If different wheels are in ­
s tall ed, wh
eel b o lts the ri ght length and bolt
head sh ap e must b e used. Thi s helps to e nsure that
w heels can b e m ounted securely and that the
brakes will work page
In mos t yo u cannot use w heel bolt s from diff erent ve hicl e. Even wheel rims from the same m od el m ay not properly.
Tires and w heel rim s approved by Volkswag en
h ave been matched precise ly to your ve hicl e
m od el and cont ribut e consid erabl y to good han­
dlin g and safe ve hicl e performance.
Tight ening
torque
bolt s must alway s be install ed with the co r­
rect tightenin g page The required
tight enin g torqu e for the wheel bolts is 88 ft-lb s Nm). After changing
torqu e wre n ch b y an authorize d Volksw age n
d eal er or a uthorized Volk swagen Facility.
Care, maintenance
Tires age even if they are not
being used and can fail suddenly,
especially
at high speeds,
causing loss
of vehicle control,
accidents,
and severe personal
injuries.
Tires that are more than 6
years old
can be used only in an
emergency and then only with
special care
and at low speed.
Wheel rims with bolted rim rings
run true and safe ly . Damage d wheel rim s must b e re­
to repair them yourself. Ha ve an authorized
Facility re pai r them for you
Wheel rims with bolted decorative covers
Ligh t-allo y wheels may have interc h angeable d ec­
o rativ e cove rs attac h ed t o th e rim with self-locki ng
screws. If yo u want to replace damaged wheel
cove rs. contact your authorize d Volkswa gen deale r or authorize d Volk swa gen Fac ilit y
improper or damaged wheel rim s can af­fect driving cause accidents and serious personal injury.
only wheel rim s approved for the ve­
hicl e.

page220.
Remember that the vehi cle
manufacturer, not the tire manu­
facturer, determines the correct
tire
pressu re for the tires on your
ve hicl
e. Never exceed the max­
imum inflation pressure listed on
the tire s idewa ll for any reaso n.
Inflat e a
spare wheel to the pres­
sure specif i
ed for the vehicle's
road whee ls
on the tire pressure
label; inflate a
compact spare
wheel to the pressure specified for
the compact spare on the tire pres­
sure label
or on a separate label for
the compact spare, if there is one.
Incorrect tire pressure can cause
a
sudden tire failure or blowout,
loss
of control, collision, serious
personal injury, and even death.
Always inflate tires to the rec­
ommended and correct cold tire
pressure before driving off.
Excessive speed and/or over­
loading
can cause heat build-up ,
sudden tire failure including a
blowout
and tread separation
and loss of control.
maintenance
If the tire pressure is too low or
too high, the tires will wear pre­
maturely and the vehicle will not
handle well.
Regularly check tire inflation
pressure, at least once a month,
and also especially before a long
trip.
Note
increases fuel
There may be differences be-
tween the pressure readings
from a tire pressure gauge
and the
pressures registered by the Tir e
Monitoring System. The
e lec tronic Tire
Moni-
toring System
is more accurate .