Vous êtes sur la page 1sur 21

Golf ‘98

Construction and operation

Self-Study Programme No. 200

Dieses Dokument wurde erstellt mit FrameMaker 4.0.2.


Dear Reader,

The Self-Study Programme series has been kee-


ping you informed about the construction and • The contents are based on the workshop
operation of Volkswagen and Audi technol- manuals.
ogy for the past 24 years .
• The chapter entitled “Servicing” informs you
about changes in our servicing procedures.
In conjunction with the launch of the new Golf,
we have taken the opportunity to revise slightly
the layout of our Self-Study Programme. We hope that the Self-Study Programme will
provide you with useful information and assist-
ance in your daily work.
• In keeping with the times, the style of our
Self-Study Programmes is now friendlier and
more easily distinguishable.
With kind regards of your Self-Study Pro-
gramme Team K-VK-12

ONE
for ALL?

ALL for ONE!

You can find your new


Golf in the middle of
the Self-Study Pro-
gramme.

New Important
Note

This Self-Study Programme is Please refer to the relevant Service


not a Workshop Manual. literature for all inspection,
adjustment and repair instructions.

2
At a glance

An all-new Golf............................................................ 4
News
Vehicle dimensions
Environmental protection, recycling
Occupant protection, anti-theft measures

Body .............................................................................. 18
Fully galvanised body
High-strength panels
Bumpers

Engines .......................................................................... 23
Engine-gearbox combination
Engine
Cruise control

Power transmission ..................................................... 38


Manual gearbox
Automatic gearbox

Running gear ................................................................ 40


Steering
Front axle/rear axle
Braking system
Wheels/tyres

Electrical system .......................................................... 49


Vehicle electrical system
Convenience system
Headlights
Rain sensor

Heating, air-conditioning system .............................. 57


Heating
Manual air-conditioning system
Climatronic

Service ........................................................................... 60
Body
New special tools

3
An all-new Golf

• NEW
EW S
S• N
•NEW
S d
S • NEW Golfe
NEW 1974,
E W S• S i n c e
O L F...
WS •N the G ourth
The f tion
S •NE i n
de-
ctive -
gene
ra
NEW 974 d i s t ep
h 2, 1 ith its ed a r
nM a r c . . . w s establish
O or a
ccess
the su eetle sign h as a highly .
ehicle
F i o n

GOL
B uta t
to the led off r i s m atic v
t r o l line. ch a
firs d uction
p r o
the

The d ...
o n d legen Sa fe t y
sec swage
n
a
e pro-
nts ar sys-
o l k c c u p n
of V The o y a moder
t e d b e l t
hting tec ng b t force
ts ent lig eaturi l
tem f ers and be
umen s t r u m
e In ions
instr
n
d-blu e vers y te n s i o
lue red-an ble in thre c capabilit rs, tw
o
a nd-b v a i l a
iagn o s t i limite
Red-
-a
self-d
- has

de
b a g s and si
evel ize ai
r t seat
h trim l evel versio
n. full-s in the fron
i g s
H
entr y - l airbag ts.
in the backr
es
New hts
lig
head

...
Body
with ar
12-ye ty
Seat y warra
n
their or
e a n d show k-
r mem
inctiv x inner wo
ved p l e
l i g h t s deri co m
ad ings.
val he round
The o e original ly dist-
th h
from hts are hig
l i g
head

4
4
WS •

aThe
N

s
E

The n
W

pact a
S

Golf
ew m

sets

f
like a
looks d again
an
n
ards.

e
specia
n
odel

ew st
and-

cture
lly o
been d in the dri
o
...S

f t

ver fo
h

sa
e

v
• NEW

afety
S

gains
ty stru ptimised a ll area.
otwe

e
exten
30%.
u l

d

l
NEWS •N

olf ha
new G ide im-
ts

s
g

t h
E

s
WS•

e us
the e

e
e
nv

ised b
sa

o d
It

y
a
of

ke of
For th ironment:
i

It

Conv
ie

o
s

n
tem

alvan f PVC und ehicle by


The f bout 4 kg ife of the v
s a f
o
u ll
t
r
t

c
h
e
h
e
f
e

en-
e
l
c
e
and is ition.
comp

sys-

olf
f the G and
erseal
theref
et
tiona
s s

en

Safe
r

d
lif
a
y

e
d

,
l
o
e

u
0

f
t
velop
evolu Golf desig andard
lassle h technical the
ig
cts a h re superior

a
%
n.
st

the be come.
tions

T h
to

Over recyclable ul
s
Go i its long us g
l f

h u
ment

nefit
to

e c

tralise
o

d
new
of the at the

s in
e
sour
r

WOB - VK 12
ef
v
s con ces for
ble re f genera-

ience
onven decen-
has a
system layout.

V.A.G
01 - Moto
NDIA
relek
GNO
- EIGE tronik
SE

1 2
4 5
HELP

7 8
C 0
3
6
9
Q
HELP

PRINT

5
An all-new Golf
E W S•
W S •N
S • NE roven
e the p al
• NEW Go l f a
in the tic and ma
r
nu

EWS o m a
xes auetarboxes.
S• N e a r b o
The g
g

•NEW
WS
S • NE are es
NEW
s- mi
ngin low e lev-
The e i e v e
ch igh
they a d offer a h rt.
rful. an fo
powe sed sions iving com
a n d f d r
rn
mode n a harmo pt,
ni el o
e d o co ce
n
Bas icient
l - e f f
fue

asu res s
asure
e ft me of me pro-
nti-th b e r o
A A num en taken t theft
v e b e c t i ve
ha
o r e effe
vide m ion.
t
protec
g
t eerin
The s
ng as
steeri ent of
o w e r
The p the adjust ering
m
ditio ning
w e l l a s
e - a n d-a f t s te
dded A ir con
r
the fo provide a ter,
n t w e e n hea g
colum t. se be ionin
Choo air-condit tronic.
comfo
r
ng g ear a l
manu and CLIM
A
unni
The r un-
system
i o n o f the r
t
nterac ents
The i ar compon f driv-
e
ning g good leve
lo
l kswagen
a Vo
olf is
giv e s .
mfort
ing co The G

ront axle
The f

ear axle
The r

6
6
the “+ dimensions“ in the drawing are comparative
Vehicle dimensions
values with the predecessor model

Width 1735 mm
+ 40 mm
Height 1439 mm

Track width, front 1513 mm

+ 16 mm
Aerodyna- Drag Frontal area,
mic = coefficient x projected
drag surface area
+ 35 mm

cd x A m2

0.65 m2 = 0.31 x 2.1 m2 Length 4149 mm

Wheelbase 2511 mm

+ 39 mm
+ 131 mm

Rear track width 1494 mm

Through-loading 1005 mm
1005 mm
width

Tank capacity 55 litres

+ 34 mm

SSP 200/066
7
An all-new Golf

Environmen- The Volkswagen Group is Recycling at a high level


making eco-efficient,
tal protection progressive technologies
available world-wide.
In stripping centres the parts removed from
It employs these technologies scrap cars are sorted into clean material streams
throughout the life cycle of its according to type and then recycled. In many
products and beyond. cases, plastics, metals and insulating materials
can even be made into the original product
again.

The overview below shows what materials


are used in the Golf:

34 kg Glass 3.1%

44 kg Rubber 4.0%

12 kg Insulating materials 1.1%

174 kg Plastics 16.0%

10 kg Paint 0.9%

27 kg Light alloys 2.5%

14 kg Electrics/cable 1.3%

17 kg Non-ferrous metals 1.6%

58 kg Petroleum/oil/grease 5.3%
SSP 200/008

2 kg Miscellaneous 0.2%

696 kg Steel/iron 64.0%

1088 kg Total weight

On the following pages we will explain


to you our eco-friendly policy on raw materials
using insulating materials as an example.

8
a a
a
Recycling Principle:
• Avoidance comes before
reduction
• Reduction comes before recovery
• Recovery comes before disposal

Recycled insulating materials

Trims and covers made from renew-


able materials

2.1 kg flax fibre moulding


material used for the wheel-
house trim

SSP 200/009
Cotton fibre fleece
in insulating mats
and luggage com-
partment floor
coverings

0.5 kg flax fibre -


moulding material
used for the tailgate
trim

0.8 kg flax fibre -


moulding material
for seat backrest
cover

1.5 kg wood fibre


moulding material
in the doors and side
panels
Renewable raw materials are used every vehi-
cle. Their recyclability is a major factor. The
raw materials which are made into components
are processed and recycled.

For example, the c o t t o n f i b r e f l e e c e


used in insulating mats is a recyclate of garment
cuttings.
Waste fibre recovery is industry’s contribution
to reducing the burden on waste disposal sites.

F l a x f i b r e m o u l d i n g m a t e r i a l is contained in
trim panels and covers.
The straw left over from the linseed harvest was
burnt for many years. However, approximately
25% of fibre component can be used as a basic
material for fibre mouldings. The quality of the
fibres need not meet the high standards of the
textile industry, but it does satisfy the high qual-
ity standards for trim panels.
Flax fibres are highly workable and have excel-
lent material properties.

W o o d f i b r e m o u l d i n g m a t e r i a l is used for trim


panels. The basis of wood fibre moulding mate-
rials are the pine woodchips left over from the
production of wooden beams and boards in
sawmills.
Wood fibre moulding material meets the
requirements of the automobile industry.
These include: low weight, low emissions, high
strength and non-splintering properties.

99
An all-new Golf

Occupant protection
There is more to occupant protection than the
airbag, belt tensioner and stable side protection.
Most of the impact energy is absorbed by the
car body. The front seat belts
Achieving such a high standard of safety means have two pyrotechnical belt tensioners which operate
paying special attention to detail. according to the same principle as the rotary-piston
engine.

The full-size airbags


for the driver and front passenger sides are
almost twice the size they were before.

64 litres 120 litres

SSP 200/013

You can read about the design and


function of this seat belt tensioner in
Self-Study Programme No. 192.

SSP 200/011

A 3-point seat belt


and a 3rd head restraint
are available for the rear middle seat.
The side airbags The rear seat belts do not have belt tensioners.
for the driver and front passenger.

12 litres

SSP 200/12

10 SSP 200/014
Lashing eyes

The four lashing eyes in the luggage compart-


The paddings ment enable luggage to be secured safely.

are integrated in the door and side trims. They


protect the pelvis and rib areas of occupants
during a side impact.

SSP 200/016

The child safety seat fastening system


SSP 200/015
Welded on the vehicle body are retaining eyelets to which
child safety seats equipped with the ISOFIX fastening sys-
tem can be easily secured.

The fuel tank

is now located in front of the rear axle for


added safety in a rear collision.

SSP 200/018

SSP 200/017

11
An all-new Golf

Anti-theft measures

A number of measures have been taken to pro-


vide more effective theft protection.

Lock cylinder freewheel in


tailgate lock
- Inner-profile key
- Lock cylinder freewheel
for steering wheel lock
- Slip clutch on steering
Anti-theft alarm
column

Bonnet lock cover - Lock cylinder freewheel in


outer door handle
- Encapsulated internal door
lock with central locking and
SAFE feature

SSP 200/076 Immobiliser

The door lock is encapsulated and there is a


metal reinforcement around the door lock.
These measures prevent would-be thieves pierc-
ing a hole through the bodyshell in this area and The bonnet lock cover makes breaking open the
levering open the door handle. bonnet more difficult.

SSP 200/077 SSP 200/078

12
Anti-theft measures

The steering system


The striker pin of the ignition lock can no
longer be sheared off. This makes it impossible
to steer the vehicle.

A corrugated tube is located on the steer-


Steering column ing column. A bush with oblong holes is
press-fitted on it. The steering column
Bush
and the bush joined by an interference fit
via the corrugated tube.

Corrugated tube

Striker pin

SSP 200/073
This is how it works:
Bush

The striker pin of the ignition lock engages in


the oblong holes of the bush when the ignition Steering
key is removed from the ignition. If an attempt column
is made to turn the steering wheel by applying a Corru-
force of approx. 150 Nm, the corrugated tube gated tube

will be friction-locked between the steering col-


umn and bush. Striker pin
It is not possible to steer the vehicle or shear off
the locking pin.

Inserting the ignition key in the ignition with-


draws the striker pin from the oblong holes of
the bush.
The vehicle can again be steered since the corru-
gated tube and the bush now rotate with the
steering column.
Striker pin

SSP 200/074 13
An all-new Golf

Anti-theft measures

The lock cylinder freewheel is integrated in the front doors, tailgate and igni-
tion lock.
It prevents these locks being forced and limits
the damage caused by an attempted break-in.

The lock-cylinder unit comprises the


following components:

Lock cylinder

Locking plate

Clutch

Door operating linkage


Lock cylinder housing

Freewheel sleeve

Sliding ring

Function of door lock cylinder freewheel shown SSP200/108


below using a door lock as an example

When the key is not inserted in the


ignition, the locking plates engage
in the freewheel sleeve.

Lock cylinder

Locking plate

Freewheel
sleeve

SSP 200/131

14
Inserting the matching key in the
Door lock ignition draws the locking plates
into the lock cylinder. When the
Door operating ignition key is turned, the lock cyl-
linkage inder in the freewheel sleeve rota-
tes and opens the door lock via
the sliding ring and the door oper-
Sliding ring ating linkage.
Lock cylinder

Freewheel
sleeve

Key

SSP 200/132

If the wrong ignition key is used or


Door lock another tool, the locking plates
remain in the freewheel sleeve.
Door operating When the lock cylinder is turned,
linkage the freewheel sleeve is also rotated.
The freewheel sleeve and the slid-
ing ring are moved by two cams
Sliding ring inside the lock cylinder housing. In
the process, the lock cylinder is
disconnected from the sliding ring.
The lock cylinder turns without the
Locking plate sliding ring or the door operating
Freewheel linkage. The door lock is not
sleeve opened.
Cam inside
lock cylinder housing

SSP 200/133

The lock cylinder freewheel and the encapsu-


lated internal door lock minimise damage
caused by an attempted break-in.

15
An all-new Golf

Anti-theft measures

Immobiliser
This is an electronic theft deterrent. It is acti- The differences between the 2nd generation
vated when the ignition is turned on. The immobiliser and the previous generation are as
immobiliser prevents unauthorised persons from follows:
operating the car by intervening in the engine
control unit.
• The immobiliser control unit is integrated in
the dash panel insert.
• In addition to the fixed code, the engine
immobiliser control unit transmits a self-var-
ying code to the transponder integrated in the
vehicle ignition key.

Reader coil on ignition lock

Engine immobiliser control unit


integrated in dash panel insert
Ignition key with
transponder

Engine control unit

SSP 200/064

After the ignition is turned on, the transponder If these arithmetic operations produce identical
sends a fixed code to the engine immobiliser results, the vehicle key is recognised as the cor-
control unit. If this code is correct, a self-vary- rect one. As before, a check is performed to see
ing code is generated in the engine immobiliser if the self-varying code of the engine immobi-
control unit by a random generator. The self- liser control unit and the engine control unit
varying code is transmitted to the transponder match. If they match, the vehicle is ready to
inside the vehicle ignition key. This starts a operate.
series of secret arithmetic operations in the
transponder and the engine immobiliser control The advantage of these secret arithmetic opera-
unit. tions is that the calculated self-varying code
cannot be decoded. In addition, the vehicle igni-
tion keys cannot be copied.

16
Anti-theft measures

Anti-theft alarm The function can be integrated in two different


control units:
This monitors the doors, the bonnet, the tailgate
and the ignition lock.
In the central locking control unit
on vehicles without electric windows

In the central control unit for the convenience system


on vehicles with electric windows

Microswitch in
door locks
Microswitch
in tailgate lock

Microswitch in
door locks
Microswitch in
bonnet lock

Indicator lamp for central


locking/SAFE locking
system

Ignition lock
Central control unit for convenience system
WOB or central locking control unit
- VK 1
Indicator lights 2

Signal horn for anti-theft alarm


SSP 200/112

The anti-theft alarm is switched on when the If the vehicle is broken into in one of the monito-
vehicle is locked once with the ignition key. red areas, a signal is sent to the control unit and
To lock the vehicle without switching the anti- the alarm is tripped. The alarm is reproduced
theft alarm on, the vehicle must be locked twice audibly by activating the signal horn for the anti-
within a period of 5 seconds. theft alarm and visually by activating all the indi-
cator lights.

Depending on the car’s specification, the self-


diagnosis can be performed using
- address word 35 in the central locking con-
trol unit or
- address word 46 in the convenience system
central module.

17
Body

The fully galvanised body

The new Golf has a fully galvanised body and In the past, only body areas of the Golf prone to
therefore offers greater protection against corrosion were galvanised.
corrosion (12-year anti-corrosion perforation Now, for the first time, all body parts are either
warranty). hot-dip galvanised or electrolytically
galvanised.

hot-dip electrolyti-
galvanised cally
galvanised

SSP 200/019

All parts which are externally All outer skin panels are
visible are hot-dip galvanised. electrolytically galvanised

Rough surface Smooth surface

Zinc coating approx. 10µm thick Zinc coating approx. 8µm thick

Does not change shape easily. Changes shape easily.

18
The paintwork structure

The paintwork is specifically structured to


increase body corrosion protection even more.

Vehicle paintwork structure

The electrolytic zinc coating provides a good


basis for the upper paintwork layers.

Sheet steel

Zinc coating
SSP 200/020

Zinc phosphate
coating
EC primer dip
coating

Filler

Top coat

Clear coat

Coating system approx. 100µm thick

19
Body

High-strength panels

They are specially alloyed thin panels which are thinner than deep-drawn panels yet they
achieve high strength as a result of subsequent are just as strong. A great deal of weight is
heat treatment. saved in this way.
Therefore, it is possible to use panels which

Roof cross Spare wheel well


Interior B-pillar brace reinforcement

Plenum cham-
ber
reinforcement

Support brak-
ket for engine
support
Cover plate for
side member
SSP 200/021
High-strength panels

Thermal post-treatment
This is a welcome “side-effect” of the stove 170° C

enamelling process during which the body is


heated to approximately 170°C anyway.
The advantage of this effect is that the body
panels, made of a relatively soft material, only
achieve their ultimate strength once the shaping
SSP 200/022
process has been completed.

20
Front bumper

In a frontal collision at speeds of up to approx.


15 kph, the bumper together with the cross
member absorb enough energy to prevent the
side members from being damaged.

Side member

Cross member

Bumpers SSP 200/023

Rear bumper

The rear bumper has been enlarged.


As a result, a low-speed rear collision does not
cause damage to the body side section.

These measures will reduce repair costs.

SSP 200/123

21

Vous aimerez peut-être aussi