2019 Volkswagen Golf Mk7 R Download Service & Repair Manual
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Maintenance
Golf 2017 ➤
Golf Sportsvan 2018 ➤
Golf Variant 2017 ➤
e-Golf 2017 ➤
Edition 03.2018
Service
Service Department. Technical Information
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Maintenance
Heading
1. Engine list
2. Service work
3. General information
4. Descriptions of work:
5. Exhaust emissions test
6. Glossary
7. ---Change history---
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg D4B806C0C13
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Contents
1 Engine list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Information about flexible or fixed service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Service tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 General warnings for working on high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Raising vehicle with lifting platform or trolley jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 Entries in service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 Severe operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.6 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.7 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.8 Countries with hot climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.9 Country overview for petrol not compliant with EN 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.10 Country overview for diesel not compliant with EN 590 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.11 Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.12 Countries with high levels of dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.13 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.14 Shortened intervals for spark plug replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Descriptions of work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1 Swivel joints and suspension link mountings: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2 All-wheel drive coupling: changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.3 Automatic headlight control and static cornering light: checking function . . . . . . . . . . . . . . 47
4.4 Automatic gearbox 09G: changing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.5 Battery (12V): checking battery terminal clamps for secure seating . . . . . . . . . . . . . . . . . . 48
4.6 Battery (12V): checking with battery tester (always refer to workshop manual) . . . . . . . . . . 52
4.7 Status of battery (12V): reading - sending diagnosis protocol via online connection . . . . . . 52
4.8 Front passenger front airbag: checking key switch and “ON/OFF function” . . . . . . . . . . . . 52
4.9 Tyres: checking condition, wear pattern, tyre pressure and tread depth . . . . . . . . . . . . . . 53
4.10 Brake and clutch system: changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.11 Brake system and shock absorbers: inspecting for leaks and damage . . . . . . . . . . . . . . . . 114
4.12 Brake fluid level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.13 Brakes, front and rear: checking thickness of brake pads and condition of brake discs . . 116
4.14 Diesel fuel filter: draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.15 Diesel fuel filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.16 Diesel particulate filter: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.17 Dual clutch gearbox 0D9: changing gear oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.18 Dual clutch gearbox 0DD: changing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.19 Dual clutch gearbox 0DL: changing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.20 Dual clutch gearbox 0GC: changing gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.21 Three-phase current drive: calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.22 Electric windows: checking positioning (open and close functions) . . . . . . . . . . . . . . . . . . 123
4.23 Natural gas system: inspect natural gas tank for corrosion and leakage. . . . . . . . . . . . . . . 124
4.24 Natural gas system: checking wax layer between natural gas fuel tank and fuel tank shut-off
valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.25 Natural gas tank: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.26 Natural gas filler connection and sealing cap: checking condition, cleaning if necessary and
checking seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.27 Fault memory of all systems: reading with vehicle diagnostic tester , correcting possible faults
according to repair guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.28 Boots: inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.29 High-voltage battery: checking charge level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.30 Maintenance of high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.31 High-voltage battery: charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Golf 2017 ➤ , Golf Sportsvan 2018 ➤ , Golf Variant 2017 ➤ , e-Golf 2017 ...
Maintenance - Edition 03.2018
Contents i
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4.32 High voltage components and high-voltage cables: inspecting for damage and correct routing
and securing of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.33 Hybrid components: inspect for damage to high-voltage components and wires. . . . . . . . . 132
4.34 Interior and exterior body: inspecting for corrosion with doors and flaps open . . . . . . . . . . 133
4.35 Poly V-belt: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.36 Poly V-belt: checking condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.37 Cooling system: checking frost protection and coolant level . . . . . . . . . . . . . . . . . . . . . . . . 134
4.38 Air filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.39 Multi-purpose additive for diesel fuel: adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.40 Multi-purpose additive for petrol fuel: adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.41 Engine and components in engine compartment: inspecting for leaks and damage (from
above and below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.42 Engine cover panel “top”: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.43 Engine compartment cover (noise insulation) “bottom”: removing and installing . . . . . . . . 149
4.44 Engine oil level: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.45 Engine oil: draining, renewing oil filter and replenishing engine oil . . . . . . . . . . . . . . . . . . 150
4.46 Engine oil: capacities and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.47 Panoramic sliding sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.48 Panorama sliding roof with rear panorama roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.49 Road test: performing (driving behaviour, noises, air conditioner etc.) . . . . . . . . . . . . . . . . 170
4.50 Wheel securing bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.51 Tyre Pressure Loss Indicator: calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.52 Tyre repair set: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.53 Window wash/wipe system and headlight washer system: checking function . . . . . . . . . . 174
4.54 Headlight adjustment: checking halogen headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.55 Headlight adjustment: checking LED headlights with cornering light . . . . . . . . . . . . . . . . . . 180
4.56 Headlight adjustment: checking LED headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.57 Headlight adjustment: checking fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.58 Sliding sunroof drains: checking for blockage, cleaning if necessary . . . . . . . . . . . . . . . . 192
4.59 Service interval display: resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
4.60 Service interval display: recoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.61 Track rod ends: checking clearance, firm seating and boots . . . . . . . . . . . . . . . . . . . . . . . . 194
4.62 Dust and pollen filter: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . 194
4.63 Transportation mode: switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.64 Transportation devices: removing blocking pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.65 Clock and date: setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.66 Underbody: inspecting for damage to underbody sealant, underbody panels, routing of lines,
plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.67 Front differential lock: changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.68 Warning stickers, e-Golf: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.69 Warning stickers, Golf GTE: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.70 Toothed belt (petrol engines): renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.71 Camshaft drive toothed belt (diesel engines): renewing . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.72 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
5 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
5.1 Exhaust emissions test for petrol engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
5.2 Exhaust emissions test for diesel engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
6 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
7 ---Change history--- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Golf 2017 ➤ , Golf Sportsvan 2018 ➤ , Golf Variant 2017 ➤ , e-Golf 2017 ...
Maintenance - Edition 03.2018
ii Contents
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1 Engine list
(VIGG001147; Edition 03.2018)
Golf BQ1 Petrol engines in hybrid vehicles ⇒ page 1
Diesel engines ⇒ page 4
Golf estate
BV5
Petrol engines ⇒ page 6
Diesel engines ⇒ page 8
e-Golf BE2 Electric motor ⇒ page 9
Golf SV
AN1
Petrol engines ⇒ page 10
Diesel engines ⇒ page 11
Note
To ease the search for an engine, the engine codes are listed in
alphabetical order.
Golf BQ1 petrol engines
Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine
Displace‐
ment
I 2.0 1.4 1.0 1.0
Engine code CHHA CHPA CHZC CHZF
No. of cylinders/valves per
cylinder
4/4 4/4 3/4 3/4
Power kW at rpm 169/4200-6000 103/4500-6000 81/5500 63/5000-5500
Torque Nm at rpm 350/1500-4000 250/1500-3500 175/1500-3500 160/1500-3500
Bore ∅ mm 82.5 74.5 74.5 74.5
Stroke mm 92.8 80.0 76.4 76.4
Compression ratio 9.6 10.5 10.5 10.5
Injection/ignition Motronic SIMOS
12.1
TSI turbocharger
Motronic
MED17.5.21
TSI turbocharger
Motronic Bosch
ME 17
TSI
Motronic Bosch
ME 17
TSI
RON unleaded, at
least
95 95
(in exceptional cir‐
cumstances at
least 91 RON, but
with reduced out‐
put)
95 95
Camshaft drive Chain Toothed belt Toothed belt Toothed belt
Engines ⇒ Petrol engine Petrol engine Petrol engine Petrol engine
Displace‐
ment
I 1.0 1.2 2.0 2.0
Engine code CHZK CJZA CNTA CNTC
No. of cylinders/valves per
cylinder
4/4 4/4 4/4 4/4
Power kW at rpm 63/5000-6500 77/5000 155/4300-6200 155/4300-6200
Torque Nm at rpm 175/1500-3500 175/1400-3500 350/1600-4200 350/1600-4200
Bore ∅ mm 74.5 71.0 82.5 82.5
Stroke mm 76.4 75.6 92.8 92.8
Golf 2017 ➤ , Golf Sportsvan 2018 ➤ , Golf Variant 2017 ➤ , e-Golf 2017 ...
Maintenance - Edition 03.2018
1. Engine list 1
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The 2019 Volkswagen Golf Mk7 R Download Service & Repair Manual is a comprehensive guide that provides detailed information on servicing and repairing the Volkswagen Golf Mk7 R model. This manual is specifically designed for the 2019 model.
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