Volkswagen Golf / Golf Plus. Manual - part 187

 

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Volkswagen Golf / Golf Plus. Manual - part 187

 

 

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4.10.1

Brake fluid level (dependent upon lining/

pad wear): Check

Brake fluid level at delivery inspection:
– For delivery inspection, fluid must be at MAX. marking -1-.

Note

In order that brake fluid does not overflow the reservoir, MAX

marking -1- must not be exceeded.

Brake fluid level at inspection service:
The fluid level must always be judged in conjunction with lining/

pad wear.
When vehicle is in use, fluid level tends to drop slightly due to

lining/pad wear and automatic adjustment.
• Recommended brake fluid level, if brake pads are almost at

wear limit:

“At MIN. marking or just above” -2-, “REPLENISHING IS NOT

REQUIRED”.
• Recommended brake fluid level when brake pads are new or

well within wear limit:

“Between MIN. and MAX. marking”.

4.11

Brake system and shock absorbers:

Perform visual check for leaks and dam‐

age

Check following components for leaks and damage:
♦ Brake master cylinder
♦ Brake servo (for anti-lock brake system: hydraulic unit)
♦ Brake pressure regulator and
♦ Brake calipers
♦ Presence of dust caps on brake fluid bleeder valves
– Ensure that brake hoses are not twisted.
– Ensure that brake hoses do not touch any vehicle components

when steering is at full lock.

– Check brake hoses for porosity or brittleness.
– Check brake hoses and lines for chafing.
– Check brake connections and fastenings for correct seating,

leaks and corrosion.

Maintenance - Edition 11.2009

58

    4. Descriptions of work

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WARNING

Faults found must always be rectified (repair measure).

4.12

Front and rear brake pads/linings:

Check thickness

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-

♦ Electric hand torch and mirror
Carry out the following procedure:
The adapter to loosen and tighten anti-theft wheel bolts is in the

vehicle tool kit 

⇒ page 112

 .

4.12.1

Front brake pads:

– For better evaluation of remaining pad thickness, remove the

wheel on the side where the brake pad wear indicator is in‐

stalled.

– Pull off wheel bolt covers if necessary 

⇒ page 112

 .

– Mark position of wheel relative to brake disc.
– Unbolt wheel bolts and remove wheel.

Maintenance - Edition 11.2009

4. Descriptions of work    

59

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– Measure thickness of inner and outer pads.
a - Pad thickness “without” backplate
Wear limit: 2 mm
The brake pads have reached their wear limit at a pad thickness

of 2 mm (without backplate) and must be renewed (repair meas‐

ure). Inform customer!

Note

When replacing brake pads, always check brake discs as well for

wear! Checking and if necessary replacing the brake discs is a

repair measure.

– Check brake disc for wear: “Running gear/Brake systems” ⇒ 

Brake system; Rep. Gr.  46 ; Repairing front brakes “Repairing

front brakes”

– Install wheel in marked position.
– Tighten wheel bolts diagonally and alternately. Torque setting

⇒ page 112

– Place adapter in vehicle tool kit after completing work.
– Reinstall wheel bolt covers if necessary.

4.12.2

Rear brake pads:

– Illuminate area behind hole in wheel using an electric hand

torch.

– Determine thickness of outer pad by checking visually.
– Illuminate inner pad with an electric hand torch and mirror.
– Determine thickness of inner pad by checking visually.
a - Inner and outer pad thickness without backplate
Wear limit: 2 mm
The brake pads have reached their wear limit at a pad thickness

of 2 mm (without backplate) and must be renewed (repair meas‐

ure). Inform customer!

Note

When replacing brake pads, always check brake discs as well for

wear! Checking and if necessary replacing the brake discs is a

repair measure.

– Check brake disc for wear: “Running gear/Brake systems” ⇒ 

Running gear; Rep. Gr.  46 ; Repairing rear brakes “Repairing

rear brakes”

4.13

Checking diesel particulate filter

Note

When checking the diesel particulate filter the ash mass limit val‐

ue is read.

– Connect vehicle diagnostic tester 

⇒ page 32

 .

Maintenance - Edition 11.2009

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    4. Descriptions of work

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– Switch on ignition.
– Touch the field or button on the screen for “GUIDED FUNC‐

TIONS”.

If the display is not as shown in the procedure: ⇒  Operating in‐

structions for vehicle diagnostic tester
– Confirm with 

 >

 button.

– Select one after the other:
♦ Brand
♦ Type
♦ Model year
♦ Engine code
– Confirm vehicle identification.
– Select vehicle system “Engine”.
– Select “Checking ash mass of diesel particulate filter”.
Follow instructions on display.
– End test.
– Switch off ignition and separate diagnostic connections.

4.14

6-speed dual clutch gearbox (DSG)

02E: Change oil and filter

Note

For the 7-speed dual clutch gearbox changing oil and filter is not

necessary.

– Procedure: “Power transmission/Dual clutch gearbox” ⇒  Pow‐

er transmission; Rep. Gr.  34 ; Changing oil and filter “Chang‐

ing oil and filter”.

4.15

Electric windows: Check positioning

(open and close functions)

Note

The automatic opening and closing features for the electric win‐

dows do not function after disconnecting and reconnecting the

battery. Therefore, with immediate effect, before a new vehicle is

delivered, the window adjusters must be reactivated. Once the

windows have been reactivated, the battery must not be discon‐

nected again.

WARNING

After batteries have been disconnected and reconnected the

roll-back function of the electric window regulators is disabled.

Severe pinching injuries could result!

Carry out the following procedure to reactivate the electric window

automatic functions:

Maintenance - Edition 11.2009

4. Descriptions of work    

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