Transcription
Golf ‘98Construction and operationSelf-Study Programme No. 2001Dieses Dokument wurde erstellt mit FrameMaker 4.0.2.
Dear Reader,The Self-Study Programme series has been keeping you informed about the construction andoperation of Volkswagen and Audi technology for the past 24 years . The contents are based on the workshopmanuals. The chapter entitled “Servicing” informs youabout changes in our servicing procedures.In conjunction with the launch of the new Golf,we have taken the opportunity to revise slightlythe layout of our Self-Study Programme.We hope that the Self-Study Programme willprovide you with useful information and assistance in your daily work. In keeping with the times, the style of ourSelf-Study Programmes is now friendlier andmore easily distinguishable.With kind regards of your Self-Study Programme Team K-VK-12ONEfor ALL?ALL for ONE!You can find your newGolf in the middle ofthe Self-Study Programme.NewImportantNoteThis Self-Study Programme is Please refer to the relevant Serviceliterature for all inspection,not a Workshop Manual.adjustment and repair instructions.2
At a glanceAn all-new Golf. 4NewsVehicle dimensionsEnvironmental protection, recyclingOccupant protection, anti-theft measuresBody . 18Fully galvanised bodyHigh-strength panelsBumpersEngines . 23Engine-gearbox combinationEngineCruise controlPower transmission . 38Manual gearboxAutomatic gearboxRunning gear . 40SteeringFront axle/rear axleBraking systemWheels/tyresElectrical system . 49Vehicle electrical systemConvenience systemHeadlightsRain sensorHeating, air-conditioning system . 57HeatingManual air-conditioning systemClimatronicService . 60BodyNew special tools3
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the “ dimensions“ in the drawing are comparativevalues with the predecessor modelWidth1735 mmHeight1439 mmTrack width, front1513 mmAerodynamicdrag0.65 m2 Dragcoefficientx 40 mm 16 mmVehicle dimensionsFrontal area,projectedsurface areacdxA m20.31x2.1 m2 35 mmLength4149 mmWheelbase2511 mm 39 mm 131 mmRear track width1494 mmThrough-loadingwidth1005 mmTank capacity1005 mm55 litres 34 mmSSP 200/0667
An all-new GolfEnvironmental protectionThe Volkswagen Group ismaking eco-efficient,progressive technologiesavailable world-wide.It employs these technologiesthroughout the life cycle of itsproducts and beyond.Recycling at a high levelIn stripping centres the parts removed fromscrap cars are sorted into clean material streamsaccording to type and then recycled. In manycases, plastics, metals and insulating materialscan even be made into the original productagain.The overview below shows what materialsare used in the Golf:34 kgGlass3.1%44 kgRubber4.0%12 kgInsulating materials1.1%174 kgPlastics16.0%10 kgPaint0.9%27 kgLight alloys2.5%14 kgElectrics/cable1.3%17 kgNon-ferrous metals1.6%58 kgPetroleum/oil/grease5.3%2 kgMiscellaneous0.2%696 kgSteel/iron64.0%1088 kgTotal weightSSP 200/008On the following pages we will explainto you our eco-friendly policy on raw materialsusing insulating materials as an example.8
aaRecyclingPrinciple: Avoidance comes beforereduction Reduction comes before recovery Recovery comes before disposalRecycled insulating materialsFor example, the c o t t o n f i b r e f l e e c eused in insulating mats is a recyclate of garmentcuttings.Waste fibre recovery is industry’s contributionto reducing the burden on waste disposal sites.aCotton fibre fleecein insulating matsand luggage compartment floorcoveringsRenewable raw materials are used every vehicle. Their recyclability is a major factor. Theraw materials which are made into componentsare processed and recycled.Trims and covers made from renewable materials0.5 kg flax fibre moulding materialused for the tailgatetrim0.8 kg flax fibre moulding materialfor seat backrestcoverF 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 intrim panels and covers.The straw left over from the linseed harvest wasburnt for many years. However, approximately25% of fibre component can be used as a basicmaterial for fibre mouldings. The quality of thefibres need not meet the high standards of thetextile industry, but it does satisfy the high quality standards for trim panels.Flax fibres are highly workable and have excellent material properties.2.1 kg flax fibre mouldingmaterial used for the wheelhouse trim1.5 kg wood fibremoulding materialin the doors and sidepanelsSSP 200/009W 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 trimpanels. The basis of wood fibre moulding materials are the pine woodchips left over from theproduction of wooden beams and boards insawmills.Wood fibre moulding material meets therequirements of the automobile industry.These include: low weight, low emissions, highstrength and non-splintering properties.99
An all-new GolfOccupant protectionThere is more to occupant protection than theairbag, belt tensioner and stable side protection.Most of the impact energy is absorbed by thecar body.Achieving such a high standard of safety meanspaying special attention to detail.The front seat beltshave two pyrotechnical belt tensioners which operateaccording to the same principle as the rotary-pistonengine.The full-size airbagsfor the driver and front passenger sides arealmost twice the size they were before.64 litres120 litresSSP 200/013You can read about the design andfunction of this seat belt tensioner inSelf-Study Programme No. 192.SSP 200/011A 3-point seat beltand a 3rd head restraintare available for the rear middle seat.The rear seat belts do not have belt tensioners.The side airbagsfor the driver and front passenger.12 litresSSP 200/1210SSP 200/014
Lashing eyesThe four lashing eyes in the luggage compartment enable luggage to be secured safely.The paddingsare integrated in the door and side trims. Theyprotect the pelvis and rib areas of occupantsduring a side impact.SSP 200/016The child safety seat fastening systemSSP 200/015Welded on the vehicle body are retaining eyelets to whichchild safety seats equipped with the ISOFIX fastening system can be easily secured.The fuel tankis now located in front of the rear axle foradded safety in a rear collision.SSP 200/018SSP 200/01711
An all-new GolfAnti-theft measuresA number of measures have been taken to provide more effective theft protection.Lock cylinder freewheel intailgate lock- Inner-profile key- Lock cylinder freewheelfor steering wheel lock- Slip clutch on steeringcolumnAnti-theft alarmBonnet lock cover- Lock cylinder freewheel inouter door handle- Encapsulated internal doorlock with central locking andSAFE featureImmobiliserSSP 200/076The door lock is encapsulated and there is ametal reinforcement around the door lock.These measures prevent would-be thieves piercing a hole through the bodyshell in this area andlevering open the door handle.SSP 200/07712The bonnet lock cover makes breaking open thebonnet more difficult.SSP 200/078
Anti-theft measuresThe steering systemThe striker pin of the ignition lock can nolonger be sheared off. This makes it impossibleto steer the vehicle.A corrugated tube is located on the steering column. A bush with oblong holes ispress-fitted on it. The steering columnand the bush joined by an interference fitvia the corrugated tube.Steering columnBushCorrugated tubeStriker pinThis is how it works:The striker pin of the ignition lock engages inthe oblong holes of the bush when the ignitionkey is removed from the ignition. If an attemptis made to turn the steering wheel by applying aforce of approx. 150 Nm, the corrugated tubewill be friction-locked between the steering column and bush.It is not possible to steer the vehicle or shear offthe locking pin.SSP 200/073BushSteeringcolumnCorrugated tubeStriker pinInserting the ignition key in the ignition withdraws the striker pin from the oblong holes ofthe bush.The vehicle can again be steered since the corrugated tube and the bush now rotate with thesteering column.Striker pinSSP 200/07413
An all-new GolfAnti-theft measuresThe lock cylinder freewheelis integrated in the front doors, tailgate and ignition lock.It prevents these locks being forced and limitsthe damage caused by an attempted break-in.The lock-cylinder unit comprises thefollowing components:Lock cylinderLocking plateClutchDoor operating linkageLock cylinder housingFreewheel sleeveSliding ringFunction of door lock cylinder freewheel shownbelow using a door lock as an exampleSSP200/108When the key is not inserted in theignition, the locking plates engagein the freewheel sleeve.Lock cylinderLocking plateFreewheelsleeveSSP 200/13114
Inserting the matching key in theignition draws the locking platesinto the lock cylinder. When theignition key is turned, the lock cylinder in the freewheel sleeve rotates and opens the door lock viathe sliding ring and the door operating linkage.Door lockDoor operatinglinkageSliding ringLock cylinderFreewheelsleeveKeySSP 200/132If the wrong ignition key is used oranother tool, the locking platesremain in the freewheel sleeve.When the lock cylinder is turned,the freewheel sleeve is also rotated.The freewheel sleeve and the sliding ring are moved by two camsinside the lock cylinder housing. Inthe process, the lock cylinder isdisconnected from the sliding ring.The lock cylinder turns without thesliding ring or the door operatinglinkage. The door lock is notopened.Door lockDoor operatinglinkageSliding ringLocking plateFreewheelsleeveCam insidelock cylinder housingSSP 200/133The lock cylinder freewheel and the encapsulated internal door lock minimise damagecaused by an attempted break-in.15
An all-new GolfAnti-theft measuresImmobiliserThis is an electronic theft deterrent. It is activated when the ignition is turned on. Theimmobiliser prevents unauthorised persons fromoperating the car by intervening in the enginecontrol unit.The differences between the 2nd generationimmobiliser and the previous generation are asfollows: The immobiliser control unit is integrated inthe dash panel insert. In addition to the fixed code, the engineimmobiliser control unit transmits a self-varying code to the transponder integrated in thevehicle ignition key.Reader coil on ignition lockEngine immobiliser control unitintegrated in dash panel insertIgnition key withtransponderEngine control unitSSP 200/064After the ignition is turned on, the transpondersends a fixed code to the engine immobilisercontrol unit. If this code is correct, a self-varying code is generated in the engine immobilisercontrol unit by a random generator. The selfvarying code is transmitted to the transponderinside the vehicle ignition key. This starts aseries of secret arithmetic operations in thetransponder and the engine immobiliser controlunit.16If these arithmetic operations produce identicalresults, the vehicle key is recognised as the correct one. As before, a check is performed to seeif the self-varying code of the engine immobiliser control unit and the engine control unitmatch. If they match, the vehicle is ready tooperate.The advantage of these secret arithmetic operations is that the calculated self-varying codecannot be decoded. In addition, the vehicle ignition keys cannot be copied.
Anti-theft measuresAnti-theft alarmThis monitors the doors, the bonnet, the tailgateand the ignition lock.The function can be integrated in two differentcontrol units:In the central locking control uniton vehicles without electric windowsIn the central control unit for the convenience systemon vehicles with electric windowsMicroswitch indoor locksMicroswitchin tailgate lockMicroswitch indoor locksMicroswitch inbonnet lockIndicator lamp for centrallocking/SAFE lockingsystemIgnition lockWOB-Indicator lightsCentral control unit for convenience systemor central locking control unitVK 12Signal horn for anti-theft alarmSSP 200/112The anti-theft alarm is switched on when thevehicle is locked once with the ignition key.To lock the vehicle without switching the antitheft alarm on, the vehicle must be locked twicewithin a period of 5 seconds.If the vehicle is broken into in one of the monitored areas, a signal is sent to the control unit andthe alarm is tripped. The alarm is reproducedaudibly by activating the signal horn for the antitheft alarm and visually by activating all the indicator lights.Depending on the car’s specification, the selfdiagnosis can be performed using- address word 35 in the central locking control unit or- address word 46 in the convenience systemcentral module.17
BodyThe fully galvanised bodyThe new Golf has a fully galvanised body andtherefore offers greater protection againstcorrosion (12-year anti-corrosion perforationwarranty).hot-dipgalvanisedIn the past, only body areas of the Golf prone tocorrosion were galvanised.Now, for the first time, all body parts are eitherhot-dip galvanised or sedSSP 200/01918All parts which are externallyvisible are hot-dip galvanised.All outer skin panels areelectrolytically galvanisedRough surfaceSmooth surfaceZinc coating approx. 10µm thickZinc coating approx. 8µm thickDoes not change shape easily.Changes shape easily.
The paintwork structureThe paintwork is specifically structured toincrease body corrosion protection even more.Vehicle paintwork structureThe electrolytic zinc coating provides a goodbasis for the upper paintwork layers.Sheet steelZinc coatingSSP 200/020Zinc phosphatecoatingEC primer dipcoatingFillerTop coatClear coatCoating system approx. 100µm thick19
BodyHigh-strength panelsThey are specially alloyed thin panels whichachieve high strength as a result of subsequentheat treatment.Therefore, it is possible to use panels whichInterior B-pillarare thinner than deep-drawn panels yet theyare just as strong. A great deal of weight issaved in this way.Roof crossbraceSpare wheel wellreinforcementPlenum chamberreinforcementSupport brakket for enginesupportCover plate forside memberSSP 200/021High-strength panelsThermal post-treatmentThis is a welcome “side-effect” of the stoveenamelling process during which the body isheated to approximately 170 C anyway.The advantage of this effect is that the bodypanels, made of a relatively soft material, onlyachieve their ultimate strength once the shapingprocess has been completed.20170 CSSP 200/022
Front bumperIn a frontal collision at speeds of up to approx.15 kph, the bumper together with the crossmember absorb enough energy to prevent theside members from being damaged.Side memberCross memberBumpersSSP 200/023Rear bumperThe rear bumper has been enlarged.As a result, a low-speed rear collision does notcause damage to the body side section.These measures will reduce repair costs.SSP 200/12321
Golf and again sets new stand-ards. It is the evolutionary development of the classless Golf design. It reflects a high technical standard and is therefore superior to the competition. The new model y The safety structure of the new Golf has been specially optimised against side im-pact and in the driver footwell area. of vironment: Over 90% of .
