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Service Training

AG. Volkswagen AG d
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Self-study Programme 400 ss aut
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The Golf Variant 2007
rm

ab
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ility
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spec
es, in part or in w

t to the co
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nform
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Prote AG.
The Golf Variant 2007 – design and variability

The Golf Variant 2007 continues the success story of its predecessor models. In particular, it impresses with its
dynamic design, which is characterised by its sporty, dynamic appearance, its innovative exterior, a new rear
light design and its typical Golf face.

S400_003

S400_002

G
en AGolf en AG . Volkswag
In terms of product characteristics,
ksw
agthe Variant 2007
doessets the standards in its class, e.g. as regards:
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● safety, ho ● the amount
eo of space on offer,
aut ra
● design, e.g. thessnew rear light design, ● variability,c payload and load securing,
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● quality, ● vehicle dynamics and


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● handling, ● the new panoramic sliding sunroof.


erm

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Separate self-study programmes are available on the following current topics:


rrectness of i
l purpos

● Self-study programme 390 The 7-speed Double-clutch Gearbox 0AM


● Self-study programme 405 The 1.4l 90 kW TSI Engine with Turbocharger
nf
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This self-study programme has been created in co-operation with Volkswagen de México erstellt.
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The self-study programme shows the design and Prote
cted For current testing, adjustment and repair
AG.
agen
function of new developments. instructions, refer to the relevant
The contents will not be updated. service literature.

2
Contents
AG. Volkswagen AG d
agen oes
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a
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In brief
orise . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.ee. . . ......................... 4
th or
au ac
ss

ce
e
nl

pt
du

an
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erm

ab
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

rrectness of i
l purpos

Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

nf
ercia

orm
m

atio
om

n in
or c

thi
Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
te

sd
iva

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rp

cu
o

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i t.
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t. Co py
rig
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rig
Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
by copy by
Vo
lksw
cted agen
Prote AG.

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Heating and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Radio, telephone and navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3
In brief

Where will the Golf Variant be produced?


The Golf Variant will be produced in Volkswagen's
Puebla plant in Mexico.

n AG. Volkswagen AG do
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S400_031

wit
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The Puebla plant
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This plant started operation in 1964 and produced the Prote
cted AG.
agen
Beetle. Around 14,000 staff are currently employed in
Puebla; amongst other vehicles, they produce the
New Beetle and the Jetta. These will now also be
joined by the new Golf Variant.
In certain markets, this vehicle will also be marketed
under the name Jetta Variant.

S400_080

4
… Modern clocked assembly lines …

S400_045

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... Modular production …


ole,

spec
urposes, in part or in wh

With its high standard of quality, the ultra-modern


t to the co

Puebla plant is one of Volkswagen AG's leading


production plants.
rrectne

The Golf Variant 2007 will be built on the production


ss

lines which are already in place for the Jetta


o
cial p

f in

in Mexico.
form
mer

atio
om

n
c

i
or

n thi
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cum
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5
In brief
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The Golf Variant 2007 ss
auth or
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In many disciplines, the Golf Variant 2007 again sets

an
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the standards in its class, e.g.:

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ility
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- Safety hole

spec
- Design ● Load compartment concept with extensive
es, in part or in w

t to the co
- Quality storage compartments and securing options
- Handling
- Ride comfort

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- Spaciousness
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- Multifunctionality
● Comfortable spatial availability thanks to

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or
the extended passenger compartment

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● Modern, high-quality interior . Cop py
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● Front seats with optional 4-way


lumbar support (with integrated
height adjustment)

● Modern illumination concept


for the interior lighting

● Electromechanical power steering

6
● Optional panoramic sliding sunroof ● High body stiffness

● New aerial concept

AG. Volkswagen AG d
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● New rear light design

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S400_052
es, in part or in w

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● Optional sports running gear

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● Optimised front and


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rear axle (four-link suspension)


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● Increased front and rear track width ensures
significantly better vehicle dynamics

● 2C-Climatronic (2-zone climate control)

7
In brief

Technical data
Golf Variant 2007

S400_063

AG. Volkswagen AG d
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S400_064 S400_065
rrectness of i
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The dimensions given in the pictures are in mm.


nform
mercia

at

Length 4556 mm Track width at front 1535 mm


om

ion
c

in t
or

Width 1781 mm Track width at rear 1508 mm


his
ate

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cum
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Height with roof rails 1504 mm Curb weight 1278 - 1414 kg*
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Wheelbase ht. 2578 mm Permissible gross vehicle weight
rig
ht 1800 kg
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Roof load cted 75 kg Tank capacity
agen
55 litres
Prote AG.

Braked towing capacity 1500 - Drag coefficient 0.31 Cd


up to a gradient of 8% 1700 kg*

8
Passenger compartment dimensions

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S400_069 S400_070
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The dimensions given in the pictures are in mm. Cop py
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Front headroom 972 mm Height of load sill 570 mm

Rear headroom 969 mm 505 litres**


Luggage compartment volume
Luggage compartment aperture 801 mm 560 litres***

Through loading width 1014 mm

* Depending on engine
** Without variable load floor
*** With variable load floor

9
AG. Volkswagen AG d
agen oes
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Body authorise
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Body structure

wit
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hole

spec
The basic characteristics of the Golf Variant's body
es, in part or in w

are based on the Jetta body.

t to the co
rrectness of i
l purpos

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Laser welding technology


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The laser welding concept familiar from the Jetta will
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be successfully continued in the Golf Variant for the t. Cop py
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variant-specific components in the rear area.
ht
pyri by
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In addition to the advantages already described for
the Jetta, a significantly stiffer rear end is achieved
due to laser welding.

This makes a vital contribution to the stiffness of the


vehicle as a whole.

Static and dynamic stiffness

The Golf Variant sets standards in terms of static and dynamic stiffness.
Its static stiffness is around 39% greater than that of its predecessor.

Dynamic stiffness has been increased as follows:

● 16% in torsion
● 32% in flexion

10
AG. Volkswagen AG d
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S400_051

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Legend
o

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Red = side crash area


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Yellow = passenger compartment


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Blue C =
op frame structure py
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Prote AG.

Further information on the body


can be found in self-study programme No. 354 "The Jetta 2006".

11
Body

Features
In the front area of the body, approximately up to the B-pillar, the Golf Variant takes equipment elements
from the Jetta.

Doors Front seats

The front doors have the door concept familiar from The front seats in the Golf Variant can be adjusted
the Jetta. The design of the rear doors is conventional, either mechanically or electrically. A front passenger
using an assembly carrier. seat with through-loading function is optionally
available.

AG. Volkswagen AG d
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Rear lights Prote AG.

In the Golf Variant, the rear lights are not split, and are
integrated into the relevant, rear body side panel.
Thanks to the lights, which project into the side panel,
visibility to the rear and also to the side is extensively
improved.

12
Rear seat bench

The rear seat bench is split 60 : 40 and can be folded.

olkswagen AG
ag en AG. V does
Rear sideVowindows
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The th
au aerials
for radio reception are integrated into the ra
c
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rear side windows.

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Tailgate

rrectness of i
l purpos

The tailgate gives access to a large load compartment


aperture. It is opened manually, whilst raising is
nform
ercia

supported by gas-filled struts.


m

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tion in
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S400_050
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Load compartment Prote
cted AG.
agen

The luggage compartment, which is larger than that of the


predecessor, can be put to multiple uses. This is achieved by the
storage compartments in the optionally available, variable load floor,
the securing options and the folding concept for the rear seat bench.

13
Body AG. Volkswagen AG d
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Panoramic sliding sunroof

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The Golf Variant can be optionally equipped with panoramic sliding sunroof.

ility
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The panoramic sliding sunroof can be opened to a maximum length of 660 mm. In comparison with conventional
hole

spec
sliding sunroofs, it offers the advantage that more light enters into the vehicle's passenger compartment.
es, in part or in w

t to the co
The panoramic sliding sunroof offers a sense of space comparable with that of a convertible, but with less draught.
Unlike in a convertible, the fact that the occupants are better enclosed within the body increases significantly better

rrectness of i
accident protection.
l purpos

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Panoramic sliding sunroof – glass panel 1 slid completely to the rear

orm
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Sunroof roller blind – semi-extended

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S400_107

Wind deflector – fully raised

The panoramic sliding sunroof is a large glass roof consisting of two glass panels. It is bolted to a reinforcement
frame in the body's roof structure. The seal between the panoramic sliding sunroof and the body is achieved by
means of a gasket on the body side.

The special feature of the panoramic sliding sunroof is guidance of the front panel over the rear, fixed glass panel
into the sliding position. The glass panel is raised and moved via electrically driven Bowden cables.

To protect against excess sunlight, the panoramic sliding sunroof is equipped with an electrically driven sunroof
roller blind.

The panoramic sliding sunroof is also equipped with an extending wind deflector.

14
Components
(exploded diagram)

Glass panel 2, fixed

Roof cut-out gasket


Glass panel 1, movable

Wind deflector

Sunroof roller blind mounting,


n AG. Volkswagen AG do sunroof roller blind retracted
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Right-hand mechanism ss ce
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Left-hand mechanism
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Right Bowden cable


Electric drive,
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for opening and closing


sunroof roller blind
glass panel 1
m

at
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io

Left Bowden cable Mounting frame


n
c

in t
or

for opening and closing


his
ate

do
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glass panel 1
p

cum
for

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S400_072
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AG.

Electric drive,
panoramic sliding sunroof

15
Body

Adjustment of glass panel 1

Glass panel 1 is moved to the relevant position via a mechanism in the panoramic sliding sunroof.
The mechanism is driven via an electric motor by means of n AG. Volkcable
aageBowden
swagenattached
AG do on both the left and right-
lksw es n
hand sides. The Bowden cables move the mechanism y Vwithin an adjustment range; theotrelevant
o gu roof positions can
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be reached in this way. By means of the front tend ho pieces with separate guide plate tracks ande othe relevant slides,
s au ra
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glass panel 1 is clearly positioned in the front
s area.

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Position of the mechanism Closed position
ot

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Roof vent position
hole

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es, in part or in w

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S400_116
Guide plate

rrectness of i
Pin
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Vent position
S400_113

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S400_117

thi
Bowden cable

s
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Guide plate movement

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At the start of the tilting movement, the rear section of the roof is raised via a guide plate and pins which run in this.
n

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The roof moves to the vent position. ht. rig
ht
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Sliding position
Position of the mechanism
Roof sliding position

S400_118
Pin Guide plate movement
Guide plate

S400_114
Guide plate track
Slide If the Bowden cable continues to be moved, starting
from the vent position, the front section of the
End piece mechanism is also raised and glass panel 1 is moved
to the sliding position.

This is also carried out by means of a guide plate and pins running in it. The slide runs towards the separate end
piece and guide plate track. Glass panel 1 can then be moved backwards over fixed glass panel 2.

When closing, the process runs in reverse order.

16
Operation
AG. Volkswagen AG d
agen oes
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The panoramic sliding sunroof and the sunroof roller d b ara
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blind are operated via a common switch in the display aut ra
ss c
in the front area of the roof lining. Display in the roof lining

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This switch has three functions and adjustment

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Switch for

erm
options:

ab
ility
panoramic sliding sunroof

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● Turning the switch to move
hole

spec
glass panel 1 to the sliding position
es, in part or in w

t to the co
● Pressing the switch to move
glass panel 1 to the vent position
S400_084
● Short or long push on the sunroof roller blind

rrectness of i
buttons (one-touch or jog mode) to move the
l purpos

sunroof roller blind Rotating ring

nform
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Open, press switch -


m

at
om

Emergency actuation press function for

ion
c

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vent position
or

his
ate

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If the situation necessitates, glass panel 1 or the


p

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sunroof roller blind can be closed after blocking by


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constantly pulling on the switch or via jog mode. To do Cop py
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this, the rotating ring must be in the "sliding sunroof gh ht
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c lksw
closed" position. Glass panel 1 is then closed without cted
by pull function for
agen
Prote AG.
closing force limitation. zero position and
emergency closing

S400_081

Emergency adjustment
Sunroof roller blind button "open"
If the panoramic sliding sunroof can no longer be
Sunroof roller blind button "close"
adjusted electrically, closing can alternatively be
carried out via mechanical emergency adjustment Roof completely
using a tool (Allen key, 4 mm). open,
As a result of mechanical emergency adjustment, all end of sliding position

values (pre-selection positions, protection ranges and Comfort position,


partial trapping force limit value increases) are sliding position
"erased".
Positions for open
Malfunctions such as, e.g. closing force limitation roof, sliding
position
triggering, may therefore occur when glass panel 1 is
next adjusted. Following emergency adjustment, a
workshop visit is therefore vital to re-adjust the
panoramic sliding sunroof.
S400_082
Roof slightly open, wind
deflector extended, Roof closed,
sliding position zero position

17
Body

Raising glass panel


agen
1AGto
. Vothe
lkswavent
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Vol ot g
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When raising e
ris glass panel 1 to the vent position, the antee
utho or
a
following situations are possible: ac
ss Open, press switch -

ce
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un

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press function for

an
d
itte

● In rotating ring position "roof closed", pressing the

y li
vent position
erm

ab
switch raises glass panel 1 to the vent position.

ility
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● Glass panel 1 can be closed by pulling on the
is n

h re
ole,

switch; it moves back to the zero position. Close, pull switch -

spec
urposes, in part or in wh

pull function for

t to the co
zero position and
emergency closing

rrectne
S400_108

Switch display in rotating ring position "roof closed" on use

ss o
of the press and pull function
cial p

f inform
mer

atio
m

Automatic operation = actuate switch briefly


o

n
c

i
Manual operation = actuate switch for a longer
or

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Emergency actuation t. rig
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If the situation necessitates, glass panel 1 can be closed after stopping by constantly pulling on the switch.
AG.

Glass panel 1 is then closed without closing force limitation.

Glass panel 1 Glass panel 2


raised to vent position fixed

S400_074

Glass panel 1 raised to vent position, vent position Sunroof roller blind closed

S400_101

18
AG. Volkswagen AG d
agen oes
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tho eo Roof completely open,
Opening glass spanel
au 1 ra
s c end of sliding position

ce
e
nl

pt
du

To move glass panel 1 backwards over glass

an

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Comfort position
erm

ab
panel 2 to the sliding position, the rotating ring on

ility
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the switch must be turned clockwise from the zero

wit
, is n

h re
position. In this case, the panoramic sliding sunroof
hole

spec
is opened to different lengths depending on the Sliding position, five
es, in part or in w

t to the co
setting position. positions for open
● From the first position for sliding position, the wind roof
deflector is raised.

rrectness of i
● The panoramic sliding sunroof has a comfort
l purpos

position; this is separately identified by a mark. The Sliding position,


S400_109
length to which the roof is opened in the comfort

nform
roof slightly open,
ercia

position ensures that wind noise is extensively wind deflector extended


m

at
om

i
avoided during driving.

on
c

in t
or

● The rotating ring no longer engages at the end of

his
e

Roof closed,
at

do
riv

the sliding position. To open the roof completely, zero position


p

cum
or

the rotating ring must be rotated to the end in the


f

en
ng

t.
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direction of rotation and must be held until the roof . Cop py
rig
ht
is open. opy
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Vo Emergency actuation
ht
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If the situation necessitates, glass panel 1 can be
closed after stopping by constantly pulling on the
switch. Glass panel 1 is then closed without closing
force limitation.

Glass panel 1
Sunroof roller blind
completely open
closed

Wind deflector
raised

S400_075

Sunroof roller blind closed Glass panel 1 completely open, end of sliding position

S400_102

19
Body
Close, pull switch -
pull function for zero position and emergency closing
Closing glass panel 1
Roof completely open,
end of sliding position
When closing glass panel 1, the following
situations are possible: Comfort position

● To move glass panel 1 forwards from the sliding


position to the zero position and therefore close the Sliding position, five
panoramic sliding sunroof, the rotating ring on the positions for open
switch must be rotated from its present position, roof
counter clockwise, to the rotating ring position
"roof closed".
The panoramic sliding sunroof closes automatically. Sliding position,
S400_110
● To move glass panel 1 downwards from the vent roof slightly open,
position to the zero position and therefore close the wind deflector extended
panoramic sliding sunroof, the switch must be Roof closed,
pulled down (pull function – see "Raising glass zero position
panel 1 to the vent position"). The panoramic sliding
Switch display in rotating ring position
sunroof closes automatically.
"roof closed"
on use of the push and pull function

Emergency actuation
AG. Volkswagen AG d
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olksw not
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If the situation necessitates, glass
rise panel 1 can be closed after stopping by ntconstantly
ee
pulling on the switch.
tho
Glass panel 1 is then closed u without closing force limitation. or
a ac
ss
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nl

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ab
ility

Glass panel 2
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Glass panel 1
wit

fixed
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closed
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
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orm
m

atio
om

n in
or c

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sd
iva

S400_073
o
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Glass panel 1 closed, zero position Cop py Sunroof roller blind open
t. rig
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pyri by
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by
cted agen
Prote AG.

S400_100

20
Opening and closing the sunroof roller
blind
Open sunroof roller
The panoramic sliding sunroof is supplemented by an
blind - sunroof roller
electrically driven sunroof roller blind, which is blind button "open"
installed in the rear area of the panoramic sliding
sunroof.

The roller blind can be opened or closed by pressing


the buttons within the switch. In this case, it is Close sunroof roller blind -
electrically extended or retracted beneath the two sunroof roller blind button
glass panels in the assembly frame guides.. The "close"
S400_111
sunroof roller blind can be actuated regardless of the
AG. VolkswagAutomatic
en AG
does operation = actuate sunroof roller blind
position of glass panel 1. agen
olksw not
yV gu button briefly
edb ara
ris Manual operation nte = actuate sunroof roller blind
tho eo
s au ra
c button for a longer time
s

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nl

pt
du

Emergency actuation

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For the possible sunroof roller blind
erm

ab
ility
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If the situation necessitates, and the sunroof roller operating variants, please refer to the

wit
, is n

blind fails to close due to mechanical sluggishness, it owner's manual.

h re
hole

spec
can be closed via jog mode. The sunroof roller blind is
es, in part or in w

then closed without closing force limitation.


t to the co
rrectness of i
l purpos

Glass panel 1
Sunroof roller blind completely open
nf
ercia

half open
rm
m

atio
om

n in
or c

thi
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sd
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t. Co py
rig
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rig by
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Prote AG.

S400_099

Sunroof roller blind half open Glass panel 1 completely open, end of sliding position

S400_103

21
AG. Volkswagen AG d
agen oes
olksw not
yV
Body b gu
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ise nte
or eo
uth ra
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s

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e
nl

pt
du

an
itte

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erm

ab
ility
Automatic and manual adjustment of the
ot p

wit
, is n

panoramic sliding sunroof and the sunroof roller blind

h re
hole

spec
es, in part or in w

The panoramic sliding sunroof and the sunroof roller Sliding sunroof adjustment control unit J245 is

t to the co
blind are operated via a common operating unit. This integrated into the LIN data bus and controls the
contains button 1 for tilting roof E582, button 1 for opening and closing of the panoramic sliding sunroof.

rrectness of i
sunroof roller blind E584 and sliding sunroof Sliding sunroof motor V1 is also integrated into sliding
l purpos

adjustment regulator E139. sunroof adjustment control unit J245.

nform
ercia

All control information is read in and processed Sunroof roller blind control unit J394 is also integrated
m

at
directly by sliding sunroof adjustment control unit into the LIN data bus and controls the opening and
om

ion
c

in t
J245. closing of the sunroof roller blind.
or

his
ate

Sunroof roller blind motor V260 is also integrated into

do
priv

cum
sunroof roller blind control unit J394.
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
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by lksw
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Prote AG.

Via onboard supply control unit 2 J520, which is integrated into data bus diagnostic interface J533,
the information from other control units is also read in:

● The driver door control unit J386 evaluates the information from driver side central locking lock unit F220 and
actuation of the central locking system button on the driver side.

● The driver door control unit J386 evaluates the information from front passenger side central locking lock unit
F221 and actuation of the central locking system button on the front passenger side.

● The convenience system central control unit J393 evaluates the opening of the driver or front passenger door
after switching off the ignition. If these are not opened after switching off the ignition, a power-down time of ten
minutes runs (high release signal).
Ten minutes after switching off the ignition, release for the panoramic sliding sunroof should be widhdrawn via a
request from the driver door control unit J386 and front passenger door control unit J387 to the convenience
system central control unit J393 (low release signal).
If, in the event of a fault, release for the panoramic sliding sunroof is not withdrawn after ten minutes, the drive
for the panoramic sliding sunfoof and the sunroof roller blind is switched to sleep mode by the onboard supply
control unit J519 after a further 25 minutes. Release for the panoramic sliding sunroof and the sunroof roller
blind is withdrawn if the ignition is switched off and the driver or front passenger door is opened.
The relevant behaviour of the panoramic sliding sunroof and the sunroof roller blind can be coded in the
convenience system central control unit J393 and onboard supply control unit 2 J520.

● The ABS control unit J104 reports the speed. Closing force limitation can therefore be reduced at high speeds.

● The onboard supply control unit J519 ensures that terminals 15 and X are enabled.

22
Functional diagram
(panoramic sliding sunroof)

Legend

E139 Sliding sunroof adjustment regulator


E582 Button 1 for tilting roof
E584 Button 1 for roof roller blind

F220 Driver side central locking lock unit


F221 Front passenger side central locking lock unit

J104 ABS control unit


J245 Sliding sunroof adjustment control unit
J386 Driver door control unit
J387 Front passenger door control unit
J393 Convenience system central control unit
J394 Sunroof roller blind control unit
J519 Onboard supply control unit
J520 Onboard supply control unit 2
J533 Data bus diagnostic interface

V1 Sliding sunroof motor


V260 Sunroof roller blind motor

n AG. Volkswagen AG do
lkswage es n
o ot g
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CAN drive data bus


ility
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S400_090
wit
is n

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ole,

CAN convenience data bus


spec
urposes, in part or in wh

t to the co

Thermal protection: CAN instrument cluster data bus


Hall sensors for speed and travel
rrectne

detection are integrated into the CAN data bus line


panoramic sliding sunroof drive. Thermal
ss

protection can be calculated from these LIN data bus line


o
cial p

f in

and with the voltage supply values. The


form
mer

purpose is to achieve misuse protection Input


atio
om

(play protection).
n
c

i
or

Output
thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
23
Body

Door concept
olks
wage
n AG. Volkswagen AG do
es n
o V t gu
by ara
ed
The door concept
ris already familiar from the Jetta is usednfor
tee the front doors in the Golf Variant.
tho or
s au ac
s

ce
le

The design of the rear doors is conventional, using an assembly carrier.


un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
Front doors

rrectne
The front doors consist of an outer door panel with two retaining rails and an inner door panel for mounting the
component parts. The outer door panel is bonded to the retaining rails. The retaining rails are bolted to the inner

ss o
cial p

door section.

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
a

Inner door panel


iv

o
pr

cum
r

Cover strip
fo

en
ng

t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.

Retaining rail

Cover strip

Outer door panel Retaining rail

Side impact bar


S400_049

24
Rear doors

The rear doors consist of an outer door panel and an inner door panel.
The door components are integrated into an assembly carrier, which is bolted to the inner door panel.

The outer door panel is flanged around and bonded


to the inner door panel.

Outer door
Adhesive
panel

AG. Volkswagen AG d
agen oes
Inner door panel olksw not
byV gu
ara
ed
ris nte
tho S400_048 eo
au ra
ss Inner door panel c

ce
e

S400_046
nl

pt
du

an
itte

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Assembly carrier
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
A side impact bar is also installed in the door. It is
l purpos

bolted to the inner door panel in the lower area of the


door.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
o

m
f

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ng

t.
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Cop py
ht. rig
rig ht
Inner door panel copy by
Vo
by lksw
cted agen
Prote AG.

S400_047
Side impact bar

25
Body

Storage compartment concept


The interior of the Golf Variant 2007 is characterised by a multitude of storage compartments and securing
options. AG. Volkswagen A
agen G do
es n
ksw
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss

ce
e
nl

pt
du

an
● 2 cup holders and 2 storage compartments in the centre console

itte

y li
erm

ab
(optional: smoker package)

ility
ot p
2 cup holders in the rear centre armrest

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
op
● Storage compartments in the front doors, t. C py
rig
gh ht
including bottle holder (for max. 1l bottle) pyri by
Vo
co lksw
by
cted agen
Prote AG.

● In addition to the hook on the grab handle, a coat


hook is fitted as standard on the B-pillar trim. The hook
is positioned in such a way that a jacket or a coat
does not impede visibility through the side window.

● Optional pockets on the rear of the front seat backrests

26
● Small roof console with storage compartment in
the solid roof

● Glove box in the instrument panel, which is cooled in


combination with an air conditioner

● Depending on equipment variant, a normal and a


cooled storage compartment is available in the rear
area of the centre colsone.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec

● Extensive storage compartments and securing


es, in part or in w

t to the co

options in the load compartment


rrectness of i
l purpos

nf
ercia

orm

S400_053
m

atio
om

n in
or c

thi
e

● Good load compartment partitioning thanks to


t

sd
iva

o
r
rp

cu

variably adjustable load compartment covers


o

m
f

en
ng

i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
27
Body

Load compartment concept


The load compartment in the Golf Variant 2007 has been enlarged in comparison with its predecessor. Its concept
has been designed to enable as many, diverse transportation tasks to be carried out as possible.

● Bulky goods can be easily transported thanks e.g. ● The rear seat backrest can be folded to form a flat
to the folding rear seat backrest (split 60 : 40). load floor thanks to the high mounted pivot point
A front passenger seat with through-loading and therefore offers high loading ability.
function is optionally available.

Bag hooks, folding

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec

Storage compartment for warning triangle


es, in part or in w

t to the co

and first aid kit


rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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cu
o

m
f

en
ng

t.
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op Large storage compartment in the
Large storage compartment in the luggage compartment floor - ht. C py
rig
ht
cover folded completely forwards opy
rig by
Vo luggage compartment floor -
by c lksw
cted agen
Prote AG.
28
● The compartments in the optionally available, variable load floor offer optimal storage options.
The cover of the large, rear storage compartment can be folded over completely or raised to various angles.
This enables the load compartment to be sub-divided into separate areas.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

Through-loading aperture Storage compartment open

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio

Lashing ring
om

n in
or c

thi
te

sd
iva

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rp

cu
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m
f

en
ng

t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

S400_054

Lashing ring

Cover raised vertically Small storage compartment in the luggage compartment floor -
cover open

29
Occupant protection

Safety equipment
The Golf Variant is fitted with the safety equipment familiar from the Jetta.

● The front passenger airbag can be deactivated


via a key switch in the storage compartment
on the front passenger side.

● Driver and front passenger airbags

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
● Seat belt prompt for ris nte
tho eo
u ra
driver and front passenger ss a c

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
● Seat belt pre-tensioners and belt tension
hole

spec
limiters for the front seats
es, in part or in w

t to the co
rrectness of i
l purpos

● Optional rear side airbags in combination

nform
ercia

with seat belt pre-tensioners and belt tension


m

at
limiters
om

ion
c

in t
or

his
ate

do
priv

cum
for

3-point seat belts on all seats


en


ng

t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

● Isofix attachment points on the rear,


outer seats

● Pressure sensors in the front doors

30
Top Tether

The Golf Variant is equipped with the Top Tether


system.
● Side airbag in the front seats
with two chambers

● Curtain airbag for front


and rear occupants

Cover with
Top Tether lettering

● Top Tether system

S400_112

Top Tether retainer


AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au The Top Tether system serves to securera a child seat
ss c
ce

more firmly. In this case, an additional, upper belt on


e
nl

pt
du

an

the child seat is attached to corresponding retainers


itte

y li
erm

ab

on the vehicle floor behind the rear seat bench.


ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

S400_055
l purpos

nform
mercia

at
om

ion
c

Further information on the occupant


in t
or

his
e

protection systems can be found in


at

do

Acceleration sensors in the rear


riv


p

self-study programme 318


um
or

wheel housing liners


f

en
ng

"The Golf 2004".


t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
31
Engines

Engine/gearbox combinations
Petrol engine
5-speed 5-speed 6-speed
manual gearbox manual gearbox manual gearbox
0AF 0A4 0AJ
Diesel engine

1.6l 75 kW
petrol engine with 2-valve
technology

1.4l 90 kW AG. Volkswagen AG d


agen oes
TSI engine with turbocharger olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

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erm

1.4l 103 kW/125 kW

ab
ility
ot p

TSI engines

wit
, is n

with dual charging

h re
hole

spec
es, in part or in w

t to the co
2.0l 147 kW

rrectness of i
TSI engine with turbocharger
l purpos

nform
mercia

at
om

io

1.9l 77 kW
n
c

in t
or

TDI engine with 2-valve


his
ate

technology
do
priv

cum
for

en
ng

i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
2.0l 103 kW by lksw
cted agen
Prote AG.
TDI engine with 4-valve
technology

2.0l 103 kW
TDI engine with 2-valve
technology

32
6-speed 6-speed 6-speed 6-speed 7-speed
manual gearbox manual gearbox automatic gearbox direct- double-clutch
02S 02Q 09G shift gearbox gearbox
02E 0AM

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
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ce
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un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

33
Engines

The new engine code system


To reduce engine code diversity, the 3-digit engine The new engine code generation can be recognised
codes will be provided with a new, fourth digit. as follows:
This applies only to engines with an identical, basic
engine but different outputs In the case of these ● The first digit of the engine codes is a "C".
engines, output differentiation takes place solely via ● The 3-digit engine codes will continue to be used
the engine control unit, in which case the software is on the engine block.
adapted to implement the different output and torque. ● The 4-digit engine codes can only be seen on the
Engines with a modified emissions concept will not be vehicle data sticker, the control unit and the model
provided with changed engine codes. plate.

The assignment of the new engine codes is shown


using the following example case:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
au ra
ss c

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le
un

pt
an
d
itte

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ab
pe

ility
ot

wit
, is n

h re
2.0l 103 kW TDI 4V 2.0l 100 kW TDI 4V 2.0l 96 kW TDI 4V
hole

spec
es, in part or in w

t to the co
rrectness of i
BKD AZV BEE
l purpos

nform
mercia

a
com

Engine codes - previously


ion in
r
te o

thi
s
iva

do
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cum
fo

en
ng

t.
yi Co
op py
Engine codes - new
. C rig
ht ht
rig by
py
with 4 digits
by co Vo
lksw
cted agen
Prote AG.

CKDA CKDB CKDC

S400_104

34
Where does identification take
Vehicle data sticker
place?

The 4-digit engine codes are written on the control


unit, the model plate and the vehicle data sticker.

Sticker on the engine control unit

S400_094
Model plate
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss S400_091 c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
S400_093
rrectness of i
l purpos

nform
mercia

at

The 3-digit engine code will be retained as part of the A sticker with the engine codes and a sequential
om

ion
c

engine number; these are stamped onto the engine number is affixed onto the engine in the visible area
in t
or

his
te

block. (toothed belt guard, valve cover).


a

do
priv

cum
for

en
ng

i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
Engine code on the engine block Prote
cted AG. Sticker with engine code
agen

S400_095

S400_096

35
Engines

The 1.6l 75 kW petrol engine with 2-valve technology


This engine is identical to the 1.6l 75 kW petrol engine
fitted in the current Jetta.

Technical features

● 2-valve roller rocker arm


● Aluminium engine block with ribbed sump
● Secondary air system
● Plastic variable intake manifold
● Pressure sensor system, previously hot-film air mass
meter (HFM)
● Omission of the crankcase breather, venting only
via the cylinder head
● Omission of the exhaust gas recirculation system

S400_015

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
Technical data ss Torque and outputc diagram
ce
e
nl

pt
du

an
itte

Engine code BSE


y li
erm

ab
ility

Type 4-cylinder in-line engine


ot p

wit
, is n

Displacement 1595 cm3


h re
hole

spec

Bore 81 mm
es, in part or in w

t to the co

Stroke 77.4 mm
Torque (Nm)

Output (kW)

Valves per cylinder 2


rrectness of i

Compression ratio 10.3 : 1


l purpos

Maximum output 75 kW at 5600 rpm


Maximum torque 148 Nm at 3800 rpm
nform
ercia

Engine management Simos 7.1


m

at
om

Fuel Super unleaded RON 95


ion
c

(normal unleaded RON 91


in t
or

his
e

with reduction in
at

do
riv

performance)
p

cum
for

en
g

Exhaust gas Probe before catalytic S400_016


n

t.
yi
op Engine speed (rpm)
Co
treatment converter C py
t. rig
gh ht
linear lambda probe, pyri by
Vo
co lksw
Probe after catalytic by
cted agen
Prote AG.
converter:
transient probe
Emissions standard EU 4

36
The 1.4l 90 kW TSI engine with turbocharger
The 1.4l 90 kW TSI engine is a further example of the
TSI engine model series. However, it is charged using
a turbocharger. It replaces the 1.6l 85 kW FSI engine,
and offers significantly better performance than this
engine with considerably lower fuel consumption.

Technical features
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
● Homogenous mode ed (Lambda 1)
nte
ris
ho eo
● Turbocharger
aut with waste gate ra
ss c
● Plastic intake manifold with integrated charge air

ce
le
un

pt
cooler

an
d
itte

y li
rm

Liquid-cooled charge air cooler

ab

pe

ility
● Dual-circuit cooling system
ot

wit
, is n

S400_105

h re
● Fuel system regulated according to requirements
hole

● High-pressure fuel pump with integrated pressure spec


es, in part or in w

t to the co
limiting valve Further information on this engine can be
● Innovative combustion process with intake found in self-study programme 405 "The
manifold flap change-over 1.4l 90 kW TSI Engine with Turbocharger".
rrectness of i
l purpos

nform
ercia

Technical data Torque and output diagram


m

a
com

tion in
r

Engine code CAXA


te o

thi
s
iva

do

Type 4-cylinder in-line engine


r
rp

cum
fo

Displacement 1390 cm3


en
ng

i t.
py Co
Bore 76.5 mm
t. Co py
rig
h ht
rig by
Stroke opy 75.6 mm Vo
Torque (Nm)

Output (kW)

by c lksw
cted agen
Valves per cylinder Prote 4 AG.

Compression ratio 10 : 1
Maximum output 90 kW at 5500 rpm
Maximum torque 200 Nm at
1500-3500 rpm
Engine management Bosch Motronic MED 17.5.20
Fuel Super unleaded RON 95
Exhaust gas Main catalytic converter,
treatment Lambda control
Emissions standard EU 4 Engine speed (rpm) S400_106

37
Engines

The 1.4l 103 kW/125 kW TSI engines with dual-charging


Above all, the special feature of these engines is the
combination of direct petrol injection, dual-charging
and downsizing.

- In dual-charging, these engines are charged


subject to requirements by a mechanical
compressor and/or a turbocharger.
- Downsizing means replacing a large-capacity
engine with a powerplant with smaller n AG. Volkswagen AG do
lkswage es n
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displacement and/or fewer cylinders. This reduces byV ua
d ran
ir se tee
the internal friction and therefore fuel consumption th o
u or
a ac
without any reduction in output or torque. ss

ce
e
nl

pt
du

an
itte

y li
Thanks to this concept, these engines surpass the
erm

ab
ility
ot p

performance of engines with the same output and

wit
S400_041
, is n

also consume less fuel.

h re
hole

spec
es, in part or in w

t to the co
Further information on these engines can

rrectness of i
be found in self-study programme 359
"The 1.4l TSI Engine with Dual-charging".
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
a

Technical features
iv

o
r
rp

cu
o

m
f

en
ng

t.
yi
● Two output variants with 103 kW and 125 kW C

op Engine cover with vacuum tank for intake manifold Co
py
t. rig
● Homogenous mode (Lambda 1) yri
gh flap change-over by
ht
op Vo
Double injection catalytic converter heating Grey cast iron cylinder block
c
● ● by lksw
cted agen
Prote AG.
● Turbocharger with waste gate ● Dual-circuit cooling system
● Additional mechanical supercharger ● Fuel system regulated according to requirements
● Charge air cooling ● High-pressure fuel pump with a delivery pressure
of up to 150 bar

38
Technical data

1.4l 103 kW TSI engine 1.4l 125 kW TSI engine

Torque and output diagram Torque and output diagram

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Torque (Nm)

Torque (Nm)
o

Output (kW)

Output (kW)
th eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
S400_043 S400_044
Engine speed (rpm) Engine speed (rpm)

rrectness of i
Technical data
l purpos

nform
ercia

Engine code BMY BLG


m

Type 4-cylinder in-line engine 4-cylinder in-line engine

a
com

tion in
Displacement 1390 cm3 1390 cm3
r
te o

thi
s
iva

Bore 76.5 mm 76.5 mm


do
r
rp

cum

Stroke 75.6 mm 75.6 mm


fo

en
ng

t.
yi Co
Valves per cylinder 4 Cop 4 py
ht. rig
ht
Compression ratio 10 : 1 opy
rig by 10 : 1
Vo
by c lksw
Maximum output 103 kW at 6000 rpm
Prote
cted AG. 125 kW at 6000 rpm
agen

Maximum torque 220 Nm at 240 Nm at


1500 to 4000 rpm 1750 to 4500 rpm
Engine management Bosch Motronic MED 17.5.1 Bosch Motronic MED 17.5.1
Fuel Super unleaded RON 95 Super Plus RON 98
(Super unleaded RON 95 with slightly
higher consumption and slight torque
reduction in the low engine speed range)
Exhaust gas Main catalytic converter, Main catalytic converter,
treatment Lambda control Lambda control
Emissions standard EU 4 EU 4

The different output and torque levels are achieved using software. The engine
mechanics are the same in both engines.

39
Engines

The 2.0l 147 kW TSI engine with turbocharger


The 2.0l 147 kW TSI engine with turbocharger is also
fitted in the current Golf GTI, Jetta and Passat Variant
models.

Technical features

● Single-pipe exhaust system with starter and


n AG. Volkswagen AG do
underbody catalytic converter mounted near lkswage es n
o ot g
byV ua
engine d ran
ir se tee
tho
● Ethanol-resistant Hitachi high-pressure apump
u or
ac
ss
● Non-return fuel system

ce
le
un

pt
an
d

● Homogeneous fuel injection


itte

y li
rm

ab
● Decoupled drive chain wheel in the balancer shaft
pe

ility
ot

assembly

wit
, is n

h re
● Elliptical toothed belt pulley on crankshaft
hole

spec
S400_017
● Mechanical brake servo pump
es, in part or in w

t to the co
● Continuously adjustable charge air flaps
Further information on this engine can
be found in self-study programme 337

rrectness of i
"The 2.0 l FSI Engine with Turbocharger".
l purpos

nform
ercia

Technical data Torque and output diagram


m

a
com

tion in
r
te o

Engine code BWA


thi
s
iva

do
Type 4-cylinder in-line engine
r
rp

cum
fo

Displacement 1984 cm3


en
ng

t.
yi Co
op py
Bore 82.5 mm t. C rig
gh ht
yri by
Stroke 92.8 mm cop
by
Vo
lksw
cted agen
Compression ratio 10.5 : 1 Prote AG.
Output (kW)
Torque (Nm)

Maximum output 147 kW at


5100 to 6600 rpm
Maximum torque 280 Nm at
1800 – 4700 rpm
Engine management Bosch Motronic MED 9.1
Camshaft timing 42° crank angle
adjustment
Fuel Super Plus unleaded RON 98
(Super unleaded RON 95 with
slight reduction in performance)
Exhaust gas Two three-way catalytic
treatment converters with Lambda control
S400_018
Engine speed (rpm)
Emissions standard EU 4

40
The 1.9l 77 kW TDI engine with 2-valve technology
The 1.9l 77 kW TDI engine is also fitted in the Golf,
and has already proved its worth in other Volkswagen
models.

Technical features

● Unit injectors with solenoid valves


● Adjustable turbocharger
● Optional engine version with catalytically coated
diesel particulate filter
● Switchable cooler for exhaust gas recirculation

Information on the diesel particulate filter S400_019


can be found in self-study programme 336
"The Catalytic Coated Diesel oParticulate
n AG. V lkswagen AG do
Filter". wage es n
olks o t gu
yV
db ara
rise nte
ho eo
ut ra
Technical data ss a c Torque and output diagram
ce
le
un

pt
an
d
itte

y li

Engine code BXE (without diesel


rm

ab
pe

particulate filter)
ility
ot

wit

BLS (with diesel particulate


, is n

h re

filter)
hole

spec

Type 4-cylinder in-line engine


es, in part or in w

t to the co

Displacement 1896 cm3


Bore 79.5 mm
rrectness of i

Output (kW)
Torque (Nm)

Stroke 95.5 mm
l purpos

Valves per cylinder 2


Compression ratio 18 : 1
nform
ercia

Maximum output 77 kW at 4000 rpm


m

a
com

tio

Maximum torque 250 Nm at 1900 rpm


n in
r
te o

thi

Engine management Bosch EDC 16 with


s
iva

do

unit injector system


r
rp

cum
fo

en
g

Fuel Diesel, min. 51 CN


n

t.
yi Co
op py
Exhaust gas gh
t. C
Exhaust gas recirculation and rig
ht
treatment pyri oxidising catalytic converter/
by
Vo
co lksw
by
diesel particulate filter
Prote
cted AG.
agen
Engine speed (rpm) S400_020
Emissions standard EU 4

41
Engines

The 2.0l 103 kW TDI engine with 4-valve technology


This engine is identical to the 2.0l 103 kW TDI engine
in the Golf 2004.

Technical features
n AG. Volkswagen AG do
lkswage es n
o ot g
● Unit injectors with solenoid valves byV ua
d ran
ir se tee
● Adjustable turbocharger tho
or
au ac
● 4-valve technology ss

ce
e
nl

pt
● Two camshafts, driven by toothed belts du

an
itte

y li
● Switchable cooler for exhaust gas recirculation
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
S400_021
Further information on this engine can
l purpos

be found in self-study programme 316


"The 2.0l TDI Engine".

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

c
Technical data Torque and output diagram

um
for

en
ng

t.
yi Co
Cop py
.
Engine code BKD t rig
gh ht
pyri by
Vo
o
Type 4-cylinder in-line engine
c by lksw
cted agen
Prote AG.
Displacement 1968 cm3
Bore 81 mm
Stroke 95.5 mm
Valves per cylinder 4
Compression ratio 18 : 1
Output (kW)
Torque (Nm)

Maximum output 103 kW at 4000 rpm


Maximum torque 320 Nm at 1750 rpm to
2500 rpm
Engine management Bosch EDC 16 with
unit injector system
Fuel Diesel, min. 51 CN
Exhaust gas Exhaust gas recirculation
treatment and oxidation catalytic
converter
Emissions standard EU 4
Engine speed (rpm)
S400_024

42
The 2.0l 103 kW TDI engine with 2-valve
technology and diesel particulate filter
The 2.0l 103 kW TDI engine with 2-valve technology
. Volkswagen AG
gen AG in the does
and diesel particulate filter is alsool swa
kavailable not
y V gu
Golf model year 2006. ised b ara
n r tee
ho
aut or
ac
Technical features ss

ce
e
nl

pt
du

an
itte

y li
erm

Unit injectors with solenoid valves

ab

ility
ot p

● Catalytically coated diesel particulate filter

wit
, is n

h re
● Turbocharger raised and rotated upwards by 180°
hole

spec
for mounting the diesel particulate filter close to the
es, in part or in w

t to the co
engine
● Ceramic glow plugs

rrectness of i
l purpos

S400_023

nform
ercia

Information on the diesel particulate filter


can be found in self-study programme 336
m

at
om

io

"The Catalytic Coated Diesel Particulate


n
c

in t
or

Filter".
his
ate

do
priv

cum
for

en
ng

i t.
py Co
. Co py
rig
Technical data Torque and output diagram
ht
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Engine code BMM
Type 4-cylinder in-line engine
Displacement 1968 cm3
Bore 81 mm
Stroke 95.5 mm
Valves per cylinder 2
Compression ratio 18.5 : 1
Output (kW)
Torque (Nm)

Maximum output 103 kW at 4000 rpm


Maximum torque 320 Nm at 1750 rpm to
2500 rpm
Engine management Bosch EDC 16 with
unit injector system
Fuel Diesel, min. 51 CN
Exhaust gas Exhaust gas recirculation
treatment and diesel particulate filter
Emissions standard EU 4

Engine speed (rpm) S400_024

43
Transmission

Manual gearboxes - overview


Also see
self-study
Manual gearbox Technical features programme
No.:

• Developed from 02T gearbox –


• Housing reinforced, gearbox adapted nA G. Volkswinstallation
agen AG
ageto modified does
olksw not
position by V gu
d ara
• Without speedometer sendere nte
ris
tho eo
s au ra
c
s

ce
e
nl

pt
du

an
5-speed manual gearbox
itte

y li
erm

0AF

ab
ility
ot p

wit
, is n

• Developed from 02J gearbox 328

h re
hole

• Gearshift mechanism optimised, final drive reinforced,

spec
es, in part or in w

housing adapted

t to the co
• Without speedometer sender

rrectness of i
5-speed manual gearbox
0A4
l purpos

nf
ercia

o
• Developed from 0AG gearbox 306

rm
m

atio
• Adapted for the 1.4l 90 kW TSI engine, extended output shaft,
om

distance between output shaft and differential increased, sheet

n in
or c

metal bearing mounting replaced by cast bearing mounting for

thi
te

sd
a

higher torques, toothing ground


iv

o
r
rp

cu
• Final drive reinforced, splines adapted for higher
o

6-speed manual gearbox m


f

en
ng

torques, housing adapted yi


t.
Co
0AJ • Without speedometer sender Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
• Developed from 02J gearbox Prote AG. 306
• Gearshift mechanism optimised
• Longer shafts with additional bearings, additional gear pair,
new, longer aluminium housing cover, housing adapted to the
installation position
• Without speedometer sender
6-speed manual gearbox
02S

• Developed from 02M gearbox 306


• Changes to selector shaft, selector forks with stops in housing,
modified bearings
• Without speedometer sender

6-speed manual gearbox


02Q

44
Automatic gearboxes - overview
Also see
self-study
Automatic gearbox Technical features programme
No.:

6-speed direct-shift gearbox 02E is equipped with a hydraulic 308


double clutch. It combines the advantages of a manual gearbox,
such as high efficiency, robustness and sportiness, with the
. Volkswagen AG
w gen AG
aadvantages does gearbox, i.e. high comfort, especially
of an automatic
ks not
y Vol on changing gears. gu
b a
ed ran
oris tee
th or
au ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
6-speed
ility
ot p

direct-shift gearbox
wit
, is n

02E h re
hole

spec
es, in part or in w

t to the co

7-speed double-clutch gearbox 0AM has been developed from 390


rrectness of i

direct-shift gearbox 02E. In contrast to the 02E, it operates with a


double clutch, an electric oil pump for the hydraulic system and
l purpos

separate oil circuits for the gearbox and mechatronics.


nform
mercia

at
om

ion
c

in t
or

his
ate

do
riv

7-speed
p

cum
for

double-clutch gearbox
en
ng

t.
yi Co
0AM Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

6-speed automatic gearbox 09G is a compact, light, electronically 309


controlled gearbox for transverse mounting.

6-speed
automatic gearbox
09G

45
Running gear

The running gear


The Golf Variant 2007's running gear continues the high standard of comfort and dynamics in its A platform
segment.
The Golf Variant is also equipped with modern McPherson strut front suspension. The modern four-link rear
suspension deserves particular emphasis in terms of its vehicle dynamics and ride comfort.

The electromechanical power steering gives the driver a precise steering feel and continuously adapts the required
steering forces to the vehicle's increasing speed.

The springs and shock absorbers have been matched to the vehicle's increased axle loads.

● Electronic stabilisation programme


based on the MK60 system from
Continental Teves

● Brake assist system

● Electromechanical power steering system,


2nd generation
AG. Volkswagen
agen AG do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce

Modern McPherson strut front suspension


e


nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

● Direct anti-roll bar connection with a


ratio of 1 : 1
rrectness of i
l purpos

nform
mercia

at
om

io

● Brake servo with


n
c

in t
or

dual rate characteristic curve


his
ate

do
priv

cum
for

en
ng

i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
46
Further information on the running gear can be found in
self-study programme No. 321 "The Golf 2004 Running Gear".

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
ho
ut ● Four-link rear suspension or
a ac
ss with very good vehicle dynamics

ce
le
un

pt
and comfort characteristics

an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
S400_036

rrectness o
cial p

f inform
mer

atio
m

● Track and camber separately adjustable


o

n
c

i
or

on the rear axle


thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
Tyre pressure monitor,
o

c by lksw
cted agen
Prote AG.
optional with Trendline,
standard with Comfortline

● Vertical accelerator pedal with contact-free


senders for the accelerator pedal position

47
Electrical system

The fuse boxes and relay positions


in the vehicle electrical system
Installation locations
Relay carrier beneath dash panel on left-
hand side, above the onboard supply
The electrical system in the Golf Variant 2007 has control unit
been taken from the Jetta 2006 and has only been
modified in the rear area. The installation locations of
the electronics box, the pre-fuse box, the fuse box and
the relay carrier are identical to those in the Golf.

The adjacent illustration


shows the installation locations.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss Electronics box on the left in the engine c
ce
le
un

compartment pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

Pre-fuse box on the left in the engine


m

a
com

tio

compartment
n in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

Fuse box in the dash panel on the left-


hand side

48
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
Relay carrier on the onboard supply control unit,

rrectness of i
beneath the dash panel on the left-hand side

l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

More detailed information on the


electrical system can be found in
self-study programme 319
"The Golf 2004 Electrical System".

S400_066

49
Electrical system
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
The networking concept

ce
e
nl

pt
du

an
itte

y li
erm
Overview of networked

ab
ility
ot p
electronic control units

wit
, is n

h re
hole

spec
es, in part or in w
To ensure flawless data exchange between the control

t to the co
units, these are networked via various data bus
systems.

rrectness of i
l purpos

The data bus diagnostic interface J533 (gateway) acts


as the interface for the following data bus systems:

nform
mercia

- CAN drive data bus

at
om

ion
- CAN convenience data bus
c

in t
or

his
e

- CAN infotainment data bus


at

do
riv

- CAN instrument cluster data bus


p

cum
for

en
g

- CAN diagnostic data bus


n

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Control units connected to

CAN drive data bus

CAN convenience data bus

CAN infotainment data bus

CAN sensor data bus

LIN data bus

CAN instrument cluster data bus

CAN diagnostic data bus

CAN data bus line


(high-speed and low-speed)

LIN data bus line

K-wire

50
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
au Legend ac
ss

ce
e
nl

pt
du

an
D Ignition/starter switch

itte

y li
erm

ab
E221 Operating unit in steering wheel

ility
ot p
(multifunction steering wheel)

wit
, is n

h re
G85 Steering angle sender
hole

spec
es, in part or in w G273 Interior monitoring sensor

t to the co
G384 Vehicle inclination sender
G397 Rain and light sensor

rrectness of i
G419 ESP sensor unit
H8 Anti-theft alarm system horn
l purpos

J104 ABS control unit

nf
ercia

J136 Seat and steering column adjustment control

orm
unit with memory function
m

atio
om

J217 Automatic gearbox control unit

n in
or c

thi
J234 Airbag control unit
te

sd
iva

o
J245 Sliding sunroof adjustment control unit
r
rp

cu
o

m
f

J255 Climatronic control unit

en
ng

t.
yi Co
op
t. C J285 Control unit in dash panel insert py
rig
gh ht
pyri J345 Trailer detector control unit
by
Vo
co lksw
by
J362 ctedImmobilizer control unit agen
Prote AG.
J364 Auxiliary heater control unit
J386 Driver door control unit
J387 Front passenger door control unit
J388 Rear left door control unit
J389 Rear right door control unit
J393 Convenience system central control unit
J394 Sunroof roller blind control unit
J400 Wiper motor control unit
J412 Mobile telephone operating electronics
control unit
J431 Headlight range control, control unit
J446 Parking aid control unit
J500 Power steering control unit
J503 Control unit with display for radio and
navigation
J519 Onboard supply control unit
J520 Onboard supply control unit 2
J525 Digital sound package control unit
J527 Steering column electronics control unit
J533 Data bus diagnostic interface
J587* Selector lever sensor control unit
J604 Auxiliary air heater control unit
J623 Engine control unit
J743* Mechatronic unit for direct shift gearbox
NOx NOx sensor
S400_067 R Radio
T16 Diagnostic connection
* With double-clutch gearbox only

51
Heating and air conditioning

Air conditioning
Three different systems are available in the Golf Variant 2007:

● The heater and fresh air system with 4-stage blower and recirculated air circuit
● The semi-automatic heater and air conditioner "Climatic"
● The heater and air conditioner "2C-Climatronic"n AG. Volkswagen AG do
wage e ks s no
Vol t gu
d by ara
e nte
ris
utho
Indirect ventilation Centre vent
eo
ra
a c
ss
(with 2C-Climatronic only)

ce
e
nl

pt
du

an
itte

Vent

y li
Vent
erm

ab
for front right footwell

ility
for windscreen
ot p

wit
Vent for rear centre
, is n

h re
(for centre console with rear vents only,
hole

spec
otherwise blind covers on the air
es, in part or in w

t to the co
conditioner unit)

Vent

rrectness of i
for rear right footwell
l purpos

nf
Vent
ercia

or
in the A-pillar

m
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu

Vent
o

m
f

en
ng

t.
in the dash panel op
yi Co
C py
t. rig
gh ht
Vent pyri by
Vo
co lksw
by
for front left footwell cted agen
Prote AG.

Vent
for rear left footwell S400_038

If the vehicle is fitted with a centre console with rear


vents, the storage compartment in the centre console
can also be cooled.

Further information on heating and air


S400_071
conditioning can be found in self-study
programme No. 318 "The Golf 2004".

52
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

Operation

spec
urposes, in part or in wh

t to the co
Depending on the vehicle's equipment, four different types of control panels are
available for the heating and air conditioning:

rrectne
With or without instant heat button for the auxiliary coolant heater

s

s o
cial p

f
● With or without potentiometer for the seat heating

inform
mer

atio
om

n
c

i
2C-Climatronic control panel
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

S400_076

Interior temperature sensor


Button assignment if equipped
with auxiliary coolant heater

In comparison with the previous equipment, the lettering on the right-hand button has been changed from "ECON"
to "AC".

The centre button on the lower panel is labelled "DUAL". This function serves to match the temperature on the front
passenger side to the temperature on the driver side. If the vehicle is fitted with an auxiliary coolant heater, this
button panel serves as an instant heat button for the auxiliary coolant heater, and is labelled with the appropriate
symbol.
Matching the temperature on the driver and front passenger side is then carried out via "AUTO".

Thermo Top V auxiliary coolant heater

The Golf Variant 2007 can be fitted with the optional Thermo Top V auxiliary coolant heater.
This undertakes the following tasks:

● Acts as an auxiliary heater for heating the vehicle interior and defrosting the vehicle's windows,
● Acts as stationary ventilation to lower the interior temperature when the vehicle is parked in the sun,
● Acts as an additional heater in vehicles with petrol or diesel engines (instead of the PTC heater
element in diesel engines).

53
Radio, telephone and navigation

The radio systems in the Golf Variant 2007


RCD 300 radio

The entry-level RCD 300 radio system offers


. Volkswagen AG
the following functions: gen AG does
swa k not
Vol gu
d by ara
e nte
ris
● Four loudspeaker channels
utho (20 Watts each), two eo
ra
a c
ss optionally connected
or four channels can be

ce
le
un

pt
● RDS FM/AM European radio (AM without LW)

an
d
itte

y li
● Indication of the stored stations with RDS names in
erm

ab
ility
ot p

the display

wit
is n

● FM 2-tuner diversity

h re
ole,

spec
● Control via the multi-function steering wheel (MFL)
urposes, in part or in wh

and multi-function indicator (MFI)

t to the co
S400_057
● Integrated single-CD player
● Control system for an external 6-disk CD changer

rrectne
● Telephone control system (hands-free)
● GALA

ss o
cial p

f
● Self-diagnosis incl. loudspeaker diagnosis

inform
● Driving school function, must be explicitly ordered
mer

atio
(indication of turn signal function and speed via
om

n
c

the display - coding function) i


or

n thi
te

sd
a

● Playback of music CDs in MP3 format


iv

o
pr

cum
r
fo

en
ng

t.
yi Co
op
RCD 500 radio C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
The higher-quality RCD 500 radio system offers Prote AG.

the following functions:

● Four loudspeaker channels (20 Watts each)


● RDS FM/AM European radio (AM without LW)
● Indication of the stored stations with RDS names in
the display
● FM 2-tuner phase diversity
● Control via MFW and MFD
● Integrated 6-disk CD changer S400_058
● Control system for an external 6-disk CD changer
● Telephone control system (hands-free)
● GALA
● Traffic Information Memory (TIM)
● Vehicle model-specific sound adaptation
The cover frame has to be removed to
● Self-diagnosis incl. loudspeaker diagnosis
remove or install a radio, in order to
● Optional connection of an external sound amplifier
access the threaded connection located
● Optional playback of music CDs in MP3 format
behind it.

54
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
Radio/navigation system RNS 300 ss

ce
e
nl

pt
du

an
itte

y li
The entry-level radio/navigation system RNS 300
erm

ab
ility
ot p

offers the following functions:

wit
, is n

h re
hole

spec
● Two-colour display (navigation via symbols)
es, in part or in w

● Four loudspeaker channels, two or four

t to the co
channels can be optionally connected
● 1 tuner principle for FM including TMC

rrectness of i
● Dynamic guidance via TMC (Traffic Message
l purpos

Channel)
● Integrated CD player

nf
ercia

S400_059

o
● Control system for CD changer

rm
m

atio
Navigation without navigation CD inserted
m


o

n in
c

(corridor function)
or

thi
te

sd
a

● Playback of music CDs in CDA, WMA and


iv

o
r
rp

cu

MP3 format
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Radio/navigation system MFD 2
agen
Prote AG.

The higher-quality radio/navigation system MFD 2


with integrated navigation system offers
the following functions:

● Multi-colour display (MFD)


● Dynamic guidance via TMC (Traffic Message
Channel)
● Four loudspeaker channels (20 Watts each)
● RDS FM/AM European radio (AM without LW)
● Indication of the stored stations with RDS names in
the display
● Control via MFW and MFD
● Audio CDs can also be played via the internal DVD S400_060
player
● Control system for an external 6-disk CD changer
● Telephone control system (hands-free)
● GALA
● TIM
● Can be combined with Volkswagen Sound and
For further information on radios, please
Dynaudio
refer to self-study programme 342 "Radio
● Self-diagnosis incl. loudspeaker diagnosis
Systems".

55
Radio, telephone and navigation
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Universal Mobile Phone Preparation (UMPP) Low s autho eo
ra
c
s

ce
le
un
In the Golf Variant 2007, Universal Mobile Phone Preparation Low is fitted exclusively with BluetoothTM

pt
an
d
itte

y li
technology.

erm

ab
ility
The data are transmitted via BluetoothTM from the mobile phone to the mobile telephone operating electronics

ot p

wit
is n
control unit.

h re
ole,
A cradle for the specific mobile phone model is required to hold the mobile phone in the mounting and to use the

spec
urposes, in part or in wh

hands-free system.

t to the co
The mobile telephone operating electronics control unit communicates with the other control units via the CAN
infotainment data bus.

rrectne
UMPP Low is suitable for the mobile telephone D and E networks.

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
Vo
UMPP Low has the following functions: co lksw
by
cted agen
Prote AG.

● Operation and display are carried out on the mobile phone and partly via the multifunction steering wheel
(optional).
● It has a hands-free system and radio mute switching.
● The mobile telephone's rechargeable battery is charged via the mobile phone mounting.
● The info and breakdown buttons are located on the mobile phone mounting. These signals are transferred via a
discrete cable connection.
● The vehicle is equipped with a GSM vehicle antenna system, which is connected directly to the mounting.
● There is a CAN data bus interface to the CAN infotainment data bus.
● Data transfer between the mobile phone and the mobile telephone operating electronics control unit takes place
via a BluetoothTM interface.
● This UMPP is diagnosis-capable.
● The power-down time can be set (max. 60 minutes).

As the mobile telephone is always connected via the BluetoothTM interface, a pairing process has to be
carried out once.
Please check the latest VOTEX information at www.volkswagen-zubehoer.de for the availability of
telephone mountings for the various mobile phones.

56
J453

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
au ra
ss J503 c

ce
le
un

pt
an
d
itte

y li
rm

ab
E440
pe

ility
ot

wit
CAN infotainment
, is n

h re
data bus R65
hole

spec
es, in part or in w

t to the co
rrectness of i
J527 J533 BluetoothTM audio R54
l purpos

data transmission
CAN convenience 64 kbit/sec via HFP*

nform
ercia

data bus
m

a
J412
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
J519 Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
R38 Prote AG.

S400_097

Charger and button line Mounting on


instrument panel
Legend

E440 Multifunction buttons on left in steering wheel J519 Onboard supply control unit
(optional) J527 Steering column electronics control unit
J412 Mobile telephone operating electronics J533 Data bus diagnostic interface
control unit R38 Telephone microphone
J453 Multifunction steering wheel control unit R54 Mobile telephone
(optional) R65 Telephone aerial
J503 Control unit with display for radio and
navigation

* Hands-free profile

57
Radio, telephone and navigation

The aerial concept ksw


agen
AG. Volkswagen AG d
oes
not
Vol
by gu
d ara
Radio systems RCD 300 and RCD 500 rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
S400_061
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

The RCD 300 and RCD 500 radio systems require two aerials for the internal dual-tuner diversity receiver to
yi
t.
Co
op
receive radio signals. The AM/FM aerial is designed as a roof mounted aerial. C py
t. rig
gh ht
yri
The FM aerial is located in the rear right side window. p by
co Vo
by lksw
cted agen
Prote AG.

Radio/navigation system RNS 300

Auxiliary heater
radio receiver

S400_062

The RNS 300 radio/navigation system only requires one aerial for the internal 1 tuner radio receiver to receive
radio signals. The AM/FM aerial is located in the rear right side window.
The signals for telephone, auxiliary heater and navigation are received via a separate roof aerial.

58
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
Radio/navigation system RNS MFD ole,

spec
urposes, in part or in wh

t to the co
rrectnes
Auxiliary heater

s o
cial p

f
radio receiver

inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
S400_098

The RNS MFD radio/navigation system requires two aerials for the internal dual-tuner diversity receiver to receive
radio signals. The AM/FM aerial is located in the rear right side window,
the FM aerial in the rear left side window.

The signals for telephone, auxiliary heater and navigation are received via a separate roof aerial.

59
400

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

© VOLKSWAGEN AG, Wolfsburg


All rights and rights to make technical alterations reserved.
000.2812.02.20 Technical status 05.2007

Volkswagen AG
Service Training VSQ-1
Brieffach 1995
D-38436 Wolfsburg

❀ This paper has been manufactured from pulp bleached without the use of chlorine.

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