Technical platform

Like the Audi A3 and the Skoda Octavia, the new Golf is based on the A-platform. The platform components are therefore almost identical from a technical aspect.

Engines

Running gear

Braking system

Electrical system

Heating/ air-conditioning system

22

Engines
Engine-gearbox combinations
Gearbox Engine 02K 1.4-ltr. 4V 55 kW 5-speed manual gearbox 02J 4-speed automatic gearbox 01M

1.6-ltr.

74 kW

1.8-ltr. 5V

92 kW

1.8-ltr. 5V 110 kW Turbo

2.3-ltr. V5 110 kW

1.9-ltr. SDI 50 kW

1.9-ltr. TDI 66 kW

1.9-ltr. TDI

81 kW

23

Engines
German emissions standard
In Germany, a new emissions standard has been in force since July 1997. This standard, referred to as Emission Stage D3, specifies lower emission limits. Customers driving a vehicle which meets this emissions standard are eligible for government tax benefits.

The table below shows the relationships between the engines and the D3 emissions standard as well as EU II.

Engine

Engine code

Gearbox

Emission Stage D3 EU II x

Measures

Engine management

1.4-ltr. 55kW

AHW AKQ

manual manual manual automatic x x

Magneti Marelli 4AV

Primary catalytic converter Software update

1.6-ltr. 74kW

AEH AKL

x x x x x
Software update Trimetallic catalytic converter Two primary catalytic converters Software update

Simos 2

automatic manual automatic

1.8-ltr. 92kW 1.8-ltr. 110kW 2.3-ltr. 110kW

1.9-ltr. SDI 50kW

AGN

Bosch Motronic 3.8.5

AGU

manual automatic

Bosch Motronic 3.8.3

AGZ

manual automatic

Secondary air injection

Bosch Motronic 3.8.3

AGP

manual

x
Variable turbine geometry

Bosch Electronic Diesel Control

manual 1.9-ltr. TDI 66kW ALH automatic AGR

1.9-ltr. TDI 81kW 24

Enlarged oxidation catalytic converter Cooler for exhaust gas recirculation (auto gearbox only)

Bosch Electronic Diesel Control

manual automatic

x x Bosch Electronic Diesel Control

AHF

manual automatic

1.4-ltr. 4V engine (55 kW)

The 1.4-ltr. 4V engine is a new development and has the following special features: Aluminium engine block Static high-voltage distributor

You can find more detailed information on this engine in Self-Study Programme No. 196.
SSP 200/054

Output kW
80

Torque Nm
200

70

180

Displacement: Compression ratio: Output: Torque: Engine management: Fuel:

60

160

1390 cm3 10.5 : 1 55 kW at 5000 rpm 128 Nm at 3300 rpm Magneti Marelli 4AV Premium unleaded (95 RON)

50

140

40

120

30

100

20

80

10

60

0 0 1000 2000 3000 4000 5000

40 6000

Engine speed rpm

The engine may also be run on regular unleaded fuel (91 RON), but with reduced max. power.

SSP 200/053

25

Engines
1.6-ltr. engine (74 kW)

The 1.6-ltr. 4-cylinder in-line engine has the following special features: Aluminium engine block with internal vent pipe Press-fitted cast iron cylinders Plastic twin-path intake manifold Static high-voltage distributor Pressure switch for power steering Clutch pedal switch

SSP 200/045

Output kW
96

Torque Nm
220

84

200

Displacement: Compression ratio: Output: Torque: Engine management: Fuel:

72

175

1595 cm3 10.2 : 1 74 kW at 5600 rpm 145 Nm at 3800 rpm Simos 2 Premium unleaded (95 RON)

60

150

48

125

36

100

24

75

12

50

0 0 2000 4000 6000

Engine speed rpm

The engine may also be run on regular unleaded fuel (91 RON), but with reduced max. power.

SSP 200/046

26

1.8-ltr. 5V engine (92 kW)

The 1.8-ltr. 4-cylinder in-line engine with five valves per cylinder has the following special features: Variable valve timing Plastic twin-path intake manifold Static high-voltage distributor Hot film air mass meter with reverse flow detection Pressure switch for power steering Clutch pedal switch

SSP 200/061

Output kW
96

Torque Nm
220

84

200

Displacement: Compression ratio: Output: Torque: Engine management: Fuel:

72

175

1781 cm3 10.3 : 1 92 kW at 6000 rpm 170 Nm at 4200 rpm Motronic 3.8.5 Premium unleaded (95 RON)

60

150

48

125

36

100

24

75

12

50

0 0 2000 4000 6000

Engine speed rpm

The engine may also be run on regular unleaded fuel (91 RON), but with reduced max. power.

SSP 200/055

27

Engines
1.8-ltr. 5V turbo engine (110 kW)

The 1.8-ltr. 4-cylinder in-line engine with five valves per cylinder and turbocharger has the following special features: Static high-voltage distributor with individual ignition coils Pressure switch for power steering Clutch pedal switch

SSP 200/062

Output kW
160

Torque Nm
220

140

200

Displacement: Compression ratio: Output: Torque: Engine management: Fuel:

120

175

1781 cm3 9.5 : 1 110 kW at 5700 rpm 210 Nm at 1750 rpm Motronic 3.8.3 Premium unleaded (95 RON)

100

150

80

125

60

100

40

75

20

50

0 0 2000 4000 6000

Engine speed rpm

The engine may also be run on regular unleaded fuel (91 RON), but with reduced max. power.

SSP 200/063

28

2.3-ltr. V5 engine (110 kW)

The 2.3-ltr. 5-cylinder V-engine is a derivative of the VR6 engine in terms of its design. It has the following special features: Twin-path intake manifold Hot film air mass meter with reverse flow detection Static high-voltage distributor with 5 individual ignition coils Pressure switch for power steering Clutch pedal switch
SSP 200/050

The construction and function of this engine are described in Self-Study Programme No. 195.

Output kW
160

Torque Nm
220

140

200

Displacement: Compression ratio: Output: Torque: Engine management: Fuel:

120

180

2326 cm3 10.0 : 1 110 kW at 6000 rpm 205 Nm at 3200 rpm Motronic 3.8.3 Premium unleaded (95 RON)

100

160

80

140

60

120

40

100

20

80

0 500 1500 2500 3500 4500 5500

60 6500

The engine may also be run on regular unleaded fuel (91 RON), but with reduced max. power.

Engine speed rpm

SSP 200/052

29

Engines
1.9-ltr. SDI engine (50 kW)

The 1.9-ltr. 4-cylinder in-line engine is a naturally aspirated diesel with direct injection. It has the following special features: Two-stage EGR valve Electrically controlled intake manifold flap Preset injection pump with adjustable rib belt wheel Vertical oil filter

SSP 200/065

Output kW
80

Torque Nm
170

70

160

Displacement: Compression ratio: Output: Torque: Mixture preparation

60

150

50

140

Fuel:

1896 cm3 19.5 : 1 50 kW at 4000 rpm 130 Nm at 2200 rpm Direct injection with electronically controlled distributor injection pump 45 CN diesel

40

130

30

120

20

110

10

100

0 0 1000 2000 3000 4000 5000

The engine may also be run on biodiesel.

Engine speed rpm

SSP 200/059

30

1.9-ltr. TDI engine (66 kW)

The 1.9-ltr. turbocharged diesel engine with intercooler has the following special features: Preset injection pump with adjustable rib belt wheel Lightweight valve gear Vertical oil filter with replaceable paper insert Intake manifold flap

SSP 200/051

Output kW
80

Torque Nm
300

70

275

Displacement: Compression ratio: Output: Torque: Mixture preparation

60

250

50

225

Fuel:

1896 cm3 19.5 : 1 66 kW at 3750 rpm 210 Nm at 1900 rpm Direct injection with electronically controlled distributor injection pump 45 CN diesel

40

200

30

175

20

150

10

100

0 0 1000 3000 5000

The engine may also be run on biodiesel.

Engine speed rpm

SSP 200/057

31

Engines
1.9-ltr. TDI Engine (81 kW)

This 1.9-ltr. TDI engine has a higher power output than the 1.9-ltr. TDI engine developing 66 kW because of its variable turbine geometry.

SSP 200/051

Output kW
90

Torque Nm
300

80

275

Displacement: Compression ratio: Output: Torque: Mixture preparation

70

250

60

225

Fuel:

1896 cm3 19.5 : 1 81 kW at 4150 rpm 235 Nm at 1900 rpm Direct injection with electronically controlled distributor injection pump 45 CN diesel

50

200

40

175

30

150

20

100

10 0 1000 3000 5000

The engine may also be run on biodiesel.

Engine speed rpm

SSP 200/058

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The intake manifold flap

In the 1.9-ltr. TDI engine, a flap is integrated in the intake manifold. This flap stops engine vibrations when it is turned off.

SSP 200/113

Diesel engines have a high compression ratio. They tend to vibrate when turned off due to the high compression pressure of the intake air.

The intake manifold flap shuts off the air supply when the engine is switched off. This minimises the quantity of air compressed and ensures the engine runs out smoothly.

This is how it works:

When the engine turned off, the engine control unit sends a signal to the intake manifold flap change-over valve. The change-over valve then switches the partial pressure for the vacuum box, and the vacuum box closes the intake manifold flap.

Intake manifold flap

Intake manifold Intake air

Ignition lock

Engine control unit

Vacuum box

Intake manifold flap change-over valve

SSP 200/114

33

Engines
The hot-film air mass meter with reverse flow detection
Some engines have a hot-film air mass meter with reverse flow detection. An optimal mixture composition is essential for low exhaust emissions and high engine power output, both of which are heavily dependent on metering the intake air mass accurately. The opening and closing action of the valves produces a reverse flow in the intake air mass inside the intake manifold. The hot-film air mass meter with reverse flow detection detects the returning air mass. It then generates a signal and sends it to the engine control unit. This ensures highly accurate air mass metering.

Air mass meter

Intake air

Reverse flow

Intake manifold
SSP 200/098

The design
The electric circuit and the sensor element of the air mass meter are accommodated in a compact plastic housing. Located at the bottom end of the housing is a metering duct into which the sensor element protrudes. The metering duct extracts part of the intake and return air flows and routes this partial flow past the sensor element. The signal which the sensor element generates is processed by the electric circuit and sent to the engine control unit.
Metering duct Electric circuit Sensor element Partial air flow
SSP 200/099

Housing

Housing cover

You can find detailed information in SelfStudy Programme No. 195.

34

The clutch pedal switch

is located at the foot controls. It supplies the Clutch operated signal to the engine control unit. Signal utilisation when clutch is operated: In vehicles equipped with a TDI or SDI engine, the quantity of fuel injected is reduced. This prevents engine vibrations when a gearshift is performed. In vehicles with a cruise control system, the cruise control function is disabled.

SSP 200/096

In petrol-engined vehicles (upwards of 74 kW), the throttle closing damper function is disabled.

This is how it works:

The clutch pedal switch informs the engine control unit when the clutch is operated. The engine control unit then disables the throttle closing damper function. The throttle valve closes more quickly and this prevents a short-term increase in revs caused by excess air.

Engine control unit

Clutch pedal switch Throttle valve control unit

SSP200/115

35

Engines
Pressure switch for power steering
This is located on the vane pump. It informs the engine control unit when the vane pump is under a heavy load.

The vane pump is driven by the engine by the ribbed V-belt. At full steering lock the vane pump is required to produce a high pressure. A greater load is also placed on the engine, and idling speed may drop sharply. Using the signal sent by the pressure switch, the engine control unit is able to recognise the engine load state in good time and adjust the engine idling speed accordingly.

SSP 200/095

This is how it works: The pressure switch for the power steering informs the engine control unit when there is a high pressure inside the vane pump. The engine control unit activates the throttle valve positioner which opens the throttle valve by a certain angle. Engine idling speed is maintained.

Engine control unit Throttle valve control unit

Pressure switch for power steering

SSP 200/118

36

Cruise control system

This controls the road speed according to the drivers wishes without the driver actually having to operate the accelerator pedal. The cruise control system (CCS) was previously controlled by an independent control unit and the throttle valve was actuated by a vacuum box. The cruise control system is now controlled by the engine control unit. The throttle valve is actuated by the throttle valve control unit.

Signals to engine control unit Engine speed signal Road speed Brake operated Clutch operated

Engine control unit Cruise control switch ON/OFF signal Operation of throttle valve positioner

Feedback of throttle valve position

Throttle valve control unit

SSP 200/097

This is how it works: Switching the cruise control system ON tells the engine control unit to maintain the current road speed. The engine control unit then activates the electric motor of the throttle valve gear and actuates the throttle valve according to the vehicles current speed. To regulate the cruising speed, the engine control unit requires the sensor signals shown in the diagram above.

You can find detailed information in Self-Study Programme No. 195.

37

Power transmission
The gearbox
Two manual gearboxes and one automatic gearbox are used in the new Golf. All gearboxes have a pendulum support and are attached to the engine oil sump by bolts. This reduces the transmission of vibrations from the engine-gearbox assembly to the body. The manual gearboxes have hydraulic clutch control.

5-speed manual gearbox 02K is an advanced development of the 5-speed manual gearbox 020.

SSP 200/070

5-speed manual gearbox 02J is an advanced development of the 5-speed manual gearbox 02A.

SSP 200/071

38

The 4-speed automatic gearbox 01M This is now networked with a CAN databus. Final drive is via two tripod roller joint shafts.

CAN databus
In the new Golf, the engine control unit, automatic gearbox control unit and ABS control unit are linked by CAN data lines.

SSP 200/072

Automatic gearbox control unit

Engine control unit

ABS control unit

CAN data line

SSP 200/106

You can find detailed information on the CAN databus in Self-Study Programme No. 186.

Tripod roller joint shafts

The tripod roller joint shafts prevent vibrations and noise from being transmitted from the engine-gearbox assembly to the body.

SSP 200/124

39