Volkswagen Golf / Golf GTI / Golf Variant. Service manual - part 3

00 – General, Technical Data

1

Safety Precautions

(Edition 12.2015)

⇒ “1.1 Start/Stop System Safety Precautions”, page 1
⇒ “1.2 Safety Precautions, Road Test with Testing Equipment”,

page 1
⇒ “1.3 HID Headlamps Usage and Safety Precautions”,

page 2

1.1

Start/Stop System Safety Precautions

Pay Attention to the following When Working on Vehicles with a

Start/Stop System:

WARNING

Danger of personal injury because the engine can start auto‐

matically on vehicles with Stop/Start System.

♦ If necessary, the engine can be started automatically on

vehicles with an activated Start/Stop System. A message

will appear in the instrument cluster.

♦ Make sure that the Start/Stop System is deactivated when

operating on the vehicle (turn off ignition, turn on ignition

again if necessary).

1.2

Safety Precautions, Road Test with

Testing Equipment

If Measuring Equipment Are Required during a Test Drive, Ob‐

serve the Following:

WARNING

Distraction  and  inadequately  secured  measuring  equipment

poses an accident risk.
There is a risk due to deployment of the front passenger airbag

in an accident.

• Operating measuring equipment while driving creates a

distraction.

• Unsecured measuring equipment can cause injuries.
♦ Always secure measuring equipment with a strap on the

rear seat and have a second person in the rear seat op‐

erate it.

1.3

HID Headlamps Usage and Safety Pre‐

cautions

Never Change a Headlamp Bulb If You Are Not Familiar with the

Corresponding Steps, Safety Precautions and the Tool.

WARNING

Life-threatening danger due to high voltage.

♦ It is necessary to disconnect the battery wire strap before

working on HID headlamp components. These parts are

marked with yellow high voltage symbols.

♦ Then switch the low beams on and back off. This removes

any possible residual voltage.

♦ Turn off the ignition and all electrical equipment and re‐

move the ignition key.

♦ The HID lamp control module should never be operated

without an HID headlamp bulb.

♦ Due to the high voltage, the HID headlamp bulb can only

be operated inside the headlamp housing. When ignited,

a HID headlamp bulb operates at over 28000 V).

WARNING

Risk of injury from burning, UV rays, blinding and explosion.

♦ Due the high temperatures, absorption of UV rays, and the

risk of blinding, the HID headlamp bulb should only be op‐

erated inside the headlamp housing.

♦ Do not look into the beam of light. It may interfere with the

ability to see for a significant period of time.

♦ HID headlamp bulbs are under pressure and can crack

when bulbs are replaced.

♦ Always wear safety glasses and gloves when removing

and installing HID bulbs.

WARNING

Pollution risk.

♦ HID headlamp bulbs are hazardous waste. They contain

metallic mercury (Hg) and traces of thallium.

♦ Do not destroy HID headlamp bulbs and avoid contact with

burst glass bulbs.

♦ Observe disposal regulations.
♦ Dispose of HID headlamp bulbs in suitable containers at

an authorized collection site.

Caution

♦ Do not touch HID headlamp bulb glass cones with bare

hands. The remaining fingerprint would evaporate due to

the heat of the operated bulb and condense on the reflec‐

tor which would impair headlamp luminosity. Use clean

cloth gloves to insert the HID headlamp bulb.

♦ Only replace faulty HID headlamp bulbs with the same

version of lamp. Bulb identification can be found on bulb

socket or on the glass cone.

♦ Connectors must engage correctly when installed and

must be checked for proper connection.

2

Repair Information

⇒ “2.1 Contact Corrosion”, page 4
⇒ “2.2 Wire Routing and Securing”, page 4

2.1

Contact Corrosion

Contact corrosion can occur if incorrect fasteners (bolts, nuts,

washers) are used.
For this reason, only fasteners with a special surface coating are

used.
In addition, rubber or plastic parts and adhesive are made of ma‐

terial that does not conduct electricity.
If there are doubts as to whether parts are suitable or not, use

new parts. Refer to Parts Catalog.
Observe:
♦ Use only original replacement parts that have been tested and

are compatible with aluminum.

♦ Use only Volkswagen accessories.
♦ Damage resulting from contact corrosion is not covered by

warranty.

2.2

Wire Routing and Securing

Wires should be marked before they are removed to prevent con‐

fusing them and to guarantee the installation position. This also

includes fuel lines, hydraulic lines, vacuum lines, EVAP systems

and electrical lines. Make sketches or take photos if necessary.
Due to the restricted space in the engine compartment, make sure

to allow for sufficient clearance to all moving or hot components

to avoid damaging the wires.