1993 VOLKSWAGEN GOLF gearbox

Downloaded from www.Manualslib.com manuals search engine CONTROLS AND EQUIPMENT
Dashboard and Controls ..... 4

. ey s, Cen tral locking . . .... 6, 7

::"tl-thef t warning system .... 8
Joors .......................... .... 9
oot lid .... ........... . . . . . 10
::Iectric windows .. . .. 10

• ~Irrors . . ..... . ... 12
Seal belts 13
"" rbag System . . . . . 18
Safe ty for children .. ... 21
ead restraints . . . . . .. 24

= ro nt seats . . . . . . . . . . . .. 25
Rear seat . . . 27

L u ggage compartment ... . ... . ...... 28

M esh partition (Estate) ...... 29

L u ggage compartment cover /

F olding/sliding cover
... 30
Pedals, Hand brake .. 31
Manual gearbox .... ... .... 31
Automati c gearbox . . . .. .......... 32

H eig ht-adjustable steering wheel ..... 35

I gnition lock. . . . . .. 35

Starting/stopp ing engine 36, 38
\lIstrumellts .. .... 39
Warning lamps ....... 46

Switches . . . . . . . . . . . . . . 50

Turn signal and dip lever ............. 53
Cruise control system ........... 54
Wi ndscreen wipe r and washer system 55
Heating an d ventilation .. . ...... 56
Air cond itioner ......' 59
Sliding/ti ltin g roof. . . . . . . . . . . . ... 65
Sun visors / Interior lights 66,67
Cigarette lighter, Ash tray ..... 68

Shelves and boxes . . . . . . . . . . . ... 69
Roof rack / Roof ra ilings ... 70

DRIVING TIPS
The firs t 1500 km -and after wards .... 71
Driving economically and ecologically .. 72
Brakes. . . . . . . . . . . . . . . . 75
Tra iler tow ing . .. ..... . .... ... ...... 77
Driving a four- wheel drive vehicle .. 79

GENERAL MAINTENANCE
Filling the tan k, Fuel. 81, 82

Care of vehicle ........ .. . . 85

Bonnet . . ... 90

Engine compartment .. ...... .... .... 91
Engine oil ..... .......... ........... 92
Automatic transmission fluid (ATF)* ... 96
Power-assisted steering .. 96

Cooling system . . . . . . . . . . .. . 97

B rake fluid ...... 99

Battery . . . . .. 100

Spark plugs. V-belts . . . . . . . . . 102

Washer system
... . .. 103

Windscreen w iper blades . . . 104

Dust a
nd pollen filter * . 104

Wheel s . 105

D riving abroad ..... ............... 110

Accessories, modifications and
renewa l ot parts .............. III
Mobile telephones and tw o-way rad ios 111

DO -lT-YOURSELF
First -aid kit, Warn ing triangle ........ 112

Storage of vehicle tools, spare wheel

a n d ball coupling trailer bracket ...... 113
Vehicle tools, Spare wheel 114

CONTENTS
Changing w heels . 116

F uses . ........ .. .. . . . ... . .... 119

Changing bulbs. . .... .. . 121
Installing radio . . . . .. 127

E mergency starting .. .. 128
Tow starting / to wing . . .. 129

L ift ing vehicle ......... 131

SPECIAL INFORMATION
Body ..... .... . .......... 132

Environmental compatibility ... 133

TECHNICAL DATA
Engine data . .. , .... .... . 134

P er forman ce .. ... ... ... . .. 136

Fuel consump tion .. 137

Wh eels
. . 139

T yre pressures
.. .. ... .. . . .. ... 1 4 1

Weights ... 143

Trailer weights .. 144

Dimensions. ...... .. ... 145

Capacities " ..... 146

Vehicle identification data ... 147

ALPHABETICAL INDEX
Alph abetical index ... 148

3

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Pedals
- _ movement of the peda ls must never be ~S ncted .
::-thIs reason, do not put articles in the '00 well which cou ld roll or slide under­
- 3ath th e pedals.
- • In t
he case of defects on the brake sys­
'em, a greater pedal travel may be necess­a , t should always be possib le to depress
- "'e clut ch and acce le rator pedals fully.
All peda ls must be able to return , unh in-Jere d, to their rest positions. .
= o r these reasons, the only foot mats which e 'Y'\ay be used are those which leave the
ed al area compl ete ly free and which are pre ve nted from slipping .
'11
Hand brake
To apply the handbrake pull lever up firmly . On hills th e 1 st gear, or with automatic gear­
box the parking lock, sho uld also be en­
gaged. The handbrake should a lways be ap­plied so firmly that it is not possible to drive inadve rtentl y with the handbrake on.
W h
en handbrake is applied with the ignition on, the brake warning lam p* comes on.
To release handbrake, pu ll lev er up slightly ,
press locking knob in and push lever right
do w n.
Manual gearbox
• Only engage reverse gear when vehicle is st ationary With the engin e is running, de­
press clutch fully and wait a fe w seconds before mo ving gear lever. ThiS prevents
g rating noises .
When
rev erse gear is engaged with ignition on , the reversing lights come on.
Note
When driving you shou ld not rest your hand
on th e gear lever . The pressure of your hand is transmitted to the selector forks In the
gearb ox and can cause premature wear on the forks .
31

Downloaded from www.Manualslib.com manuals search engine Automatic gearbox*
Driving programmes
The gearbox control unit is equipped with two driving programmes:
• Sport programme
• Economy programme
The programme is selected automati­cally depending on operation of the accel­
erator pedal.
The sport programme is selected if the
accelerator pedal is operated rapidly. In this
case the accelerator pedal need not be de­
pressed to the point of kick-down (see
Page 33). In the sport programme, full use is made of the engine's power reserves
through delayed change to higher gear
The
economy programme is selected
when the acce lerator, pedal is operated
s lowly or normally. Fuel consumption is re­duced by changing early into higher gear and later into lower.
Selector lever lock
In positions "P" and " N" with the ignition
s wi tc h on the selector lever is locked . To move the selector lever out of these posi­
t ions the brake pedal must be depressed and the selector lever button pushed in .
This prevents a gear being engaged inadver­
tently
and the vehicle unintentional ly mov­
ing off .
A de l
ay circuit prevents the selector lever
f rom locking when it is moved quickly past the" N" position (for Instan ce from" R" to "
D " ) This enables for examp
le the vehicle
to be " rocked" out of a "bogged down "
position The shift lock only locks the selec­
tor
leve r if it is left in the " N" position for
more than about 1 second without the
brake pedal being depressed.
At speeds above 5 km/h the selector lever
is automatically switched-off in position "N".
Selector lever positions
P -Parking lock
The driving wheels are lock ed mechanically
The parking lock may only be engaged
when the vehicle is stationary. Before mov­
ing the lever in or out of the" P" position the
lock button in the selector lever handle
must be pressed. Before moving the selec­
tor lever out of
the" P" pOSition, the brake
pedal must also be depressed w hen the
ignition is switched on .
R -Reverse gear
The reverse gear should only be engaged
when the vehicle is station ary and with the
eng ine id ling. Before engaging the position
"R " from the positions "P" or "N " the

brake pedal must be d epr essed and the lock

b u tton in the selecto r lever handle must

also be p re ssed .

The
reversing lights come on then the se­

l e cto r leve r is in the "R" position with the

ignition switched on.

N -Neutral (idling position)

To move the leve r out of neutral when sta­

tionary or at speeds below 5 km/h and with
ignit ion switc hed on depress the brake
ped al and press the lock button in the selec ­

t or lever handle .

32

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D -Normal driving position

-e four forward gears are shifted up and
~own automatically depending upon engine

:lad and road speed.

J n d er certain driving condit ions it
is advan­
--"geous to engage one of the following de­

s "ribed selector lever positions.

3 -Position for hilly regions

ne 1st, 2nd and 3rd gears are shifted up
a'1d down automatically depending upon
~ngine load, road speed and selected pro­
gramme (E or S) The 4th gear IS not en­
;}aged. This increases the engine braking ef­
-e el w hen the accelerator pedal is released.

-
his selector position is recommended in
5. uations where the gearbox alternates fre­quently between 3rd and 4th gears in the D" position .
2 -Position for steep hills
-h is selector lever position is sUitable for
n g climbs and descents. The
1 st
and 2nd gears are shifted up and
down automatically depending on engine

load and road speed . The 3rd and 4th gears

are not engaged in order to avoid unnecess­
ary gear changes. This further increases the

engine braking effect on deceleration .

1 -Position for very steep hills

This selector lever position is recom­

mended for very steep climbs and de­

scents.

To engage this gear, the lock button in the

selector leve r handle must be pressed in.
The vehicle only moves in 1st gear. The 2nd,

3rd and 4th gears are not engaged. Maxi­

mum possible engine braking effect is now
available.

The cruise control
* cannot be used in posi­

t ion "1".

Note
When changing down manually the select or
lever can be moved into the lower gear posi­
tion, but the automatic will not change
down until it is n o longe r possible to over­
rev the engine.
Kick-down device
The kick-down device gives maximum ac­celeration. When the accelerator pedal is pressed righ t down past the fu ll throttle
position, depending on road speed and en­
gine speed, the box changes down into a
lower gear. The shift up into the next higher
gear then takes place as soon as the maxi­
mum specified engine speed is reached.
Notes on driving
Starting
The engine can only be started when selec­
tor lev er is at "N" or "P". See also " Starting
engine" on page 36 .
Selecting a driving range
When the vehicle is stationary and the engine is running always de­press the foot brake when selecting a gear.
When the vehicle is stationary do not depress the accelerator when selecting a gear.
If the lever is moved accidentally into "Nu when driving, release ac­celerator and let the engine speed drop to idling before selecting a for­ward gear again.
33

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• Attention • When the engine is running it is necessary to hold the vehicle with the foot brake in all gears. Because with an automatic gear­box the transfer of power is not fully interrupted even at idling speed -and the vehicle tends to "creep". If a driving range is selected while the vehicle is stationary, the throttle must on no account be opened (e.g. by hand from in­side the engine compartment). The vehicle can then start mov­ing, possibly even when the hand brake is applied.
Before working on a running en­gine, ensure that selector lever is
in position "p" and thatthe hand­brake is applied.
Moving off
Select driving range (R, 0, 3, 2, 1) Wait until the gearbox has shifted and the power flow is made to the driving
wheels (light selection jerk perceptible). Then one can accelerate.
Stopping
To stop vehicle temporarily such as at traffic
lights, it is only necessary to apply the
brakes. It is not necessary to move selector
lever to "N". The engine should however on ly be running at idling speed.
Parking
On level ground all you need do is engage
the parking lock. On a gradient the hand­
brake should be applied firmly first and then
the parking lock engaged. This will ensure
that the locking mechanism
is not too heav­
ily loaded and makes the lock easier to dis­
engage .
Tow starting
On vehicles w ith automatic gearbox the en­
gine cannot be started by towing or pushing
the vehicle. See page130 .
When the battery
is flat. the engine can be started from the battery of another vehicle
by using jumper cables See" Emergency starting", page 128.
Towing
If the vehicle has to be towed at any time ,
you must read the instructions in the sec­
tion "Towing/tow starting on page 129.
Emergency programme
If functional defects occur in the electronic system the gearbox can, amongst other
things, carry on operating in two emergency
programmes: •
The gearbox continues to change up
and
down automatically as before but hard shift

jerks are however noticeable. The vehicle

should
be taken to a Volkswagen dealer.

• The gearbox no longer changes up and
down automatically.

The gearbox can then be shifted manually

but in the selector leve r positions "0", "3"
and "2" only the 3rd gear is available.

I n se lector lever positions " 1 " and " R", the
1 st and reverse gears
are available as nor­
mal .
However, the converter must. due to the
absence of 2nd gear work harder ,
and under
certain circumstances this causes the con­
verte r to overheat.
In a case such as this the
vehicle should be taken, as soon as poss­
ible, to a Volkswagen dealer.
34

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Starting the engine
General hints
Attention When starting the engine in con­fined spaces there is a danger of poisoning.
• Before starting, move gear lever to neu·
tral (with automatic gearbox: Selector lever in "P" or"N" position) and apply handbrake fi rmly
•
On vehicles with a manual gearbox de­
press the clutch pedal when operating
starter
so that starter only has to turn en­
gine .
• As soon
as engine starts, release the
ignition key so that starter can dise ngage .
• After starting a co
ld engine It may sound
noisy for a moment or two because the 011 pressure has to build up in the hydraulic
tappets first. This is normal and no cause for
alarm .
~Do not warm engine up by run­~ning it with vehicle stationary. Drive off straight away.
Do not overrev or use full throttle until the
engine has reached the normal operating
temperature .
• On vehicles with a catalytic con­verter the engine must not be started by towing the vehicle in ex· cess of 50 m. Otherwise unburnt fuel can pass into the converter and lead to damage.
• Before trying to start engine by towing, the battery from another ve· hicle should be used for starting if possible -see page 128.
Petrol engines
These engines are equipped with a petrol in­
jection system that automat ically supp lies
the correct fuel/air mixture at all ambient
temperatures.
When engine
is cold or at operating temperature do not accelerate before or
during the starting procedure.
I f the engin e does not start at once, stop
us ing th e starter after 10 secs. wait about
half a m in ute and then try again.
If the engine sti
ll does not start, the electric
fuel pump fuse may have blown -see page
119 .
When the engine
is very hot it may be
neces sary to accelerate slightl y after the
engine has start
ed.
/
36

Downloaded from www.Manualslib.com manuals search engine DO-lT-YOURSELF
Installing radio
When service installing a radio or replacing
a set installed by the factory the following
points should be noted
• The connection "
in the vehicle is for
Genuine Volkswagen radiosll from Model Year 1994.
• Radios with oth er con nections must be
connected with a n adapter cab le which can also be obtained from a Volkswagen dealer.
Attention On no account cut wires off and leave them without insulation. If necessary use a proper adapter. Otherwise the wiring can be overloaded or short circuits can occur -Fire danger!
11 Not availab le i n all export mark ets
Apart from this, important elec­tronic components can be damaged or the functioning impaired. If for example the speed signal is dis­turbed this can lead to faulty engine management, automatic gearbox, ABS etc.
Even connecting the speed signal to radio sets with speed dependent volume control from other manufac­turers can cause such faults.
• It is advisab le therefore to have the in­
sta llation of the radio system done by a Volkswagen dealer. They are fully informed
about the technical features of the vehicle,
have the Genuine radios
1), the necessary
fitting parts from the Genuine Volksvvagen
Accessory Programme 1
) and work in ac­
cordance with the guidelines developed by
the factory . •
The radios from the Genuine Volk­
swa gen Accessory Programme
1
) are similar
to those used in the factory and ensure
trouble-free Installation .
These sets are
in keeping with the ad­vanced technology and well-planned easy­
to-operate design.
In Germany there is also an Exchange Ser­
vice for the se radios so that even after years
of use a set requir ing repair
can be ex­
changed cheaply for a completely recondi­
tioned, good-as-new set by a Volkswagen
dealer.
• Loudspeakers, fitting parts, aerials and
supp
ression kits shou ld also be taken from
the Genuine Volkswagen Accessory Pro­
gramme1) These parts have all been
specially developed for each vehicle model.
127

Downloaded from www.Manualslib.com manuals search engine DO-lT-YOURSELF
• The emergency lights must be switched
on on both vehicles -unless local regula­
tions differ.
•
Turn ignition key to "Drive" position so that the steering wheel is free and the turn
signals, horn, and, if necessary, the wind­
screen wiper and washer can be used.
•
As the brake servo only works when the
engine is running, considerab ly more pres­
sure is required on the brake pedal when
the engine is not running
•
On vehicles with power assisted steer­
ing more force is required to turn steering
wheel when engine is not running.
• When there
is no lubricant in the manual
gearbox/automatic gearbox, the vehicle
may
on l y be towed with driving wheels
lifted.
Tow starting
The following points must be
noted when tow starting:
• Before moving off, engage 2nd or 3rd
gear .
• Switc h ignition
on. • As soon as engine starts, depress clutch and move gear lever into neutral to avoid
running into the towing vehicle.
• On vehicles with a catalytic con­verter the engine must not be started by towing the vehicle in ex­
cess of 50 mll. Because then, fuel can pass into the converter and cause damage.
• For technical reasons tow start­ing a vehicle with an automatic gearbox is not possible.
Towing
When towing vehicles with an auto­matic gearbox, the following points
must be noted in addition to the details on the previous page :
• Selector lever
at " N". • Do not have the vehicle towed faste r
than 30 mph (50 km/h)
• Do not
tow further than 30 miles (50 km).
If the vehicle has to be towed long dis­
tances it mu st be lifted at the front.
Reason: When the engine
is not running ,
the gearbox oi l pump is not working and the
gearbox is not adequately lubricated fo r
high speeds or long distances .
• With a breakdown vehicle the vehicle
may only be suspended at the front.
Reason: If given a rear suspended tow, the
drive shafts turn backwards . The plane tary
gears
in the automatic gearbox then turn at
such high speeds that the gearbox will be severely damaged in a short time .
1) Does not apply to Diese l e ng ines wi h cata­
lytic conve rter
Note for the Golf syncro:
• The veh icle can be towed like any two­
wheel drive Golf.
• With a recovery vehicle the car
can be
towed with front or rear wheels suspended.
If the vehicle has to be towed with the rear
wheels lifted and the rear wheels cannot
turn freely, one must ensure that the free­
wheel
in the rear axle has not been bridged
beforehand by driving vehicle in reverse. To reintroduce the freewheel action the gear
lever must be moved briefly in to 1 st gear
wi th ignition on and then back in to neutral.
1 30