engine VOLKSWAGEN GOLF PLUS 2007 Repair Manual

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

Failure to heed warnin g light s and instrument cluster text message s can cause the ve hicl e to break down in traffic and result in a and seriou s personal injury .
Never ignore warning light s or text I NGS.
Engine coolant specifications
introdu ctory information and heed th e on pag e 252.
The engi ne c ooling sys tem is fille d
p erce nt of Volk s wa gen engi ne coo lant additi ve G 12 plu s-plu s (TL-VW 774 G) o r G 12 plus (TL -VW F). Both of these engin e coola nt ti ve s are purple.
This mixtur e pro vides antif r eeze pro te ction down
to -13 a ls o he lps to pro tec t th e light
allo y pan s in th e eng in e coolin g sys te m against
corro sio n. In addit ion, the mi xture help s preve nt
c alcium dep os its and in creases the bo ilin g point of the e ng in e coola nt.
T o
protec t th e e ng in e, the mi xture must a lway s co nt ain nt le a st
mate conditions , th e perc entage of coola nt ti ve can be in cre ased. Howe ver, the coo la nt ti ve pe rc e n ta ge mu st never be m ore than oth erw ise , ant ifreeze prot ection is reduce d a nd
th e ability of the mi xture to coo l th e e ngine is als o
r educed.
Whe n addin g e ngine coolant, use a mixture of till ed water and at l ea st c o o la nt addit ive G 12 plu s- plu s for optimum co rro sion protection
Core, maintenanc e
Always stop the vehicl e as soon as it is saf e to do so.
Note
Failure to heed warning lights o r text can re s ult in veh icle damage.
Too little antifreeze protection in the en gin e coolin g syste m can cause eng in e failure and vere injuri es.
be used.
At extremely cold temperatures, the coolant could freeze, cau sin g the v ehicl e to brea k down. The heater would als o no t work, and ve hicl e cupants could be without protection at free zing temperatures.
Note
N eve r mix original Volkswagen engine coo lant additives with other additi ve s no t approved by
Volkswagen. Mixing Volkswage n coo la nt
facturers can serio usly damage th e engine and th e engi ne coolin g sys te m .
Eng in e coolant additive G 12 plus-plus can b e
m ixed with G 12 plus and G
If the fluid in th e e ngine coo lant res ervoir is any color but purple (s u ch
this is th e case, the gin e coolant mus t b e r epla ced immedi ate ly . envi se serious m alfun ction s or engine damage can occ ur!
E ng in e coolan t a nd engine c oo lant additi ves can pollute th e environm ent. le akin g opera ting a nd disp ose of th em in
acco rdance with appli cable e nvir o nm ent al la ws
a nd

read and note the introductory
on page 252.
If th e coolant level drops too low, the engin e
coo lant level/ tempe ratur e warni ng ligh t lights up.
Park the ve hicl e on level ground.
Always let the engin e cool
th e engine hood
There is a fig.
When the eng in e is co ld, check the e ngine
coolant leve l relat ive to th e marking on th e sid e of th e expa nsio n tank fig. 154.
Always protec t face, hands and arms from h ot
escaping coo lant o r steam by cover ing the cap with a larg e, thi ck rag.
Carefully unsc rew the
Add new engine co olant ac co rding to Volkswagen specifications page 254)
Th e engi ne coo lant leve l must b e in sid e the mark s on the sid e of the 154. Do
not above top edge of the
the engine compartment
Fig. 155 Coolan t e xpans ion tank cap in the eng in e
compartment.
Screw the lid tightly.
Even in a n em erge ncy, do not use any other kind of coolant addi tive if eng ine coolant meeting
Volkswagen pa ge 254) is una v ail­
able! Instead, add distilled water
page 254.
H
ot steam and hot engin e coo lant can cause se­
rio us burns.
Never open the hood if yo u sec steam o r coolant esca ping from the engine compartment. Always wait until you no longer see or hear steam or coolant escapin g from the engine.
Always let the e ngin e cool down compl etel y
before carefully opening th e hood.
When the engin e has coo le d down and you are ready to open hood:
- F
irmly apply the parking brake and shift (automatic) o r Neutral (manual only).
- Hemov e
the vehicl e key from the ignition.
- Always keep c
hildren and others away from the en gin e compartment and never
leave them unsupervise d.
The engine coolant system is under pressure
w hen the engine is hot. Neve r unscrew the coolant expansion tank cap whe n the engine is hot. Hot coolant can spray out and ca use severe burns and other serious injuri es.
254 255

Checking the
the engine compartment: Remove the
cove r from the vehicle
first read and n o te th e introducto ry
o n p age 257.
the ve hicle battery does quire mainten an ce.
th e ve hicl e for work in th e engin e page 242
page 242.
the battery cover
De pending o n the e ng in e ty pe, there are different kinds of battery covers:
cove r: fig . 156 in directi o n of th e arrow and re m ove the cove r upward.
With a soft cove r: th e s ide
If the lighti ng conditi ons a re poor, use see the ba tt ery charge indicato r and w ha t co lor it is. Neve r use
The round ba tt ery ch a rge wind ow level
the engine compartm ent Fig
. 157
the engine compart ment:
p la ce d. Have it ch ec ke d by an thorize d Volkswagen deale r o r an authorize d Volk swage n cility.
Ba ttery electro ly te leve l is to ry.
Working on the batterie s can cause se riou s acid burns, exp lo sion, or electri cal shock.
Alway s wear eye protection and protective
glove s.
tect above a ll your hands, your arms, and your fa ce and eyes from spilling or squirting acid .
Never tilt the vehicl e battery. Acid could out of the battery vents and burn you.
Never open
258 259

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.

Never charge a frozen or thawed battery. A
disch arged battery can freeze at temperatures around +32
Note
Never disconnect t11evehicle battery when the ignition is s witched on or the engine is running, as the electrica l system or electronic components can be damaged.
Note
Never connect power-generating equipment,
such as a solar panel or battery charger, to the 12-volt s ocket or the c igar ette light er in order to
charge the vehicle battery. This can damage the vehicle's electrical system.
Battery acid can pollute th e e nvironment. Operating mu st be collecte d and posed of properly, following all applicable
261

In this section information on th e fol­
l owing:
Washing the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 263
Washing with a power washer ................ .
Cleaning windows
and outside mirrors ......... .
Cleaning
and changing the winds hield wiper
b l
ades .......................
. . . . . . . 267
Cleaning wheel rims . . . . . . . . . . . . . . . . . . . . . . . . . 268
Care of rubber door and window seals . . . . . . . . . 268
De-icing door lock cylinders . . . . . . . . . . . . . . . . . . . 268
Undercoating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Cleaning the engine comportment ....... -. . . . . 269
Regu l
ar and expert ca re helps to preserve the value of your vehicle. expert care may also be o ne of th e requirements of you r New Vehicle Lim ited if co rros ion re pair or repa intin g is neces­
s ary.
Veh icle care produc ts avai lable fro m your au­
th orized Volkswagen d eale r or A uthorized
Int erio r care and page
Preparations for work ing in the e ngine com­page 242
Parts. accessorie s. repair s and modifications
Vehicle care produc ts ca n be dangerous. Im­
proper usc c a n cause accid ents, burns, poi­sonin g, or oth er seri ous persona l injuries.
Alway s sto re vehicle care products only in o rigina l co ntainers that are securely closed.
Alway s read and heed all th e in structions and all o n the pac kag e.
To reduce the risk of poiso ning, never usc empty food or beverage containers that might m is lead someone int o frum
A lways keep vehicl e ca re products out of the reach of childre n .
Never usc fuel, turpentine, eng in e o il, nail poli sh r emov er or ot her vo la til e fluid s for ve­
hicl e ca re. They are po isonous and hi ghl y flam­
mable.
Improper care and cleaning of ve hicl e compo­nent s can impact the safe ty feature s of the ve­
hicl e and cause serio us personal injury.
A lways clea n and maintain vehicl e compo­nent s according to manufacturer's instructions.
use ap1>roved or recomm ended
clean ers.
Vehi cle care products containing s olvents can damage plastics and other ve hicl e th e material s.
Wash th e ve hicl e only des ig ­nated was h loca tio ns to preve nt wa ter con­
t a minated with oil. grease and fuel from enterin g the storm drain sewe r system. In some are a s it is
a gains t th e to wash motor ve hicles anywhere than other than sp ecified design ated car
was hing locatio n s.
choo se those that are no t harmful to the en­viron ment.
Never th row out ve hicl e care produ cts with ordina ry house ho ld waste. Always read and hee d all th e in structi ons and on the

To he lp prev ent paint damage to the engine
hood , place wiper blades against th e winds hie ld
after they have dried . Do not le t them snap back
in to p lace.
Washing with a power washer
first r ead and note the introdu ctory information and heed the on pagc262.
A lways follow the instr u ctions
th ere is enoug h dis tan ce to soft ma te­
ria ls s uch as rubb er h ose s or insulatin g material as
well a s th e s en so rs of the Dis tance Co ntrol
sys te m . Th e
Never usc conce ntrated jet nozz les or dirt bla sters
Imp rope r usc of power washers can cause se­
rious invisibl e permanent d a m age leading to
ti re failur e and loss of ve hicle cont rol. This can cause accide nts and se riou s person al injury.
Keep sufficient di stance b e tween wate r je t
and tir es. Never wash tir es with a no zzle that sprays th e wa ter out in a direct stream re g ard­
l ess of th e di stance to the tir e and even for a very
short time .
Neve r u sc b lasters ." to clean tires. Even
a relatively long spraying dista nce and very
s hort applicatio n tim e can do visi ble or inv is ibl e damage to tire s.
Core, maintenance
Lock the hatc h to prevent unintentional ope ning in the car
the ve hicl e has been wash ed , th e wet
b ra kes or, in winter, brake discs or pads coated
w ith icc, rea ct slowe r and need l onger stopping
dista nces.
A lways dry the brakes and clean off any ic e
coa ting s with a few care ful applicatio ns of th e
bra ke. Make sure no t to endan ge r ot11er motor­
i sts or c yclists or disobey legal requi rements.
Note
Wate r temperature should not be m ore tha n
To he lp prevent damag e to paint, do not was h th e ve hicl e in dir ect sunli ght.
In order for and Assis t to work correctly, the sensors in the rear bumper must b e kept clean and clear of snow and ice. When using a pow er was her or steam clean er,
onl y spray the se n so rs directly for a short peri od
o f tim e and always keep the nozzle at l eas t4
in ch es em) from the sensor.
D o not clea n icy or snow- covere d w indow s
w ith
When washin g or rinsin g the vehicle in cold
weather, do no t let wate r ge t into the lock cylin ­
d
ers or po int the hose at gaps around th e doo rs ,
hood or rea r hatcl1. The w ate r could freeze on t11c
locks and sea ls and mak e it difficu lt to open th e

rims
Please fir st read and no te the introducto ry inform atio n and heed the WARN INGS on page 262.
Cleaning
steel wheel s
S
tubborn brake dus t can b e removed an in ­dustrial clean e r. s teel wheel s regularly with
a se pa rat e s po nge.
Repai r any paint damage o n steel wheels befor e rust begins to fo rm .
Cleaning alloy
wheels
Every two weeks: Wash road salt and brak e dust ofT alloy wheel s, and clean the w heels w ith an ac id-
of rubber door and window
Please information and heed the WARNINGS on p age262.
T he
rubbe r seals around the d oors and w indow s
will s ta y soft a nd flexib le, sea l bett er and la st
De-icing door
Please informatio n and heed th e WARNINGS on page 262.
Volkswage n recommends us in g only genuine Volkswagen spray with lubricating and anti -corro­
s iv e pro perti es de-ice door lock cylind ers.
Undercoatin g
Ple ase read and n ot e the introductory heed th e o n page 262.
The ve hicl e underbody is co ated to help protect it
f rom corrosio n and damage. The undercoating could b e damaged durin g normal u se. We there­
for e recommend that you have the protectiv e coat­in gs on the underbody and su sp e nsion in spected
regularly, and repaired if necessary.
compound to the wheel s.
road and brake dust are not re m ove d regu­
larly, they can corrode m etal.
the protective coating is damaged, fo r example
b y s tone impact, repai r the damaged area right
longer if the seals are treat ed regu larly with a suit­
able rubbe r care product.
B efor e applyin g the treatment, usc a soft cloth to
r emove dust and dirt from the rubber
Lock de-ic ers that contain grease solvents can cause the lock cylinder to
Undercoating and rust-proofin g products can catch fire on the hot ex h au st sy stem or any othe r
h ot engine componen t.
Neve r apply additional undercoating or rust
proofi ng on or near the ex hau st manifold, the exhaust pipes, catalytic converter, the heat s hields, or any oll 1e r hot vehi cle component

Please first read and note the introductory information and heed the o n page 262.
The e ngin e compartment of a ve hicle is a ge ro u s area page 242.
If nec essary, the e ngin e compartment should be
clean ed b y an authorized Volkswagen dealer or
a uthori zed Volkswage n
tectio n and damage electrical components, among oth er things. In addition, water could enter dire ctly into the ve hicl e interio r through the plenum CD.
If the engine compartment is extremely dirty, have
it clean ed prof essionally by your authorized swage n dea ler or authorized Volkswagen Fac ility .
Plenum chamber
The pl enum ch am ber is loca te d in the engin e compartment betwee n wind shi eld and engin e, under a pe rforated cover. Outs ide air is take n into
the vehicl e int erior fro m the pl enum chambe r via the heating and air cond itioni ng sys tem.
Regularly remove leaves and other loose object s
from the plenum chamber cover by hand or with a
vacuum cleaner.
Injuri es, sca lding , accident and fire hazard s can occur gine compartment!
Before working in the engine compartment, be sure to fa miliarizeyourselfwith the n ecessary
procedures and generally accepted safety
caut.ions page 242.
Note
------------------~
vere dam age to the veh.icle .
Wash th e e ngine compartm ent only in cial wash bays so that th e oily dirt and fuel
res idue th a t are washed off the vehicl e
legalto was h the en g in e compartm ent anywhere
other than at su ch sp ecified locations .
268 269