Volkswagen Golf Cabriolet (2012) Self Study Program

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Service Training

Self-study programme 498

The Golf Cabriolet 2012

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The Golf Cabriolet 2012 - the continuation of a great tradition.

s498_007

Presented as a four-seater cabriolet based on the Golf 2009, this model comes in a completely open format without roll bar. The design shows its individual character compared with the Golf hatchback thanks to the new rear end, the flat roof line and the greater inclination of the windscreen frame.

One technical highlight is the fully automatic electrohydraulic fabric convertible roof that can be opened in  9 seconds at vehicle speeds up to 30 km/h. Maximum safety is provided by an active roll-over protection system, airbags for the driver and front passenger, head-thorax airbags for the front seats and a knee airbag on the driver's side. It has been possible to improve the high level of static and dynamic stiffness even further compared with the hatchback by adding special structural reinforcements to the underbody, the side panels, the sills, the rear bulkhead and the doors.

The new Golf Cabriolet provides a high level of ride comfort and features the quietest and one of the most spacious interiors in its class. The luggage compartment volume is 250 litres, which is also fully usable when you open the convertible roof.

The new Golf Cabriolet 2012 is characterised by elegance, dynamics, convincing quality and precision.

The self-study programme presents the design and function of new developments! The content will not be updated. 

Current testing, setting and repair instructions can be found in the provided service literature.

Important

note

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Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Electrohydraulic Convertible Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Occupant Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Heating and Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Convenience Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Radio, Navigation and Telephone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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Introduction

s498_345

s498_012

Wolfsburg

Osnabrück

The Golf Cabriolet 2012

The Golf Cabriolet success story

The start of production for the new Golf Cabriolet in March 2011 sees Volkswagen continue the success story of the Golf Cabriolet built between 1979 and

2002. It is being built at Volkswagen's Osnabruck plant in the German state of Lower Saxony. The factory covers all stations of the automobile process chain from vehicle development to tooling and production.

The Golf Cabriolet through the eras

From the introduction of the first Golf Cabriolet in 1979 until the end of production in 2002, the Golf Cabriolet sold over 680,000 units across the world.

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s498_011

Overview of equipment features

The list below shows you important standard and optional equipment for the new Golf Cabriolet 2012. The range of options builds on the standard equipment by means of equipment and design packs.  These may vary from country to country.

Here are some of the equipment features for the new cabriolet:

• Xenon headlights with cornering lights and LED daytime running lights incl. front fog lights, optional

• Tinted tail lights using LED technology

• Electrohydraulic fabric roof, fully automatic

• Undivided rear seat bench, backrest split symmetrically, foldable

• Knee airbag on driver's side

• Active roll-over protection system

• Start/stop system*

• Windbreak, optional

* Only for BlueMotion technology

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Introduction

s498_327

1,508 mm1,535 mm

1,782 mm

2,578 mm

4,246 mm

1,423mm

Technical data

Exterior dimensions and weights

The data refers to a vehicle without driver, with standard equipment, a 1.2l 77kW TSI engine and  tyre size 205/55 R16.

Exterior dimensions Weights/further data

Length 4,246 mm

Width 1,782 mm

Height 1,423 mm

Wheelbase 2,578 mm

Track width at front 1,535 mm

Track width at rear 1,508 mm

Gross vehicle  weight rating

Kerb weight 1,341 kg

1,850 kg

Max. trailer load, braked 1,200 kg

Turning circle 10.9 m

Tank capacity 55 litres

Drag coefficient 0.34 c

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s498_328

884 mm

1,686 mm

684 mm

1,471 mm

334 mm

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Interior dimensions and volumes

Interior length 1,686 mm

Luggage compartment volume 250 litres

Height of open rear lid 1,471 mm

Height of load sill 684 mm

Height of luggage compartment aperture

Width of luggage compartment aperture

334 mm

884 mm

Front headroom 1,007 mm

Headroom – 2nd seat row 948 mm

Knee room – 2nd seat row *

* Sufficient knee room can only be obtained

by reducing the knee room of the first  seat row.

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s498_005

s498_021

Body

Body structure

Overview

The body of the Golf Cabriolet 2012 is based on the Golf 2009. The outer panels, the A-pillars and the rear bulkhead are new and were specially developed for the Golf Cabriolet 2012.  Body parts from the Scirocco and from the Audi A3 Cabriolet have also been used.

Explanation of colours

Parts specific to Golf Cabriolet 2012

Parts from Golf 2009

Parts from Scirocco

Parts from Audi A3 Cabriolet

Cavities and anti-drum measures

The body cavities are acoustically sealed with insulation foam. The insulation is glued in or inserted in an unexpanded state during body assembly. It then expands to fill the respective cavities once it is exposed to heat during processing.

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s498_020

Roll-over protection

system

Rear bulkhead

Bolted connections

s498_022

A-pillar

(ultra-high-strength)

Reinforcement in

bending zone

Rear bulkhead

The fixed rear bulkhead comes in a single piece and has been specially designed for the Golf Cabriolet

2012. It has integrated reinforcements for securing the rear seat bench and holds the roll-over protection system. The red markings in the illustration show the bolted connections between the roll-over protection system and the rear bulkhead (four on each side).

Reinforced A-pillars

The design of the A-pillar is based on the A-pillar from the EOS. In crashes or if the car rolls over, the Apillar of a cabriolet needs to withstand considerably greater forces than a vehicle with a conventional roof. Sheet thicknesses of 2 mm are used to meet these tougher requirements.

Thermoformed, ultra-high-strength sheet metals are used on the inside of the A-pillar.  In crashes, they provide support on the inside, i.e. the “pressure side”. A reinforcing piece on the outside at the bending zone provides additional stability and guarantees safety in the passenger compartment should the vehicle “roll over”.

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Body

s498_024



Roof cross member

Windscreen cross member/ bulkhead

s498_026

Inner panel

Outer panel

Roof cross member and bulkhead

The roof cross member is designed for roll-over and has an integrated fitting for the convertible roof locking mechanism. The windscreen cross member taken from the Scirocco forms the bulkhead and is connected to the A-pillars.

Body side panel

The body side panel incorporates the sheet metal sill

and consists of an inner and outer panel.  The inner panel is made up of several parts while the outer panel is single-piece.

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s498_028

Support

B-pillar

B-pillar and heel plate area

The concept for the B-pillar has been taken from the Audi A3 Cabriolet. The raised support of the heel plate to the B-pillar helps improve side collision performance. The front seat belt mounting has been integrated into the B-pillar.

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Body

s498_280

Motor with

Bowden cables

Lock

Door frame

Guide

rails

Assembly

flap

s498_282

Stowage compartment

Windbreak

mountings

Doors and window regulators

In addition to the usual side storage compartments, the doors have a holder for 1.5 -litre water bottles and a compartment for the high-visibility waistcoat.

The functional components for the window regulators are connected directly to the door structure.  This means that assembly carriers are not used.  The adjustment concept for the window regulators is the same as for the EOS.

Side panel trim (rear)

The whole side trim panel is covered with foam sheet

along the window sill. There is a storage compartment on the left-hand side. The mountings for the optional windbreak have also been integrated into the side trim panel.

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s498_284

Access to hydraulic pump

Luggage compartment floor (toolkit and spare  wheel underneath)

2nd side

access

Load-through

hatch



First-aid box

s498_286



Insert parts

Lock reinforcement



Reinforced hinges

Luggage compartment with  load-through hatch

The luggage compartment volume of 250 litres is available both when the convertible roof is open and when it is closed. There is a cover in the side luggage compartment trim via which you can access the hydraulic pump for emergency operation of the convertible roof.

There is a facility for securing a first aid box to the side trim of the luggage compartment (Germany only).

When the rear seat backrests are folded forward, the luggage compartment also has a load-through hatch that reaches over the rear seat bench. The loadthrough hatch is 526 mm wide and 381 mm high.

Rear lid

The rear lid is made up of an inner and an outer panel. Reinforcements are welded to the inner panel. The reinforced hinges connect the hinge bolting points to the bolting points for the rubber buffers. The insert parts that form the assembly openings for the lights are welded to them. The lock reinforcement is manufactured as a drawn part. The outer panel is fitted over it.

The rear lid has an electrical release. There is no mechanical lock cylinder since manual release is possible when the power is disconnected by means of a Bowden cable.

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Body

LockBowden cable

s498_288

Loop behind coverBowden cable

s498_230

Rear lid manual release mechanism

The rear lid does not have a mechanical lock cylinder. If the Golf Cabriolet has a flat battery, the rear lid can be unlocked manually via a Bowden cable. The Bowden cable runs from the lock in the rear lid via the hinge along the hydraulic pump past the  B-pillar and to the door frame on the driver's door.  In the door frame, the Bowden cable ends with a loop that protrudes from the frame metal. The loop is hidden by a plastic cover that can be levered off with the key. Pull the loop to release the lock in the rear lid mechanically.

The luggage compartment cannot be opened without the vehicle key if the vehicle battery is flat. First the driver's door needs to be opened mechanically with the key via the lock cylinder so that you can access the Bowden cable for the manual release mechanism in the door frame.

14

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Floor panel

s498_029

Aluminium

engine shield



Members for sill panel area

Diagonal struts

Subframe

Member for sill panel area

The members in the sill panel area increase the stiffness of the whole body and thus improve occupant safety in side collisions.  They provide additional body reinforcement in the areas where the diagonal struts are connected.

Diagonal struts

The front and rear diagonal struts increase the torsional stiffness of the body and minimise the torsional oscillation and vibrations that are typical of cabriolets.

Aluminium engine shield

Together with the assembly holder, the aluminium engine capsule reduces the relative movement between the front subframe and the ends of the front longitudinal members.

Subframe

The subframe increases the stiffness of the body and reduces its vibrations. It is directly connected to the spare wheel well.

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Body

s498_023

Interior

The proven technology of the Golf 2009 is used for the whole front section including the cockpit and the dash panel. In contrast to the Golf 2009, the retaining clips from the Scirocco are used to secure the cockpit trim in the Golf Cabriolet 2012.

The rear seat backrest can be folded down to use the load-through hatch in the luggage compartment.

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Centre console with armrest

s498_025

s498_222

Lumbar support

adjustment

s498_200

Centre console

The basic version of the centre console has a storage compartment and a drink holder for 1.5-litre bottles. A taller version of the centre console with an armrest is available as an option (see illustration). The Golf Cabriolet 2012 comes with a 12 V socket as standard.  The switch for operating the convertible roof is located next to the handbrake lever as in the EOS.

Front seats

The manually adjusted 8-way front seats in the Golf Cabriolet 2012 have:

• Longitudinal adjustment and height adjustment

• Backrest tilt adjustment

• Lumbar support adjustment

• Integrated head-thorax airbag

• Whiplash-optimised head restraint system  (for Euro NCAP 5 stars)

• Easy-Entry

Windbreak

The windbreak is available as an optional accessory. It minimises wind buffeting in the interior while the car is travelling. The mountings are integrated into the side trim. Once the windbreak has been installed, passengers can no longer be seated on the rear seats.

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Electrohydraulic Convertible Roof

s498_307

1

2

3

Overview of convertible roof design

The Golf Cabriolet 2012 has a fully automatic, fabric convertible roof with heated glass rear window.  The convertible roof is operated by an electrohydraulic system with an automatic, electric motor-operated locking/ release mechanism.

The convertible roof is permanently fastened to the body structure in the area of the C-pillar. When closed, it is securely locked to the roof cross member. When the convertible roof is open, it is folded into a z-shape on top of the luggage compartment. For the first time, the convertible roof can also be operated while the vehicle is travelling at slow speeds up to 30 km/h.

The structure of the convertible roof is shown in three layers for better understanding:

• Convertible roof cover with insulation and rear window

• Convertible roof frame with electrohydraulic convertible roof mechanism

• Headliner

The convertible roof for the Golf Cabrio with the three layers: convertible roof cover with insulation and rear window (1), convertible roof frame with electrohydraulic system (2) and convertible roof headliner (3)

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Convertible roof cover

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s498_306

The convertible roof cover consists of the convertible roof canvas and the convertible roof insulation that is connected to it. The cover is made up of one centre and two side panels. The convertible roof canvas has three layers. The outer layer is made from a polyacrylic fabric, the middle layer from synthetic rubber and the inner layer from polyester. All layers are permanently fastened to each other. The insulation also has three layers with outer layers made from polyester fleece and an inner layer of foam. Together with the improved sealing concept in the area of the doors and the roof cross member, this convertible roof cover concept improves the noise and heating comfort in the passenger cell.

The convertible roof cover is fastened to the convertible roof frame with fabric-retaining strips. This method prevents excessive ballooning of the convertible roof on the road. The two lengthways seams on the convertible roof cover are designed so that they function as rain gutters and drain off rainwater in a longitudinal direction. This function is supported by round cord embedded in the side panels.

The heated rear window made from single-pane toughened glass is bonded to the convertible roof cover during production by means of high-frequency welding.

Convertible roof cover with insulation (1) and heated rear window (2) and fabric retaining strips (3)  on convertible roof frame (4)

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Electrohydraulic Convertible Roof



Front bracing hoop

Main pillar with roof frame, control elements, main guide elements and sealing strips

Main mounting

Rear window guide element

Bracing

hoop 2

Bracing

hoop 3

Bracing

hoop 4

Bracing

hoop 5

s498_309

Convertible roof mechanics

The electrohydraulic convertible roof mechanism includes the folding convertible roof frame with the main pillars that fold at four joints. In addition, the convertible roof mechanism comprises the electrohydraulic convertible roof operating system and the electrical convertible roof locking mechanism in the front bracing hoop along with the roof cross member.

Convertible roof frame

The convertible roof frame is made up of the following components:

- the two main mountings on the left and right

- the two main pillars with moving fabric retaining brackets

- the left- and right-hand main guide elements

- the side roof frame

- the front bracing hoop

- the control elements

- the bracing hoops

- the rear window guide elements

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Main mounting

Hydraulic cylinder

s498_308

Front bracing hoop when convertible roof is closed

Formation of

parallelogram

Front bracing hoop when convertible roof is open

s498_311

Main mounting with hydraulic cylinder

The arrangement of joints allows the convertible roof to be folded into a Z-shape and placed on top of the luggage compartment. The area of the front bracing hoop has been made large enough so that it covers the opened convertible roof almost completely and thus protects both the rear window and the convertible roof cover. The convertible roof on the Golf Cabrio 2012 opens in approx. 9 seconds and closes in approx. 11 seconds.

The movement of the convertible roof frame

Each main pillar has four joints and is connected to the body via the main mounting. The hydraulic cylinders are on the main mountings. The linear movement of the hydraulic cylinder is converted into the pivoting and folding movement of the convertible roof via the main guide elements and the control elements.

When the convertible roof is opened, the front bracing hoop stays at the same angle almost over the complete path of the roof since the roof frame forms a parallelogram. The rear window guide elements ensure that the rear window is guided towards the luggage compartment as the convertible roof opens until it reaches its end position with the outside of the window facing downwards under the front bracing hoop. The rear window is then fully protected by the front bracing hoop.

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Electrohydraulic Convertible Roof

Automatic convertible roof locking mechanism

Convertible roof hydraulics

s498_312

Electrohydraulic system

System overview

The electrohydraulic system for operating the convertible roof consists of the following main components:

• the convertible roof actuation control unit J256

• the convertible roof actuation button E137 in the centre console

• the convertible roof operation warning lamp K215 in the control unit in dash panel insert J285

• the hydraulic system with the convertible roof actuation hydraulic pump V118

• the convertible roof front switch F202 in the left-hand main mounting

• the convertible roof stowed switch F171 in left-hand main mounting

• the convertible roof lock with convertible roof lock motor V223, the convertible roof latch open switch F294 and convertible roof latch closed switch F295

• the left latch switch for convertible roof F169 and right latch switch for convertible roof F170 in the roof cross member

The electrohydraulic system is connected to the data bus network via the convenience CAN data bus (a) and via the data bus diagnostic interface J533. The control unit also receives the necessary additional signals, for example, the outside temperature (measured by ambient temperature sensor G17) and the speed signal via the CAN data bus.

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Data bus communication

s498_082

a

The convertible roof actuation control unit communicates with the numerous other control units via the convenience CAN data bus and the data bus diagnostic interface. This allows, for example, the side windows to be automatically dropped down slightly to make it easier for the convertible roof to move when it is opened. Then, when it is closed again, the side windows are raised to fit perfectly into the window seals. This requires that the convertible roof operation control unit instructs the door control units to activate the window regulator motors accordingly. The convertible roof control system receives the speed signal required for roof operation via the powertrain CAN data bus and the diagnostic interface of the ABS control unit.

Key

E137 Convertible roof actuation button

E586 Window regulator button

F169 Left latch switch for convertible roof

F170 Right latch switch for convertible roof

F171 Convertible roof stowed switch

F202 Convertible roof front switch

F294 Convertible roof latch open switch

F295 Convertible roof latch closed switch

G17 Ambient temperature sensor

J104 ABS control unit

J255 Climatronic control unit

J256 Convertible roof actuation control unit

J285 Dash panel insert control unit

J301 Air conditioning system control unit

J386 Driver door control unit

J387 Front passenger door control unit

J388 Door control unit, rear left

J389 Door control unit, rear right

J519 Onboard supply control unit

J533 Diagnosis interface for data bus

J623 Engine control unit

K215 Convertible roof operation warning lamp

V118 Convertible roof actuation hydraulic pump

V223 Convertible roof lock motor

Sensor/input

Actuator/output

Powertrain CAN data bus

Convenience CAN data bus

a Combi CAN data bus

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Electrohydraulic Convertible Roof

Hydraulic pump V118 in pump housing

Hydraulic cylinder on right hand main mounting

Hydraulic cylinder on lefthand main mounting

Convertible roof frame with convertible roof cover

s498_337

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9

s498_313

Hydraulic system

Hydraulic system set-up

The hydraulic system consists of the following components, among others:

Left- and right-hand hydraulic cylinders

1

Return restrictor

2

Emergency operation mechanism

3

Non-return valves (pressure controlled)

4

Control lines

5

Hydraulic pump V118

6

Shuttle valve

7

Reservoir

8

Pump housing

9

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This is how it works:

1

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6

7

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2

s498_315

s498_314

When a convertible roof procedure is started, the convertible roof actuation control unit activates the hydraulic pump.  The direction of rotation of the pump and the position of the shuttle valve in the pump decide whether the hydraulic cylinders extend or retract. If the hydraulic cylinders are extended, the convertible roof will open.  When the hydraulic cylinders are retracted, the convertible roof closes.

The shuttle valve ensures that hydraulic fluid can be fed into or flow out of the reservoir when the rotation direction of the pump is switched by the control unit. Two control lines each connect one of the two pressure-controlled non-return valves to the hydraulic circuit for the opposite direction of travel. If the pressure side changes with the direction of rotation of the pump, the assigned non-return valve is held open from there by the respective control line so that hydraulic fluid can flow from the cylinder to the pump.

The non-return valves are closed when not activated. Thanks to this hydraulic self-blocking system, the system pressure is maintained and the convertible roof remains in the position it reached.

Hydraulic cylinder

1

Control line

2

Non-return valve

3

Hydraulic pump

4

Convertible roof 

5

actuation control unit

Shuttle valve

6

Reservoir

7

Supply

Return

Depressurised

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Electrohydraulic Convertible Roof

Emergency operation screw

Convertible roof actuation hydraulic pump

Housing

s498_303

s498_316

Convertible roof actuation hydraulic pump V118

Task and installation location

The hydraulic pump for convertible roof actuation is located behind a flap on the left of the luggage compartment. It is connected to the hydraulic system via plastic hydraulic lines and operates the hydraulic cylinders when the convertible roof is actuated.

How it works

By switching the rotation direction of the pump electrical drive, the delivery direction is reversed thus setting the direction of the convertible roof travel.

Convertible roof stowed switch F171

Installation location and task

The convertible roof stowed switch is a Hall sender.  It is located on the left-hand main mounting of the convertible roof frame. The convertible roof actuation control unit uses the signal from F171 to detect when the convertible roof has reached its end position on top of the luggage compartment.

Effects of failure

If a fault occurs in the pump during convertible roof operation, it will only be possible to close the convertible roof manually after turning the emergency operation screw. Automatic opening or closing is no longer possible (see emergency operation).

26

Effects of failure

Without the signal from F171, the convertible roof actuation control unit cannot establish whether the convertible roof has reached its end position on top of the luggage compartment. The system switches to fault mode and the convertible roof can only be closed manually. The emergency operation procedure must be performed in this case.

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Convertible roof front switch F202

s498_331

Installation location and task

The convertible roof front switch is also a Hall sender. It is located on the base of convertible roof in the lefthand main mounting. The convertible roof actuation control unit uses the signal from F202 to detect when the convertible roof has reached its end position on the roof cross member and when the automatic locking procedure can be initiated.

Effects of failure

Without the signal from F202, the convertible roof actuation control unit cannot establish whether the convertible roof has docked with the roof cross member and reached its end position. The system switches to fault mode and the convertible roof can only be closed manually. The emergency operation procedure must be performed in this case.

A maximum of 25 seconds are available for the convertible roof to reach one of the two end positions (open/ closed) each time it is operated. This time limit applies from the moment the convertible roof actuation button (E137) is pressed regardless of the convertible roof position.

If this time limit is exceeded, the convertible roof actuation control unit will stop the operation.

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Electrohydraulic Convertible Roof

Front bracing hoop

Locking hook

Carrier plate with locking mechanism

Locking hook

s498_310

s498_220

Motor

Convertible roof

lock switch

Rotating

switch actuator

Gearbox for

locking mechanism

Convertible roof lock

Installation location and task

The electrical convertible roof locking mechanism is located in the front bracing hoop under a plastic cover.  It fastens the closed convertible roof securely to the roof cross member.

Electrical convertible roof locking mechanism in front bracing hoop

Design

A carrier plate holds the electric drive motor, the gearbox connected to the locking linkage and two microswitches with a switch actuator, which belong to the locking recognition system. Linkages are used for the connections to the two locking hooks. During locking, the locking hooks engage in corresponding catches in the roof cross member and thus fasten the convertible roof securely to the front body structure.

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This is how it works:

s498_333

Locking hook in the front bracing hoop (a), locking hole in the roof cross member (b)

The convertible roof control system can only clearly determine whether a convertible roof operation has been successfully completed and the convertible roof is in one of the two safe positions “Convertible roof closed and locked to the roof cross member” or “Convertible roof open and placed on top of luggage compartment” if it has received all information from the switches in the main mounting and from the convertible roof locking mechanism.

The convertible roof lock motor V223 is activated by the convertible roof actuation control unit J256 once the convertible roof has reached its end position on the roof cross member and the control unit detects this position. This is done using the convertible roof front switch F202 on the main mounting. The rotation direction of the convertible roof lock motor is reversed to open or close the locking mechanism.

A maximum of 4 seconds activation time is allowed in the control unit for the travel between the locked (F295) and unlocked (F294) positions to protect the system against overloading if the convertible roof movement is obstructed. If this time is exceeded, a system emergency run is activated.

The signal from the switches F169 and F170 “Convertible roof locked at front” indicates the end of the convertible roof closing procedure. If this signal is not issued, the system will continue to ask the operator to close the convertible roof. (The hydraulic pump has already been switched off after the signal from F202.)

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Electrohydraulic Convertible Roof

Drive

Switch actuator

Angled lever

Switch

s498_317

s498_318

Convertible roof latch open switch F294 and latch closed switch F295

Installation location and task

The two microswitches are located on the carrier plate with the locking mechanism in the front bracing hoop. The switches are operated by a rotating switch actuator via two angled levers. When the motor V223 starts running, the switch actuator rotates and actuates one of the two angled levers once one of the end positions is reached. The lever then opens the associated switch. If the actuator moves in the opposite direction, the other angled lever will be actuated and the second switch is thus opened while the first switch is closed.

The end position of the locking hook corresponds with one end position of the switch actuator so that only one of the two switches is opened by the angled lever at one time with “Hook in unlocked position” or “Hook in position locked”. This allows the convertible roof lock control unit to determine whether the locking hooks are in one of the two end positions or in-between.

“Convertible roof unlocked” position

30

“Convertible roof locked” position

Effects of failure

Without the signal from the two switches, the convertible roof actuation control unit cannot determine whether the locking hooks are in one of the two end positions. The system switches to fault mode and the convertible roof can only be closed manually. The emergency operation procedure must be performed in this case.

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Left F169 and right F170 latch switch for convertible roof

F169 F170

s498_332

Locking

hook

Front bracing hoop

Switch

Roof cross member

s498_336

Roof cross member

Front bracing hoop

s498_335

Locking hook and switch before locking

Installation location and task

The switches are on the left and right in the roof cross member on the locking holes. They are operated by the locking hooks when they hook into the locking holes on the roof cross member.

These two switches allow the convertible roof control system to determine whether the two locking hooks, which are already in the end position “closed” according to the signal from F294 and F295, have actually managed to hook into the locking holes on the roof cross member. Only then is the convertible roof securely fastened to the roof cross member on both sides of the vehicle and in a safe position so that the convertible roof operation can be completed.

Locking hook and switch after locking

F169 and/or F170 have been actuated or not, it will enter the fault “Convertible roof front lock switch, implausible signal” in the fault memory after a set maximum time has expired. The system switches to fault mode and the convertible roof can only be closed manually. The emergency operation procedure must be performed in this case.

Effects of failure

Without the signal from F169 and F170, the convertible roof actuation control unit cannot establish whether the convertible roof is connected to the roof cross member by the locking hooks on both sides of the vehicle. Since the control unit J256 cannot determine whether

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Electrohydraulic Convertible Roof

Emergency

operation screw on

hydraulic pump

Convertible roof

actuation control

unit J256

Emergency

operation handle

s498_350

Further electrical components

Convertible roof actuation control unit J256

Installation location and task

This control unit is located in the luggage compartment on the left next to the convertible roof actuation hydraulic pump V118. It controls the whole electrohydraulic system for the convertible roof in interaction with other control units within the Golf Cabriolet CAN data bus network. It communicates, for example, both with the ABS control unit on the powertrain CAN data bus and with the door control units and the air conditioning system control unit on the convenience CAN data bus. Faults in the roof control system electrics are stored in the fault memory of the convertible roof actuation control unit.

Effects of failure

If the control unit is faulty, it will only be possible to open and close the convertible roof manually.  The emergency operation procedure must be performed in this case.

Further control unit functions

The system has a so-called “Tamper protection” function to protect the hydraulic pump and electric locking mechanism against overheating and damage due to constant running. It is activated if the convertible roof is operated without interruption for a long period (approx. 2 minutes). In this case, the “tamper protection” function will block convertible roof operation for approx. 10 minutes if the convertible roof is closed. If the convertible roof does not reach the “closed” status after approx. 2.5 minutes of constant operation, the convertible roof operation will be stopped immediately and can only be moved to the rear, open end position.  The convertible roof will remain in the position reached without the button being pressed again. The message “Temperature too high, convertible roof” will appear on the dash panel insert display. It is then only possible to operate the convertible roof again after it has been disabled for 25 minutes.

The convertible roof operation warning lamp K215 in the dash panel insert will flash as a warning and indication that convertible roof operation has been disabled by the tamper protection function.

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Convertible roof actuation button E137

Installation location and task

The convertible roof actuation button is located in the centre console. It has two switching directions.

in. If, after the opening procedure, you hold the button for a further 3 seconds, the side windows will be lowered completely. If you hold the button or pull it again after the closing procedure, the side windows will be raised completely. There is an additional button within the button. This is the central window regulator button E586.  It can be used to operate all side windows at the same time (manual/automatic run).

Effects of failure

Without the signal from the convertible roof actuation button, automatic convertible roof operation is only possible using the convenience function via the door lock.

s498_319

Pressing and holding opens the convertible roof. Pulling and holding closes the convertible roof.

If you let go of the button during a convertible roof operation, the roof operation will stop and the convertible roof will stop in the position reached. Operating the button again resumes the convertible roof operation according to the direction you move it

Convertible roof operation warning lamp K215

s498_320

Installation location and task

The warning lamp is located in the dash panel insert. During convertible roof operation, the warning lamp is constantly illuminated and extinguishes once the convertible roof operation has been completed. If the convertible roof has not reached one of the two end positions or there is a fault in the system when the convertible roof actuation button is held, K215 will flash.

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Electrohydraulic Convertible Roof

Convertible roof operation

The convertible roof can be opened or closed if the required system conditions are met. If operation of the electrohydraulic convertible roof is not possible, the convertible roof can also be moved manually to one of the two end positions using the emergency operation system (see page 38).

Special features during roof operation

- If the convertible roof has already been unlocked for opening, this convertible roof opening procedure can also be completed at speeds greater than 30 km/h.

- It is only possible to open or close the convertible roof via the door lock by means of mechanical operation with the key once you have removed the cylinder cover on the driver-side door handle.

- If the convertible roof is moved in opposite directions 2-3 times between the positions “Convertible roof at front” or “Convertible roof at rear”, the control unit will no longer be able to clearly identify the convertible roof position.  The convertible roof operation is interrupted and the driver is asked to move the convertible roof to the end position “Opened”.

- When the convertible roof is closed, the locking hooks are only moved to the position “unlocked” after approx. four seconds to avoid collisions with the backrest console of the rear seats.

Opening convertible roof

Requirements

- Vehicle stationary or travelling at speed  30km/h with convertible roof in »closed« position

- Ignition is switched on

- Convertible roof operation not requested via convenience opening/closing

- Outside temperature is > -10 °C

- Rear lid is closed

- Onboard supply voltage is 11.4 V with convertible roof fully open or closed;   10 V is required from an intermediate position

- Hydraulic system and electrical convertible roof locking mechanism are not overheated  (tamper protection is not active)

- The convertible roof actuation button is held during whole convertible roof operation

34

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s498_321

Procedure

The button for convertible roof actuation is pressed and held down during the whole convertible roof operation.  The convertible roof operation warning lamp lights up and stays on.

The side windows are automatically lowered to a preset level (automatic drop-down position). Windows that are in or below the automatic drop-down position, are not lowered. If all side windows are below the automatic  drop-down position, the convertible roof actuation control unit will unlock the convertible roof from the roof cross member. The rear window heating is deactivated and operation of the rear lid is blocked for the duration of the convertible roof operation.

Once the locking hooks have reached the “unlocked” position, the hydraulic pump starts to run and the convertible roof moves to the rear folding itself together in the process. In the meantime, the locking hooks are returned to the “locked” position.

The convertible roof stowed switch confirms that the roof has reached the end position on top of the luggage compartment and the hydraulic pump stops. The warning light goes out and use of the rear lid is enabled again. The side windows close. In this convertible roof position, the trim on the front bracing hoop covers the folded convertible roof and protects the convertible roof cover and the rear window.

35

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Electrohydraulic Convertible Roof

s498_323

Closing convertible roof

If the control unit recognises the convertible roof status »Convertible roof open« or the convertible roof is in an intermediate position because, for example, you have let go of the convertible roof actuation button,  the convertible roof can be closed by pulling and holding the button again.

Requirements

- Vehicle is stationary or is travelling at speed  30 km/h

- Ignition is switched on

- Convertible roof operation not requested via convenience opening/closing

- Rear lid is closed

- Onboard supply voltage is 11.4 V with convertible roof fully open or closed;   10 V is required from an intermediate position

- Hydraulic system and electrical convertible roof locking mechanism are not overheated  (tamper protection is not active)

- The convertible roof actuation button is held during whole convertible roof operation

36

Procedure

Pull and hold the convertible roof actuation button during the whole convertible roof operation.  The convertible roof operation warning lamp lights up and stays on. The side windows are moved to the automatic drop-down position regardless of their current position to make convertible roof operation possible. Use of the rear lid is blocked again for the duration of the convertible roof operation.

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The convertible roof actuation control unit activates the hydraulic pump in the opposite direction to opening operation. The convertible roof unfolds itself while moving to the front towards the roof cross member.  After approx. four seconds of convertible roof operation, the locking hooks move to the position “unlocked”.  The convertible roof front switch detects when the front bracing hoop docks onto the roof cross member and sends a signal to the control unit. The control unit switches the hydraulic pump off. The convertible roof has reached its end position.  The locking hooks are moved to the “locked” position and thus securely fasten the convertible roof to the roof cross member. The side windows close completely. The rear window heating is enabled again and the convertible roof operation warning lamp goes out. The convertible roof is closed.

Convenience operation

The convertible roof can also be opened or closed via the door lock. The cap on the driver door lock needs to be removed so that you can insert the vehicle key into the lock cylinder.

In contrast to the operating conditions for opening the convertible roof with the button, the ignition key may not be

inserted in the ignition lock and the ignition must be switched off in this case. Furthermore the convertible roof actuation button may not be pressed.

The vehicle must first be unlocked before the convertible roof can be opened. If the key is then turned once again in the “unlock” direction within approx. 2 seconds and held there, the procedure for opening the convertible roof will start.

You first need to lock the vehicle before closing the convertible roof. If you turn the key again in the “lock” direction within approx. 2 seconds and hold it there, the procedure for closing the convertible roof will start.

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Electrohydraulic Convertible Roof

s498_324

Emergency operation

If the convertible roof cannot be operated with the electrohydraulic system due to a fault, the roof can be operated manually. This requires three steps :

- the hydraulic system needs to be switched to emergency operation at the hydraulic pump

- the convertible roof locking mechanism on the roof cross member needs to be released manually

- the roof must be folded or unfolded to the respective end position by hand

The following section describes how to open the convertible roof manually. It is closed in the reverse sequence.

Please note the information on manual emergency operation of the convertible roof in the owner's manual for the vehicle.

Recommended measures for emergency  operation

- apply the handbrake

- lower all side windows

- turn the ignition off  (terminal 15 »off«)

- remove the ignition key  (terminal S »off«)

- close the rear lid

Switching the hydraulic system to emergency operation

Emergency operation screw and indication of rotation direction on housing of convertible roof actuation hydraulic pump

38

The hydraulic system is designed so that it holds the convertible roof in its current position when you let go of the convertible roof button (self-locking system). The emergency operation screw on the hydraulic pump must be loosened to override this self-locking system. This connects the hydraulic circuits and by-passes the self-locking system.

Procedure

The emergency operation screw can be accessed by removing the cover in the luggage compartment. Observe the direction of rotation on the pump housing before loosening the screw by approx. half a turn.

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Manually unlocking the convertible roof at the roof cross member

s498_325

Cover cap Socket for emergency

operation handle

The electrical unlocking system for the convertible roof is also not available if there is a fault. Therefore the locking hooks need to be moved manually to the “unlocked” or “locked” position.

Procedure

In the vehicle interior, use a suitable screwdriver to remove the rectangular cover from the locking mechanism trim near the front bracing hoop. Behind the cover, you will see the socket for the emergency operation handle. The emergency operation handle is stored behind the trim on the left of the luggage compartment. Fit the emergency operation handle into the guide pins in the socket and lock it by tightening the screw that is built into the handle.

Turn the handle clockwise to release the convertible roof locking hooks from the cross member.  If you turn it anti-clockwise, the locking hooks will lock the convertible roof to the roof cross member as long as the front bracing hoop has docked with the roof cross member correctly.

Manually stowing the convertible roof in the open position

If possible, a second person should help close or open the convertible roof to prevent the convertible roof and the convertible roof mechanism becoming jammed. Once the convertible roof has reached its end position, the emergency operation screw on the hydraulic pump must be returned to its original position so that the two hydraulic circuit halves are separated again. This removes the pressure equilibrium between the two halves of the hydraulic circuit. The self-locking system for the convertible roof is engaged and prevents the roof moving.

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Occupant Protection

s498_326

 

Assembly frame

Deployed  detent rail

Roll-over protection system

Overview and design

Together with the A-pillars and the roof cross member, the roll-over protection system has the task of creating a survival space for the vehicle occupants if the vehicle rolls over. It is built into the rear bulkhead as a module behind each rear seat. The main components of the roll-over protection module are spring-loaded, sturdy detent rails and an assembly frame with rail guides and a lock with trigger mechanism.

Covers on the trim panel behind the head restraints conceal the roll-over protection system from above.

How it works

The roll-over protection system is triggered together with the corresponding airbags by the airbag control unit when a defined accident situation is detected.  The roll-over protection system is deployed:

• in severe front, side and rear collisions  (high-speed crashes)

• when the vehicle rolls over 

The roll-over protection system is triggered by the electronic ignition of a pyrotechnic charge that releases the mechanical lock on the detent rail.

The detent rails are extended within milliseconds by the spring tension and form a safe roll-over protection system together with the A-pillars.  The covers in the rear bulkhead trim are pushed out and up by the detent rails.

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s498_031

Driver and

front passenger airbag

Head-thorax

airbags

Knee airbag

(only driver)

s498_038

Side impact protection cross member

Airbags

The Golf Cabriolet 2012 features the latest in occupant protection. The driver and front passenger airbags come from the Golf A6. The head-thorax airbags are located in the backrests of the driver and front passenger seats under the front of the seat cover. In a collision, they inflate between the occupant and penetrating vehicle structure.  They have been improved in terms of their location under the backrest cover.  A knee airbag comes as standard for the driver.

Side impact protection

The doors feature side impact protection as standard. The diagonal arrangement of the side impact protection members increases the area protected.  This means that, in a side collision, the side impact protection system is hit even at different crash heights. It absorbs the energy of the impact and transfers it to the side of the body.

41

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Engines

s498_045

180

160

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100

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60

40

20

40

30

20

10

0

1000 3000 5000 7000

[rpm]

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60

200

70

80

90

s498_040

[kW]

[Nm]

1.2 l 77 kW TSI engine with turbocharger

This engine is available in a standard and in a BlueMotion Technology version. The BlueMotion Technology version is equipped with a start/stop system and uses energy recovery.

Technical features

• Homogenous mode (Lambda 1)

• Switchable coolant pump

• A separated, service-friendly lightweight timing case with covers made of plastic and magnesium

• Turbocharger module with electrically operated waste gate flap control

• Crankcase breather and ventilation system with oil separation facility integrated in cylinder block and cylinder head

•Ignition transformer

Technical data

Engine code CBZB

Type 4-cylinder inline engine

Displacement 1,197 cm

Bore 71 mm

Stroke 75.6 mm

Valves per cylinder 2

Compression ratio 10 : 1

Max. output 77kW at 5,000rpm

Max. torque 175 Nm at 1,550 to 

Engine management Simos 10

Fuel Super unleaded RON 95

Exhaust gas aftertreatment Three-way catalytic conver-

Exhaust emissions standard EU5

3

4,100 rpm

You will find further information in  self-study programme no. 443  “The 1.2 l 77kW TSI Engine with Turbocharger”.

 Torque and output diagram

ter with one upstream broadband Lambda probe and one downstream steptype Lambda probe

42

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1.4 l 90 kW TSI engine with turbocharger

s498_041

200

175

150

125

100

75

50

25

0

40

30

20

10

0

1000 3000 5000 7000

[rpm]

50

60

225

70

80

90

s498_047

[kW]

[Nm]

This engine has already been used in other vehicles and has now been transferred to the Golf Cabriolet.

Technical features

• Homogenous mode (Lambda 1)

• Stratified high-pressure start

• Turbocharger with waste gate

• Intake manifold with charge air cooler with coolant flow

• Regulated duo-centric oil pump

• Demand-based fuel system

• High-pressure fuel pump with integrated pressure limiting valve

Technical data

Engine code CAXA

Type 4-cylinder inline engine

Displacement 1,390 cm

Bore 76.5 mm

Stroke 75.6 mm

Valves per cylinder 4

Compression ratio 10 : 1

Max. output 90kW at 5,000rpm

Max. torque 200 Nm at 1,500 to 

Engine management Bosch Motronic MED

Fuel Super unleaded RON 95

Exhaust gas aftertreatment Three-way catalytic conver-

Exhaust emissions standard EU5

4,000 rpm

17.5.5

ter with one upstream broadband Lambda probe and one downstream steptype Lambda probe

3

You will find further information in  self-study programme no. 405  “1.4l 90kW TSI Engine with Turbocharger”.

 Torque and output diagram

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Engines

s498_049

240

220

200

180

160

140

120

100

80

60

50

40

30

20

1000 3000 5000 7000

[rpm]

70

80

260

90

100

120

s498_053

[kW]

[Nm]

1.4 l 118 kW TSI engine with dual-charging

This engine has been adopted from the Golf without modifications.

Technical features

• Homogenous mode (Lambda 1)

• Stratified high-pressure start

• Turbocharger with waste gate

• Clutch-operated mechanical supercharger

• Air/charge air cooling

• Dual circuit cooling system

• Regulated duo-centric oil pump

• Demand-based fuel system

• High-pressure fuel pump with integrated pressure limiting valve

Technical data

Engine code CAVD

Type 4-cylinder inline engine

Displacement 1,390 cm

Bore 76.5 mm

Stroke 75.6 mm

Valves per cylinder 4

Compression ratio 10 : 1

Max. output 118 kW at 5,800 rpm

Max. torque 240 Nm at 1,500 to 

Engine management Bosch Motronic MED

Fuel Super unleaded RON 95

Exhaust gas aftertreatment Three-way catalytic conver-

Exhaust emissions standard EU5

4,500 rpm

17.5.5

ter with one upstream broadband Lambda probe and one downstream steptype Lambda probe

 Torque and output diagram

3

You will find further information in  self-study programme no. 359  “1.4l TSI Engine with Dual-charging”.

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2.0 l 155 kW TSI engine with turbocharger

s498_051

300

280

260

240

220

200

180

160

140

80

60

40

20

0

1000 3000 5000 7000

[rpm]

100

120

320

140

160

180

s498_044

[kW]

[Nm]

This engine has already been used in the Golf GTI and the Passat 2011 and corresponds to a great extent with the 2.0l 147kW TSI engine. This engine comes exclusively with the dual clutch gearbox.

Technical features

• The turbocharger pressure actuator cannot be exchanged.

• Volumetric flow-controlled external gear oil pump

• Two balancer shafts

• High-performance charge air cooler

Technical data

Engine code CCZB

Type 4-cylinder inline engine

Displacement 1,984 cm

Bore 82.5 mm

Stroke 92.8 mm

Valves per cylinder 4

Compression ratio 9.6 : 1

Max. output 155 kW at 5,300 to 

Max. torque 280 Nm at 1,700 to 

Engine management Bosch Motronic MED 17.5

Fuel Super unleaded RON 95

Exhaust gas aftertreatment Broadband Lambda probe

Exhaust emissions standard EU5

6,200 rpm

5,200 rpm

upstream of close-coupled starter catalytic converter, step-type Lambda probe downstream of catalytic converter

3

 Torque and output diagram

You will find further information in  self-study programme no. 401  “1.8l TFSI 16v 118kW engine”.

45

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Engines

s498_339

240

220

200

180

160

140

120

100

40

30

20

10

1000 3000 5000

[rpm]

50

60

260

70

80

90

s498_046

[kW]

[Nm]

1.6 l 77 kW TDI CR engine

The further developed 1.6l TDI CR engine, which has already featured in the Passat 2011, is now available for the Golf Cabriolet 2012.

Technical features

• Common rail injection system with piezo injectors

• Exhaust gas recirculation module with exhaust gas recirculation valve and cooler for exhaust gas recirculation.

• Plastic intake manifold without swirl flap adjustment

• Camshaft spur gear drive without backlash compensation

•High-pressure pump with gear-type fuel system pressurisation pump

• Electrical fuel system pressurisation pump in fuel tank

Technical data

Engine code CAYC

Type 4-cylinder inline engine

Displacement 1,598 cm

Bore 79.5 mm

Stroke 80.5 mm

Valves per cylinder 4

Compression ratio 16.5:1

Max. output 77 kW at 4,400 rpm

Max. torque 250 Nm at 1,500 to 

Engine management Simos PCR2.1

Fuel Diesel according to 

Exhaust gas aftertreatment Exhaust gas recirculation, 

Exhaust emissions standard EU5

3

2,500 rpm

You will find information on the design and function of the 1.6l TDI CR engine in self-study programme no. 442  “The 1.6ltr. 77kW TDI Engine with Common Rail Injection System”.

 Torque and output diagram

DIN EN 590

oxidation catalytic converter and diesel particulate filter

46

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2.0 l 103 kW TDI CR engine

s498_207

300

280

260

240

220

200

180

160

50

40

30

20

1000 3000 5000

[rpm]

60

70

320

80

90

100

s498_348

[kW]

[Nm]

The second generation 2.0l TDI CR engine has already been used in the Passat and Sharan. Both diesel engines for the Golf Cabrio are available in standard or BlueMotion Technology versions.

Technical features

• Common rail injection system with solenoid valvecontrolled injectors

• Exhaust gas recirculation module with exhaust gas recirculation valve and cooler for exhaust gas recirculation.

• Intake manifold without swirl flap adjustment

• Electrical fuel system pressurisation pump in fuel tank

• Electrical supplementary fuel pump in fuel supply line

Technical data

Engine code CFHC

Type 4-cylinder inline engine

Displacement 1,968 cm

Bore 81 mm

Stroke 95.5 mm

Valves per cylinder 4

Compression ratio 16.5:1

Max. output 103 kW at 4,200 rpm

Max. torque 320 Nm at 1,750 to 

Engine management Bosch EDC 17 (common rail

Fuel Diesel according to 

Exhaust gas aftertreatment Exhaust gas recirculation, 

Exhaust emissions standard EU5

2,500 rpm

injection system)

DIN EN 590

oxidation catalytic converter and diesel particulate filter

3

You will find further information on this engine in self-study programme no. 403 “The 2.0-ltr. TDI Engine with Common Rail Injection System” and in self-study programme no. 445 “The Sharan 2011”.

 Torque and output diagram

47

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.

Transmission

Engine and gearbox combinations

Petrol engines

6-speed  manual gearbox  0AJ 6F*

6-speed  manual gearbox  02S 6F*

6-speed  dual-clutch  gearbox  02E 6F*

7-speed  dual-clutch gearbox  0AM 7F*

* 5F = 5-speed front-wheel drive, 6F = 6-speed front-wheel drive, 7F = 7-speed front-wheel drive

1.2l 77kW  engine  CBZB

1.4l 90kW  TSI engine  CAXA

1.4l 118kW  TSI engine  CAVD

2.0l 155 kW  TSI engine  CCZB

48

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Diesel engines

1.6l 77kW  TDI engine  CAYC

5-speed  manual gearbox  0A4 5F*

6-speed  manual gearbox  02Q 6F*

6-speed  dual-clutch  gearbox  02E 6F*

2.0l-103kW  TDI engine  CFHC

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Transmission

Overview of manual gearboxes

The Golf Cabriolet 2012 uses the same gearboxes as the current Golf.

Gearbox type Technical features

6-speed  manual geabox  0AJ 6F*

5-speed  manual gearbox 

0A4 5F*

6-speed  manual gearbox  02S 6F*

6-speed  manual gearbox  02Q 6F*

* 5F = 5-speed front-wheel drive, 6F = 6-speed front-wheel drive, 7F = 7-speed front-wheel drive

• Developed from 0AG gearbox

• modified for 1.4 l 90 kW TSI engine, spacing between output shaft and differential enlarged, sheet metal mount replaced by cast mount for higher torques, ground toothing

• Final drive reinforced

• Without speedometer sender

•CO

• Torque capacity up to 200 Nm

• Developed from 02J

• Gearshift mechanism optimised

-optimised ratio

2

• Without speedometer sender

•CO

-optimised ratio

2

• Torque capacity up to 250 Nm

• Developed from 0A4

• Longer shafts with additional bearings, additional gear pair, new longer aluminium housing cover

• Without speedometer sender

•CO

• Torque capacity up to 250 Nm

• Developed from 02M gearbox

• Changes to selector shaft, selector forks with stops in housing,

• Without speedometer sender

•CO

-optimised ratio

2

modified bearings

-optimised ratio

2

• Torque capacity up to 350 Nm

Further  information

SSP 237 SSP 306

SSP 99

SSP 306

SSP 99  SSP 306

SSP 205  SSP 306

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Overview of dual-clutch gearboxes

The dual-clutch gearboxes allow split-second, smooth gear changes. The dual-clutch gearboxes consist of two independently working gear train halves. Each gear train half is connected to a clutch. During a gear change, one clutch is opened while, at the same time, the other clutch closes.

Gearbox type Technical features

6-speed  dual-clutch  gearbox  02E 6F*

• Hydraulic dual-clutch  (two multi-plate wet clutches)

• Greater efficiency

• Robust and sporty like a manual gearbox

• The user-friendliness of an automatic gearbox when changing gear

• Torque capacity up to 350 Nm

• Developed from 6-speed dual-clutch gearbox 02E

Further  information

SSP 308

SSP 390

• In contrast to 02E, works with a dry dual-clutch

• Separate oil circuits for gearbox and mechatronics

• In contrast to 02E, electrical oil pump for hydraulics is regulated on demand by the control unit

• Torque capacity up to 250 Nm

7-speed  dual-clutch  gearbox 

0AM 7F*

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Running Gear

Overview of running gear

The chassis of the Golf Cabriolet 2012 is based on the Golf 2009 chassis. The illustration shows you important standard and optional equipment for the new Golf Cabriolet 2012. Normal and sports chassis are available. DDC adaptive chassis control is available as an option.

• Tyre Mobility Set as standard 

• Four-link rear axle,  with bolted diagonal strut on subframe 

• Lightweight McPherson strut front axle  with bolted diagonal strut on subframe 

• ESP generation MK60-EC system from Continental Teves with integrated sensor cluster  and Hill Hold 

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s498_061

• Safety steering column  (sheet metal version)

• DCC adaptive chassis control,  optional

• Electromechanical power steering  with double pinion, 3rd generation,  with integrated steering angle sensor 

• Floor-hinged accelerator pedal, crash-optimised

You will find information on the DCC adaptive chassis control in self-study programme 423  “The Golf 2009”.  You will find further information on the DCC adaptive chassis control in self-study programme 406 “DCC Adaptive Chassis Control”.

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Heating and Air Conditioning

s498_072

s498_073

s498_075

s498_077

s498_079

Air conditioning

Three climate control systems are available for the Golf Cabriolet: a heating system, an air-conditioning system and the two-zone Climatronic system. The “ThermoTop V” and “ThermoTop Vlies” auxiliary heaters can be used depending on whether a diesel or petrol engine is fitted. The following table provides an overview and references to detailed descriptions.

Technical features SSP no.:

Heating and ventilation system

Air-conditioning system

2-zone Climatronic

ThermoTop V auxiliary heater

• Mechanical rotary switch for temperature and air distribution

• Adjustment of temperature and air flaps via flexible shafts

• One climate zone

• Electronic rotary switch for temperature and air distribution

• AC button for switching on and off

• Electrical adjustment of temperature and air flaps via control motors 

• Driver and front passenger each have own climate zone

• Control range of 18 °C-26 °C with temperature preselection

• Dual operation of zones (DUAL button)

• For vehicles with petrol engine

• With Venturi burner

SSP 471

SSP 493

SSP 445

54

ThermoTop Vlies auxiliary heater

• For vehicles with diesel engine

• With fleece burner

SSP 493

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Electrical System

s498_087

Dipped beam and main beam

(Xenon D1S, 35 W)

Daytime running and side lights

(15 LEDs,·30 W in total)

Turn signal

(24 W)

s498_089

Turn signal

(21 W)

Reversing light

(16 W)

Rear fog light

(3xLED; 3 W in total)

LED tail

and brake light

Reflector

(in lens)

Vehicle lighting

Xenon headlights with LED daytime running lights

In this headlight module, the dipped beam and main beam headlights are integrated into the Xenon module (D1S, 35 W).  Furthermore the headlights have LED daytime running and side lights.

Fifteen individual LEDs are arranged around the Xenon module. This reduces the power consumption for the daytime running lights to approximately  30 Watts. In comparison, keeping the dipped beam headlights switched on constantly as daytime running lights requires around 140 to 180 Watts.

A conventional turn signal completes the headlight module.

LED tail light cluster

The rear lights on the Golf Cabriolet 2012 are in two

parts. They are removed and installed in the same way as the Golf 2009 rear lights.

Observe the instructions in the workshop manuals when working on the front and rear lights.

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.

Electrical System

CX1

J367

J503

J604

J738

R

R78

R215

J255/J301

J256

J345

J386

J387

J519

J527

G397

J400

G273/G384

H12

J388

J389

J453

J285

T16

J533

E313

J104

J217

J234

J250

J500

J623

J745

J791

G85

J667

J668

s498_080

J772

J844

Vehicle electrical system

The following diagram shows how the control units in the Golf Cabriolet 2012 are networked.  It uses the network of a fully equipped vehicle with all options as an example.

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Key

CX1 Alternator 

E313 Selector lever 

G85 Steering angle sender 

G273 Interior monitoring sensor 

G384 Vehicle inclination sender 

G397 Rain and light sensor 

H12 Alarm horn 

J104 ABS control unit 

J217 Automatic gearbox control unit 

J234 Airbag control unit 

J250 Electronically controlled damping control unit

J503 Control unit with display for radio and navigation

J519 Onboard supply control unit 

J527 Steering column electronics control unit 

J533 Data bus diagnostic interface 

J604 Auxiliary air heater control unit 

J623 Engine control unit 

J667 Output module for left headlight 

J668 Output module for right headlight 

J738 Telephone controls control unit 

J745 Control unit for cornering light and 

headlight range control

J772 Reversing camera system control unit 

J255 Climatronic control unit 

J256 Convertible roof actuation control unit 

J285 Control unit in dash panel insert

J301 Air conditioning system control unit

J345 Trailer detector control unit 

J367 Battery monitor control unit

J386 Driver door control unit 

J387 Front passenger door control unit 

J388 Rear left door control unit 

J389 Rear right door control unit 

J400 Wiper motor control unit 

J453 Multifunction steering wheel control unit 

J500 Power steering control unit 

J791 Park assist steering control unit 

J844 Main beam assist control unit 

RRadio 

R78 TV tuner 

R215 Interface for external multimedia unit 

T16 16-pin connector 

Powertrain CAN data bus

Convenience CAN data bus

Infotainment CAN data bus

LIN data bus

CAN data bus line

LIN data bus line

K-wire

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Convenience Electronics

Camera in mirror

base

s498_094



Main beam assist control unit J844 in interior mirror housing

G44

G45

G46

G47

G213

E1

J104

J844

J519

E650

K1

Y25

J533

J285

s498_092

Main beam assist (MBA)

Main beam assist enables the main beam to be switched on and off automatically depending on the traffic situation.

Design

The “eye” of the system is a black and white camera that is integrated into the mirror base. The control unit electronics of the main beam assist control unit are located in the interior mirror housing. The control unit is connected to the data bus diagnostic interface via the powertrain CAN data bus.

Networking

Key

E1 Light switch

E650 Button for main beams

G44 Rear right speed sensor

G45 Front right speed sensor

G46 Rear left speed sensor

G47 Front left speed sensor

G213 Rain sensor

J104 ABS control unit

J285 Control unit in dash panel insert

J519 Onboard supply control unit

J533 Data bus diagnostic interface

J844 Main beam assist control unit

K1 Main beam warning lamp

Y25 Segment display in dash panel insert

Sensor/input

Actuator/output

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s498_093

Maximum 1,000 m

15 °

Scanning area

How it works

The main beam assist control unit (J844) detects light signals within a visible range up to 1,000 m in front of the vehicle and at an aperture angle of 30 ° in the direction of travel. It forwards the signals to the data bus diagnostic interface. The data bus diagnostic interface then sends a main beam light recommendation to the onboard supply control unit (J519), which switches the main beam after checking the speed.

The main beam assist system reacts:

• to a vehicle approx. 400 m in front with activated exterior lighting

• to an oncoming vehicle with activated exterior lighting up to approx. 1,000 m away

• to illuminated street lighting (built-up areas)

•to ambient light

When the main beam assist is activated, the main beam lights are switched on if the following conditions are met:

• Rotary light switch in AUTO position

• Ambient light < 0.5 lx  (main beam then remains on up to 1 lx)

• Vehicle speed > 60 km/h

• No vehicles/sources of light within scanning range of camera

If one of the conditions is not met, the main beam lights are automatically switched off.

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Radio, Navigation and Telephone

s498_101

s498_103

s498_105

s498_107

s498_109

Radios and radio/navigation systems

Three radios are available for the Golf Cabriolet: RCD 210, 310 and 510. The RNS 315 and RNS 510 radio/ navigation systems are also available. The following table provides an overview of new technical features as well as references to detailed descriptions.

Radio Technical features (new) SSP no.:

RCD 210

RCD 310

RCD 510

• Display: white negative

• New languages

•OPS (BAP)

• Bluetooth audio control

• New languages

•OPS (BAP)

SSP 493

60

Radio/navigation system

RNS 315

RNS 510

SSP 493

•ECO route

• Versions with Bluetooth (UMPP)

• New languages

•OPS (BAP)

SSP 493

•ECO route

• Distance to destination (stop-overs)

• Personal destinations (personal POI)

• New languages

•OPS (BAP)

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Aerial systems

s498_352

Left

Aerial filter

C

A

B

D

I

Right

BIACD

I

H

The aerials for GPS/GSM are fastened to a holder that is glued to the windscreen.  The aerials for AM/FM1/FM2/DAB are integrated into the windscreen as a structure. Except for the telephone aerial, all aerials are supplied with voltage from the connected devices. All aerials are self-diagnosis capable.  The aerial connectors are colour and mechanically coded.

Key

FM1/AM

FM2

FM2/DAB

GPS or FM2 and FM2/TV (Japan only)

GSM/UMTS

Auxiliary heater

AM/FM or AM/FM/TV (Japan only)

If a DAB radio or radio/navigation system is not installed, an impedance transformer for FM2 with connection “I” is installed on the left.

The connector coded “H” is used for the installation of AM/FM or AM/FM/TV for Japan.

The aerial filter is only installed if an auxiliary heater and GPS are equipped.

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Radio, Navigation and Telephone

s498_138

s498_136

s498_134

s498_132

Mobile phone preparations (UMPP)

Four mobile telephone preparations are available for the Golf Cabriolet: 9ZB, 9ZA, 9ZU and 9ZI. The following table provides an overview and references to detailed descriptions.

Mobile phone preparations (UMPP) Internal functions (expandable) SSP no.:

9ZB

• Hands-Free Profile (HFP 1.5)

9ZA

9ZU

• BT audio streaming (A2DP 1.2) and control

• Hands-Free Profile (HFP 1.5)

• BT audio streaming (A2DP 1.2) and control (AVRCP)

• Voice control (G2P/TTS)

•Read out SMS

• Hands-Free Profile (HFP 1.5)

• BT audio streaming (A2DP 1.2) and control (AVRCP)

• Voice control (G2P/TTS)

• Sim Access Profile (SAP 1.0)

• Read, write and read out SMS

(This UMPP cannot be combined with the RCD 210.)

SSP 493

62

9ZI

SSP 493

• Hands-Free Profile (HFP 1.5)

• BT audio streaming (A2DP 1.2) and control

• The function of the 3-button module is displayed on the RNS 315

(This UMPP is an internal component of the RNS 315 and needs to be enabled by ordering the corresponding PR number [19].)

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498

000.2812.55.20 Technical status 06/2011

Volkswagen AG After Sales Qualifizierung Service Training VSQ-1 Brieffach 1995 D-38436 Wolfsburg

❀ This paper was manufactured using pulp bleached without the use of chlorine..

Volkswagen Golf Cabriolet (2012) Self Study Program

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

The Golf Cabriolet 2012

Technical data

Body

Body structure

Interior

Electrohydraulic Convertible Roof

Overview of convertible roof design

Convertible roof cover

Convertible roof mechanics

Electrohydraulic system

Convertible roof operation

Occupant Protection

Roll-over protection system

airbags

Side impact protection

Engines

1.2 l 77 kW TSI engine with turbocharger

1.4 l 90 kW TSI engine with turbocharger

1.4 l 118 kW TSI engine with dual-charging

2.0 l 155 kW TSI engine with turbocharger

1.6 l 77 kW TDI CR engine

2.0 l 103 kW TDI CR engine

Transmission

Engine and gearbox combinations

Overview of manual gearboxes

Overview of dual-clutch gearboxes

Running Gear

Overview of running gear

Heating and Air Conditioning

Air conditioning

Electrical System

Vehicle lighting

Vehicle electrical system

Convenience Electronics

Main beam assist (MBA)

Radio, Navigation and Telephone

Radios and radio/navigation systems

Aerial systems

Mobile phone preparations (UMPP)