Volkswagen Golf Plus 2005 User Manual

Service Training

Self-study programme 338

The Golf Plus 2005

The Golf Plus is based on the Golf's successful history
as the benchmark in the compact class, is positioned
in the new segment of high-roof passenger cars and
can therefore safely claim leadership in the Golf
segment.

It is intended to continue to the "superior dynamics"
positioning introduced by the Golf in 2004, extending
this with characteristics such as spatial comfort,
variability and functionality.

This self-study programme provides an overview of the structure of the Golf Plus.
It informs you of the special body features, which engines and gearboxes are installed,
which front and rear axles carry the Golf, how the electronics are structured and what changes have taken place in
the convenience system.

NEW Attention

The self-study programme portrays the design and
function of new developments!
The contents will not be updated.

For current testing, adjustment and repair instruc­tions, please refer to the customer service literature
intended for this purpose.

S338_105

Note

2

At a glance

In brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Engine-gearbox combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Convenience electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Radio and navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Heater and air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3

In brief

The Golf Plus 2005

In addition to the technology familiar from the Golf,
the Golf Plus is equipped with a few further special
features.
This includes its higher body, its rear lights in LED
technology and also its split rear seat bench, which
can be separately adjusted and
moved.

● Sensor for rain and light detection

● Extensive storage compartment concept

● 2C-Climatronic

(2-zone climate control)

● Modified bonnet

Front area optimised to protect pedestrians

● Headlights in

bi-xenon technology with
cornering light function

● New headlights with three round elements

4

● Rear Seat Entertainment system

● 230V socket

● Body 95mm higher

● Rear lights

in LED technology

● Variable

load floor concept

● Split rear seat bench,

● Seating level 80mm higher

S338_001

can be separately moved and adjusted

5

In brief

Technical data

Exterior dimensions and weights

877mm 2578mm 751mm

S338_052

4206mm

1541mm

1759mm

Exterior dimensions

Length 4206 mm
Width 1759mm
Height 1580mm
Wheelbase 2578mm
Front track 1541mm

Rear track 1529mm

1580mm

S338_051

1529mm

S338_053

Weights

Permissible gross vehicle
weight

Unladen weight without
driver

Roof load 75kg
Trailed load (braked) 1200kg at 8% incline

Fuel tank capacity 55l
Drag coefficient 0.32

1900kg

1293kg

6

Interior dimensions

842mm

750 mm

1007mm

375mm

1019mm

343mm

2076mm

585mm

976mm

70mm

375mm

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Interior dimensions and volumes

Total interior length 1740mm

Luggage compartment
volume

Luggage compartment
volume with rear seat back­rest folded down

* - Without variable load floor
** - With variable load floor

425 - 505l *
402 - 443l **

1450l *
1350l **

624mm

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1008mm

S338_056

Interior dimensions, front

Headroom 1007mm
Elbow width 1468mm

Interior dimensions, rear

Headroom 976mm
Elbow width 1452mm

7

Body

The body structure

Its concept has been integrated from the tried-and-tested Golf 2004 and adapted to the requirements of the
Golf Plus.

By consistently employing high- and ultra-high-strength panels, its strength has again been
optimised without significantly increasing its weight.

Special characteristics

● The A-pillar has been modified to integrate

the quarter light.

● The roof bow has been omitted thanks to the

design of the side areas.

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8

Steel grades in the Golf Plus

Steels are classified according to their tensile strength. The higher the steel grade, the higher the tensile strength,
which is measured in Megapascals. The higher material properties are achieved by alloying and hardening the
steel in different ways. The Golf Plus body is essentially comprised of five different steel grades.

S338_096
Normal plate grade up to 180 MPa
High-strength plate grade 220 - 240 MPa
Higher-strength plate grade 280 -300 MPa
Ultra-high-strength plate grade 320 -420 MPa
Ultra-high-strength, treated plate grade over 900 MPa

1 MPa = 1 Newton/mm
The specified values refer to the yield strength.

2

S338_119

Even this limited selection of body-in­white parts shows the considerable
percentage of higher-strength panels
in the Golf Plus.

9

Body

The storage compartments

Besides a multitude of storage compartments familiar from the Golf 2004, the Golf Plus additionally offers storage
compartments in the centre console and drawers beneath the front seats.

In vehicles fitted with the Rear Seat Entertainment system, the DVD player is located in the storage compartment
between the front seats beneath the armrest.

10

S338_057

The roof console

The Golf Plus is optionally available with a large roof console.
Three unfolding storage compartments are located in the front area. The rear area houses the fold-down monitor in
vehicles fitted with the Rear Seat Entertainment system.

Glazing

S338_027

The quarter light is bonded-in.

S338_071

11

Body

The load floor

The Golf Plus has a variable load floor.
This means:

● The load floor is height-adjustable.

● The load floor can be removed.

● The length of the load floor adapts to the

longitudinally-adjustable rear seat bench.

12

Longitudinal adjustment

This is carried out by means of movable covers, which
are locked along with the rear seats. When the rear
seats are moved, the covers therefore move back and
forth together with the seats. The covers slide beneath
the load floor in this case.

S338_058

Sliding covers

Height adjustment

The load floor can be inserted at two heights.

Top insertion option Bottom insertion option

S338_106

Transverse rail

S338_029

Removing the load floor

In addition to the load floor, the transverse rail can
also be removed. This results in maximum luggage
compartment volume.

S338_122

13

Body

The seats

The front seats

The seat frames have been integrated from the Golf 2004.
The higher fastening bracket results in a seating position which is higher than that in the Golf 2004.
A front passenger seat with the through-loading option familiar from the Golf 2004 is also available as an
optional extra.

14

S338_135

Fastening bracket

The rear side of the seat backrests are fitted with
folding tables for the rear passengers.

S338_072

The rear seat bench

This is split into two. Both sections can be individually moved 160mm in the longitudinal direction.
By pulling on the release straps, the inclination of these can be adjusted, the sections can be completely folded.

S338_074

S338_073

As an additional storage option, a multi-function box
can be secured to the folding centre armrest.

15

Body

Pedestrian protection

The bumper

To reduce the risk of injury to pedestrians, the bumper cross-member is
covered with a foam part.
The pedestrian protection cross-member is located beneath the bumper
cross-member.
This reduces the risk of injury to pedestrians' legs.

Bumper cross-member

Foam

Pedestrian protection
cross-member

The bonnet hinge

To ensure that the bonnet also yields in the hinge area
in the event of an impact involving a pedestrian,
the hinges have also been provided with nominal
bending points.

Nominal bending points

S338_108

16

S338_118

The bonnet support

The windscreen wiper shafts

This area has also been optimised for pedestrian
protection by using a bonnet support instead of a gas
pressure spring.

In contrast to a gas pressure spring, the bonnet
support is able to bend in the event of an impact.

S338_117

The wiper shafts have also been revised to enhance pedestrian protection.
In the event of an impact, the shafts slide into the mounting bracket and thereby reduce the risk of injury
to the pedestrian.

Operating position

Wiper shaft

Mounting bracket

S338_097

Situation following impact

Wiper shaft slides into
the mounting bracket

S338_098

17

Occupant protection

The airbags

The airbag system familiar from the Golf 2004 is also
fitted in the Golf Plus:

● Driver and front passenger airbag

● Side airbag in the front seats

● Head airbag for the front and rear

passengers

● 3-point seat belts on all seats

● Seat belt pretensioner, belt tension limiter and seat

occupied sensor for the front passengers.

● Active headrests on the front seats

● Seat belt prompt for the driver and front passenger

● Optional rear side airbag in the wheel housing trim

in combination with rear seat belt pretensioner

18

The following crash sensors, which are already
familiar from the Golf, are installed:

● Pressure sensors in the front doors

● Acceleration sensors in the area of the rear

wheel housing

S338_067

19

Engines

Engine-gearbox combinations

Gearbox

Engine

1.4l 55 kW
SRE engine

1.4l 66 kW
FSI engine *

1.6l 75 kW
engine *

1.6l 85 kW
FSI engine

2.0l 110 kW
FSI engine *

0AF: 5-speed

manual

gearbox

0AG: 6-speed

manual

gearbox

0A4: 5-speed

manual

gearbox

20

1.9l 66 kW
TDI engine *

1.9l 77 kW
TDI engine

2.0l 103 kW
TDI engine

The engines and gearboxes marked with a * will be launched at a later point in time.

02S: 6-speed

manual

gearbox

02Q: 6-speed

manual

gearbox

09G: 6-speed

automatic

gearbox

DSG 02E: 6-speed

Direct-

Shift Gearbox*

21

Engines

The 1.4l 55 kW engine

The 1.4l 55 kW engine is the entry-level engine for the
Golf Plus. This has been taken over from the Golf
2004 and adapted to the package conditions in the
Golf Plus.

Special characteristics

● Return-free fuel system

● Crankshaft sealing flange with magnetised sender

wheel for engine speed

● Accelerator pedal module with contact-free

accelerator pedal position sender

● Clutch module with contact-free clutch position

sender

● Throttle valve control unit with contact-free throttle

valve position angle senders

● Primary catalytic converter with ceramic substrate

and reduced precious metal charge

● Main catalytic converter with reduced precious

metal charge

S338_014

Technical data

Engine code BCA
Design type 4-cylinder in-line engine
Displacement [cm³] 1390
Bore [mm] 76.5
Stroke [mm] 75.6
Valves per cylinder 4
Compression ratio 10.5:1
Max. output 55kW at 5000 rpm
Max. torque 126 Nm at 3800 rpm
Engine management

system
Fuel Super unleaded RON 95

Exhaust gas aftertreatment Primary catalytic converter, main

Exhaust emission standard EU4

Bosch Motronic ME 7.5.10

Normal unleaded RON 91
(with slightly reduced output)

catalytic converter, lambda control

Torque and output graph

180

160

140

120

100

80

Torque [Nm]

60

40

20

2000 4000 6000

Engine speed [rpm]

90

80

70

60

50

40

30

20

10

S338_015

Output [kW]

22

The 1.6l 85 kW FSI engine

This engine originates from the Golf 2004.
It differs from this only due to its switch to lambda 1
operation and super unleaded RON 95.

Special characteristics

Stratified charge and homogeneous lean operation
have been omitted due to the switch to lambda 1
(homogeneous operation). This leads to the
occurrence of less nitrogen oxide, and the omission of
complex trapping and regeneration of this.

S338_016

This leads to the following changes:

- The exhaust gas temperature sender has been
omitted,

- instead of the NO

storage reduction catalytic

x

converter, a
three-way catalytic converter has been installed,
and

- instead of the NO

sender, a transient

x

lambda probe has been installed.

Technical dat a

Engine code BLF
Design type 4-cylinder in-line engine
Displacement [cm³] 1598
Bore [mm] 76.5
Stroke [mm] 86.9
Valves per cylinder 4
Compression ratio 12:1
Max. output 85kW at 6000 rpm
Max. torque 155 Nm at 4000 rpm
Engine management

system
Fuel Super unleaded with RON 95

Bosch Motronic MED 9.5.10

(super plus RON 98 leads to an
increase in torque in the medium
engine speed range)

The switch from super plus RON 98 to super unleaded
RON 95 is achieved via ignition angle adjustment.
Operation with RON 91 is not permitted,
as ignition is retarded to the control limits in this case.

Torque and output graph

Torque [Nm]

180

160

140

120

100

80

60

40

20

90

80

70

60

50

40

30

20

10

Output [kW]

Exhaust gas aftertreatment Primary catalytic converter,

main catalytic converter, lambda
control

Exhaust emission standard EU4

2000 4000 6000

Engine speed [rpm]

Information on the fuel system can be found in self­study programme No. 334
"The FSI engine fuel system".

S338_017

23

Engines

The 1.9l 77 kW TDI engine

This engine originates from the Golf 2004.

Special characteristics

● Switchable exhaust gas recirculation cooler,

● Crankshaft sealing flange with integrated

engine speed sender wheel,

● Accelerator pedal module with contact-free

accelerator pedal position senders,

● Contact-free clutch pedal switch.

S338_018

Technical data

Engine code BKC
Design type 4-cylinder in-line engine

3

Displacement [cm
Bore [mm] 79.5
Stroke [mm] 95.5
Valves per cylinder 2
Compression ratio 19:1

Max. output 77kW at 4000 rpm
Max. torque 250 Nm at 1900 rpm
Engine management

system

Fuel Diesel, at least 51 CN
Exhaust gas

aftertreatment

Exhaust emission standard EU4

]1896

Bosch EDC 16 with
unit injector system

Exhaust gas recirculation and
oxidising catalytic converter

Torque and output graph

400

320

240

Torque [Nm]

160

80

1000 2000 3000 4000

Engine speed [rpm]

100

80

60

Output [kW]

40

20

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24

The 2.0l 103 kW TDI engine

This engine is identical to the 2.0l 103 kW TDI engine
fitted in the Golf 2004.

Special characteristics

● 4-valve technology,

● Two camshafts, driven by toothed

belts,

● New unit injectors which have been

adapted to the 4-valve technology,

● Switchable exhaust gas recirculation cooler,

● Crankshaft sealing flange with integrated

engine speed sender wheel,

● Accelerator pedal module with contact-free accele-

rator pedal position senders,

● Contact-free clutch pedal switch.

S338_019

Technical data

Engine code BKD
Design type 4-cylinder in-line engine

3

Displacement [cm
Bore [mm] 81
Stroke [mm] 95.5
Valves per cylinder 4
Compression ratio 18:1
Max. output 103kW at 4000 rpm
Max. torque 320 Nm at 1750 rpm

Engine management
system

Fuel Diesel, at least 51 CN
Exhaust gas

aftertreatment

Exhaust emission standard EU4

]1968

up to 2500 rpm
Bosch EDC 16 with

unit injector system

Exhaust gas recirculation and
oxidising catalytic converter

Torque and output graph

400

320

240

Torque [Nm]

160

80

0

1000 2000 3000 4000

Engine speed [rpm]

Further information on this engine
can be found in self-study programme No.
316 "The 2.0l TDI engine".

100

80

60

40

20

S338_021

Output [kW]

25

Power transmission

The 6-speed Direct-Shift Gearbox 02E

Following its successful, initial launch in the Golf and Touran, the Direct-Shift Gearbox is now also being fitted in
the Golf Plus.

The Direct-Shift Gearbox combines the advantages of
a manual gearbox:

- High efficiency
= low fuel comnsumption and

-Sportiness
= short shift times

with the advantages of an automatic gearbox:

-High comfort
= no manual clutch actuation or shifting

Thanks to its design, it meets both the requirements of
sporty drivers and also the comfort requirements of
drivers who prefer automatic gearboxes.

Special characteristics

- Six forward gears and one reverse gear,

- Standard and sports gearbox programmes,

- Tiptronic selector level and steering wheel switches,

-Mechatronics,

- Hill-holder function,

- Creep control,

- Pressure oil filter and oil cooler
mounted on the gearbox,

- Maximum torque 350 Nm.

The design and function of the selector lever and
ignition key removal lock correspond to those
in the Golf.

26

S338_049

Further information on the Direct-Shift Gearbox can be found in self-study programme No. 308

The 6-speed automatic gearbox 09G

The 6-speed automatic gearbox 09G is already very popular amongst customers in the Golf, Touran and New
Beetle. It sets new standards in terms of dynamics and economy in the segment of transversely mounted stepped
automatic gearboxes.

Special characteristics

- Low weight,

- High shifting comfort,

- Compact gearbox dimensions and

- High ratio between first and top gear.

The design and function of the selector lever and ignition key removal lock correspond to those
in the current models.

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Further information on these automatic gearboxes can be found in self-study programme No. 309

27

Running gear

Overview of the Golf Plus running gear

With the exception of minor modifications, this is identical to that of the Golf 2004. The springs, the shock
absorbers and the anti-roll bars have been adapted so that the Golf Plus also offers the ride comfort typical of a
Volkswagen and guarantees a high level of vehicle dynamics.

To offer a high level of ergonomic comfort, the accelerator pedal inclination angle has been changed from 65° to
57°, and the upper section of the steering column has been shortened.
The functions of the accelerator pedal and the steering column are identical to
those in the Golf 2004.

● Continental Teves ESP MK60

● Brake assist system

● Front axle suspension struts

with high transverse rigidity

28

● Electromechanical power steering

system

Further information on the running gear can be found in self-study programme No. 321
"The Golf 2004 running gear".

● Tyre pressure monitor (optional)

● Height and longitudinally-adjustable steering

column adapted to the seating position

● Vertical accelerator pedal with inclination angle

adapted to the seating position

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● Four-link rear suspension

29

Electrical system

Overview of networked electronic control units

When fitted with maximum equipment, the following
electronic control module configuration can be found
in the Golf Plus.

As in the Golf 2004, the diagnostic interface for data
bus J553 acts as the interface between the different
data buses. It also ensures that data exchange
between data buses with different speeds
is carried out in an optimal manner.

In addition to the conventional comfort, powertrain
and infotainment CAN bus systems, internal
communication between the vehicle module or sub­system components frequently takes place via
separate CAN links.
These bus links, which are dependent on the
different manufacturers, may differ from the above
mentioned links, which operate with high- and low­speed signal forms, not only in terms of their
transmission protocols, but also physically.
This different behaviour must be taken into
consideration in the case of direct measurements on
CAN systems and their electronic control units.

T16

b

J553

J503

R

J525

J364

R78

a

J220

J745

J345

J519J412

J255

J386

J387

J668

J334
J285

J608

J136

J388

J389

30

Legend

a
b

CAN powertrain data bus
CAN comfort data bus
CAN infotainment data bus
CAN sensor data bus
CAN instrument cluster data bus
CAN diagnostic data bus

J667

J743*

J234

E221

J446

J400

J217**

J587*

J584

G419

J104

J500

G85

D

J527

J604J521G397

Legend

D Ignition/starter switch
E221 Operating unit in steering wheel

(multi-function steering wheel)
G85 Steering angle sender
G273 Interior monitoring sensor
G384 Vehicle inclination sender
G397 Rain and light detector sensor
G419 ESP sensor unit
H8 Anti-theft alarm system horn
J104 Control unit for ABS with EDL
J136 Seat and steering column adjustment

control unit with memory
J217** Automic gearbox control unit
J220 Motronic control unit
J234 Airbag control unit
J255 Climatronic (and Climatic) control unit
J285 Control unit with display in dash panel insert
J334 Immobiliser control unit
J345 Trailer detector control unit
J364 Auxiliary heater 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
J393 Convenience system central control unit
J400 Wiper motor control unit
J412 Mobile telephone operating electronics control unit
J446 Parking aid control unit
J500 Power steering control unit
J503 Control unit with display for

radio and navigation
J519 Onboard supply control unit
J521 Front passenger seat adjustment with memory

control unit
J525 Digital sound package control unit
J527 Steering column electronics control unit
J533 Data bus diagnostic interface
J584 Front passenger side wiper motor control unit
J587* Selector lever sensor control unit
J604 Auxiliary air heater control unit
J608 Special vehicle control unit
J667 Power output module for left headlight
J668 Power output module for right headlight
J743* Mechatronics for Direct-Shift Gearbox
J745 Cornering light and headlight range control unit
R Radio
R78 TV tuner
T16 Diagnostic connection

J393

CAN cornering light data bus
LIN data bus
CAN data bus line
LIN data bus line
K line

* With Direct-Shift Gearbox only
** With automatic gearbox only

G384H8G273

S338_075

31

Electrical system

The electrical system in the Golf Plus essentially corresponds to that fitted in the Golf 2004.
Changes particularly refer to the exterior lights.

The exterior lights

Special characteristics

- Double round headlights with three round elements

- Split rear lights

The headlights

The double round headlights with dipped beam and
main beam reflector are fitted with H7 bulbs as
standard. The turn signals are equipped with a round
reflector.

The rear lights

In the Golf Plus, the rear lights are split into
two by the rear lid and are designed with multi­section round elements. The rear light elements in the
body are designed in LED technology and contain the
tail light, brake light and turn signal functions.
The rear light elements in the rear lid are fitted with
conventional bulbs and contain the rear fog light on
the left-hand side and the reversing light on the
right-hand side.
In pure tail light mode, the LED light elements are
actuated with just 10-15% of their maximum power
output in comparison with the brake light and turn
signal function.

Turn signal

Main beam

Tail light,

turn signal

brake light

Tail light,

S338_065

Dipped beam

Side light

S338_064

Left: rear fog light
Right: reversing light

32

If individual, defective light-emitting diodes have to be repaired, the entire LED assembly has to be
exchanged.

The inverter

As an optional extra, the Golf Plus can be equipped
with a 230V/50Hz socket for the European market or
a 115V/60Hz socket for North America. Depending on
the model, the European socket is designed without
an earthing contact.

The inverter has a continuous output of 150W.
For a short period of time of max. 2 minutes,
maximum power of 300W can be output.
In the inverter, the 12V DC low-voltage side and the
230V AC side are galvanically separated from each
other. The voltage of 230V is only available when the
engine is running in order to protect the battery.

S338_095

LED

European
socket

S338_062

When illuminated green, the two-colour LED indicates
normal operating mode on current consumption.
The LED's flashing red indicates overload.

The inverter and the socket are comprised to form an
assembly. This is located in the rear centre console
instead of the cup holder. If the socket or the inverter
is defective, the entire assembly is exchanged.

Further information can be found in self-study
programme 340 "The Passat 2006 – The electrical
system".

S338_076

Repairs to 230V systems must not be carried out in customer service workshops. If the socket or the
inverter is defective, the entire assembly must therefore be exchanged.

33

Electrical system

Trailer detector control unit J345

This ensures that the trailer's electrical components are integrated into the vehicle network.

Location

The trailer detector control unit is located behind the
luggage compartment trim on the left-hand
side panel.

Tasks

The trailer detector control unit determines
whether a trailer is connected to the trailer socket,
and makes this information available to other control
units via the CAN data bus.
It controls the trailer's lighting and also diagnoses the
functional capability of the majority of trailer bulbs.

As a CAN subscriber, it reads all messages required
for trailer operation, e.g. for the reversing light or turn
signals, and processes these to actuate the trailer's
corresponding lighting components.
This also applies to equipment-dependent
convenience electronics functions such as automatic
headlight control or the Coming-Home lighting and
safety functions such as the hazard warning lights in
the event of emergency braking.

S338_109

Trailer detector
control unit J345

Trailer socket

S338_104

Left side light
and brake light

Left turn signal Right turn signal

Right side light and

brake light

34

Rotary switch for lighting

However, the trailer detector control unit also feeds
messages into the CAN data bus, so that the affected
control units can switch to trailer mode.

Voltage supply

Onboard supply
control unit J519

CAN data bus

Trailer detector
control unit J345

Trailer socket

Tail lights on the trailer

This information is required:

- At the onboard supply system control unit to

actuate the rear fog light. This is switched off
during trailer operation to reduce the dazzle effect
to which the driver is exposed.

- At the ABS and ESP control unit to adapt the brake

system control functions to trailer operation.

- At the parking aid control unit to deactivate the

sensors for the rear sensing range.

- At the anti-theft alarm system to integrate the

trailer into monitoring when the trailer line is
connected. Since the microswitch in the trailer
socket has been omitted, this is carried out via bulb
sensing.

S338_115

When retrofitting a trailer socket, the socket must no longer simply be connected to the rear lights.
In this case, the onboard supply control unit is no longer able to carry out functions such as bulb diagnosis
via the defined bulb load or dimmed light actuation, because it is unable to distinguish between the
vehicle's lights and a possible short-circuit in the relevant power circuit.

A trailer with LEDs in its turn signals and rear lights cannot be detected, because its power consumption is
less than 5W. During trailer simulation, workshops must ensure that their test boxes provide this output
value of 5W as consumers.

35

Electrical system

Function

Based on cold monitoring of the tail lights and turn
signals, the trailer detector control unit determines
whether a trailer is connected. This is carried out via
bulb current sensing. The minimum load which has to
be connected at the control unit outputs to achieve
this is 5W per output.

The advantage of current sensing is that the bulbs can
be monitored via the self-diagnosis function. If a bulb
is defective, an entry is made in the control unit's fault
memory.
This remains there until trailer re-connection is detec­ted. This means that, even without the trailer, a defec­tive turn signal or rear light can be detected in the
trailer electrics in the workshop.

J345

NOK OK

Self-diagnosis

The trailer detector control unit monitors all
components' inputs and outputs during vehicle
operation and in the workshop, e.g. during a control
element test. The reversing light and rear fog light are
the exceptions, as neither of these were legally
prescribed for trailers until recently.

The fault memory can contain five faults and is not
equipped with "self-healing". This means that static
and sporadic faults remain stored until a trailer is
connected again.
A fault may change its status from "static" to
"sporadic" if a defective bulb is exchanged whilst the
trailer is connected.

Fault memory

Current sensing

S338_116

36

The windscreen wiper system

It is comprised of a contrarotating system with two
motors and no mechanical link between the wipers.
Due to the wiper system's contratotation principle,
the rain and light detector sensor has been located in
a new position in the Golf Plus.

J519

J533

J584

D

F266

G397

J400

J527

S338_080

E

Function

The wiper switch position is transmitted directly to the
steering column electronics control unit and then to
the onboard supply control unit via the CAN comfort
data bus.

Information on the activated wiper stage is trans­mitted by the onboard supply control unit, via the LIN
data bus, to the wiper motor control unit, and from
there to the front passenger side wiper motor control
unit. Both control units are located directly at the
wiper motors.

The wiper motor control unit controls the wiping
processes and actuates the front passenger side wiper
motor control unit in accordance with the
master-slave principle.

ab

S338_101

D - Ignition/starter switch
E - Wiper switch
F266 - Bonnet contact switch
G397- Rain and light detector sensor
J400 - Wiper motor control unit
J519 - Onboard supply control unit
J527 - Steering column electronics control unit
J533 - Data bus diagnostic interface
J584 - Front passenger side wiper motor control unit
a - Ambient temperature signal via CAN instrument cluster data bus
b - Vehicle speed signal via CAN powertrain data bus

37

Convenience electronics

Rain closing

The "rain closing" convenience function" will be
introduced for the first time in Volkswagen's Golf class
along with the Golf Plus. This is a distributed function
in which the onboard supply, convenience and door
control units, the rain and light detector sensor and,
depending on the equipment fitted, the sliding roof
control unit work together.

Rain closing is initialised in the convenience control
unit. To achieve this, the "rain closing" function must
be switched on via the personalisation menu in the
instrument cluster. It has to be re-activated each time
after starting tie engine. i.e. "terminal 15 on".

S338_102

38

Rain and light detec­tor sensor

LIN data bus

Onboard supply control unit

CAN comfort data bus

Sliding/tilting roof
module

Convenience
system central
control unit

Switch for
sliding roof

Door control unit

S338_103

Function

Once rain closing has been activated, the conveni­ence system control unit transmits a corresponding
message to the onboard supply control unit. Once this
has detected that the ignition has been switched off,
it sets the rain and light detector sensor to monitoring
mode. This mode is set to 12 hours as default.

If the rain sensor detects precipitation, it informs the
onboard supply control unit via the LIN data bus;
in turn, the former informs the convenience control
unit via the CAN data bus. Via separate CAN messa­ges, this issues the command "close windows" to the
door control units. In accordance with the EU
Directive, the window drives' excess force limitation
function is also retained in the case of rain closing.

The command for the sliding/tilting roof (STR) is trans­mitted via a separate line from the convenience
control unit to the STR module.
Whilst the door control units confirm that the windows
have been closed, the STR drive does not provide the
convenience control unit with any feedback.

To avoid inadvertant deployment of the anti-theft
alarm system the sensitivity of the interior motion
sensors is reduced whilst rain closing is being
carried out.

Deactivation conditions

The function is deactivated following:

- Successful execution of rain closing,

- "Ignition on" status detected,

- Expiry of the monitoring period.

39

Convenience electronics

Rain and light detector sensor G397

Location

The rain and light detector sensor is located in the
Golf Plus in such a way that it is positioned as high as
possible, centrally, in the wiping overlap range of
both wiper arms.

Task

The rain and light detector sensor only operates in
automatic mode if the wiper lever is set to the
"intermittent" position for rain detection and the light
switch is set to the "automatic headlight control"
position for light detection. The rain and light detector
sensor then ensures, when rain is detected on the
windscreen, that the wipers are actuated from zero to
the maximum number of wiper cycles according to the
quantity of precipitation, and that the headlights are
switched on in twilight conditions.

Sensor

Windscreen

Intermittent wiper
regulator E38

S338_132

Interior rear-view
mirror

S338_131

Wiping overlap range

Wiper level 2

Wiper level 1

The rain and light detector sensor independently
adapts to the windshield's tinting.

At wiper lever level 1, in which the wipers operate at a
speed of 42 cycles per minute without rain sensing,
the wiper speed can be independently increased up
to 60 cycles per minute with rain sensing, depending
on the quantity of precipitation.
In the case of wiper operation without rain sensing,
this value corresponds to level 2. In level 2, rain detec­tion has no influence on the wiper speed. In this case,
the wipers operate at a constant 60 cycles per minute.

Rain sensor on/
intermittent wiping

S338_136

Off

The intermittent wiper regulator can be used to
individually set the sensitivity of the rain detector.
In vehicles without a rain detector, the regulator is
used to set the length of the intervals.

40

Structure

Windscreen

Optical element

LED

Remote sensor

Sensor housing

Photo diode

Adhesive film

S338_125

Ambient light sensor

The rain and light detector sensor is comprised of a combination of light-sensitive sensor elements and an LED.
All components are mounted on a printed circuit board in the sensor housing.
An optical element rounds off the sensor housing towards the windscreen. The optical element's task is to bundle
and align the outgoing and incoming light. The entire sensor is secured to the windscreen using an adhesive film.

2

The sensed area measures 300mm

.

The LED and a photo diode are used for rain detection, whilst an ambient light and a remote
sensor are used for light detection.

The priority of both rain and light detection is subordinate to manual actuation of the relevant switch
elements. This means that even if these assistance functions malfunction, manual activation of the wipers
and driving lights always takes precedence.

41

Convenience electronics

Rain detection function

The sensor's core elements are an LED and a photo
diode. The sensor's basic principle is that the light
emerging from the LED is partially reflected by the
surface of the windscreen and, bundled by the optical
element, hits the photo diode.

LED

Optical element

The degree to which the diode's light is reflected,
and therefore the volume of light which hits the photo
diode, changes if the windscreen is coated with water
droplets or a film of water. The greater the coating,
the less light is reflected due to light refraction.
The photo diode's output signal can therefore be used
to calculate the quantity of precipitation.

The rain detrctor response time, i.e. the time which
passes between the detection of precipitation and the
emission of the output signal to the wipers, is less than
20ms.

S338_127

Reflection with a dry windscreen

Large quantity of light

S338_128

Reflection with a wet windscreen

Photo diode

= no rain

42

Small quantity of light

= rain

S338_129

Light detection function

Incoming ambient light

To distinguish between light conditions, the rain and
light detector sensor is fitted with different light
sensors. An ambient sensor detects the light
conditions in the vehicle's immediate vicinity and a
remote sensor senses the light conditions at a

Light from
remote sources

S338_130

Remote sen­sor

Optical element

Ambient light sensor

distance of up to three vehicle lengths in front in the
direction of travel.

The system detects a general decrease or increase in
brightness and switches the driving lights
on or off when the automatic headlight control
function is activated.

From the difference between both sensors' signals, the system is able to determine e.g. that the vehicle is entering a
tunnel, thereby switching on the driving lights when the vehicle enters the tunnel at the latest. The system's internal,
logical link ensures that the driving lights are only switched off once the ambient light sensor has detected an
adequate brightness value.
If the rain detector is also active in addition to the light detector, correspondingly heavy precipitation also leads to
activation of the driving lights.

Remote detection

Difference in brightness

less than

activation threshold value

= lights remain off

Ambient light detection

S338_133

The light detection function does not react to fog or underpasses.
In these cases, the driving lights have to be switched on manually.

Remote detection

Difference in brightness

greater than

activation threshold value

= lights are switched on

Ambient light detection

S338_134

43

Radio and navigation

The radio systems in the Golf Plus

Radio R100

S338_088

The R100 target group is major customers,
e.g. vehicle fleet operators.
This radio unit offers the following functions:

- Two loudspeaker channels
(front only, 20 Watts each)

- RDS FM/AM European radio (AM without LW)

- Control system for external 6-fold CD-changer

- Telephone control system (hands-free)

- Speed-dependent
volume control (GALA)

- Self-diagnosis with loudspeaker diagnosis

-Transport mode
(current requirement reduction during transport
and idle times)

Radio RCD 300

S338_089

Radio RCD 300 is available as the standard radio
system for private customers.
It offers the following functions:

- Two or four loudspeaker channels
(20 Watts each)

- RDS FM/AM European radio (AM without LW)

- Indication of the stored stations with
RDS names in the display

- FM 2-tuner diversity

- Control via the multi-function steering wheel (MFL)
and multi-function indicator (MFI)

- Integrated single-CD player,

- Control system for external 6-fold CD-changer

- Telephone control system (hands-free)

-GALA

- Self-diagnosis with loudspeaker diagnosis

-Transport mode

- Driving school function (possible indication of
turn signal function and speed via the
unit's display)

44

Due to the change in installation position and reading angle in comparison with the Golf 2004,
the displays for the radios fitted in the Golf Plus have been redesigned. This results in a different
part number.

Radio RCD 500

Radio/navigation system MFD 2

S338_091

S338_090

This, or a higher-quality radio, is required to equip the
Golf Plus with the digital sound package DSP. It offers
the folloing functions

- Four loudspeaker channels (20 Watts each)

- RDS FM/AM European radio (AM without LW)

- Indication of the stored stations with RDS names in
the display

- FM 2-tuner phase diversity

- Control via the MFL and MFI

- Integrated single-CD player

- Control system for external 6-fold CD-changer

- Telephone control system (hands-free)

-GALA

- Traffic Information Memory (TIM)

- Vehicle model-specific sound adaptation

- Self-diagnosis with loudspeaker diagnosis

- Transport mode

- Optional connection of an external
sound amplifier

A radio system with an integrated navigation
system is also available for the Golf Plus.
The operating sequences are similar to those of the
radio/navigation system fitted in the Touareg.
It offers the following functions, etc.:

- Multi-colour display (MFD)

-Dynamic guidance

- Four loudspeaker channels (20 Watts each)

- RDS FM/AM European radio (AM without LW)

- Indication of the stored stations with RDS names in
the display

- External diversity changeover box

- Control via the MFL and MFI

- Control system for external 6-fold CD-changer

- Telephone control system (hands-free)

-GALA

-TIM

- Self-diagnosis with loudspeaker diagnosis

- Optional connection of an external sound amplifier

The cover frame has to be removed to remove or install a radio, in order to access the
threaded connection located behind it.

45

Radio and navigation

The antenna concept

Four antenna equipment alternatives are currently available for the Golf Plus:

- Roof antenna and rear window with an antenna structure without connection option,

- Roof antenna and rear window with an antenna structure and one connection option,

- Roof antenna and rear window with two antenna structures and one connection option, and

- Roof antenna and rear window with two antenna structures and two connection options.

A rod or tri-band antenna may be fitted as the roof antenna.

Roof antenna and rear window with an antenna
structure without connection option

If this equipment is fitted, e.g. radio R100 is connected
to the roof antenna. As in the case of the variant
"without radio", the integrated rear window antenna
has no connection option, with the result that a
telephone, navigation and telestart cannot be
implemented with this version.

Roof antenna and rear window with an
antenna structure and one connection option

Both antennae are used by one radio (as of RCD 300)
to exploit the advantages of antenna diversity.
This means that, thanks to an integrated diversity
switch, the radio automatically uses the antenna with
the stronger input signal.
Telephone, navigation and telestart are not available
in this case.

Roof
antenna

S338_110

Radio

AM blocking circuit

FM blocking circu it FM blocking circuit

46

Roof
antenna

S338_111

Radio

Roof antenna and rear window with two antenna
structures and one connection option

AM blocking circuit

FM blocking circu it FM blocking circuit

FM impedance
converter

Radio

e.g. telephone

The roof antenna is used for the telephone,
navigation or telestart. The rear window antenna's
connection option is used for the radio, e.g. the R100.

Roof
antenna

S338_113

Roof antenna and rear window with two antenna
structures and two connection options

FM blocking circuit FM blocking circuit

FM impe-

dance

converter

External diversity box

(in MFD2 mode)

AM/FM impe-

dance converter

E.g. navigation

AM blocking circuit

Roof
antenna for
GSM/GPS/
telestart

Telephone, telestart

S338_112

The roof antenna is used for the telephone,
navigation and telestart. The two rear window
antenna connections are used for the radio.
No external diversity box is installed if the vehicle is
equipped with radio RCD 300 or RCD 500.
The GPS link to the roof antenna is also omitted in this
case.

If the Golf Plus is supplied without
preparation for antenna installation, a
dummy antenna seals the antenna bore in
the vehicle's roof. Whilst the rear window is
equipped with the integrated antenna
structure, it does not offer any
connection option.

47

Heater and air conditioner

Climate control

S338_059

Three different systems are available in the Golf Plus:

- The manual heater and ventilation system,

- The semi-automatic heater and air conditioner "Climatic" and

- The heater and air conditioner "Climatronic".

An identically designed air conditioner unit, which has been adapted to the relevant vehicle equipment, is used for
both air conditioners. The main difference is in the number and design of the air distribution
flaps. For example, the 2C-Climatronic is fitted with an additional fresh air/air flow flap.

Depending on the vehicle's equipment, the heater
and air conditioner control panels differ.
Four different variants are available:

- With or without instant heat button for the
auxiliary coolant heater and

- With or without potentiometer for the seat heating.

48

All temperature- and ventilation-relevant control
elements and the air conditioner control unit are
integrated into the control panel.

S338_060

S338_041

The vents are sub-divided. This doubles the number
of vents in the upper area of the dash panel to eight,
and enables more individual adjustment.
Better air output is made possible thanks to the larger
air duct cross-sections. The cross-sections of the rear
footwell vents have also been increased. This also
improves ventilation in this area.

The glove box is supplied with cooled air,
which is diverted directly downstream of the
evaporator.

S338_081

S338_042

The temperature-controlled storage compartment in
the Highline centre console has room for two cans of
drink. The temperature corresponds to the pre-set
interior temperature.

In the Climatronic system, a diffusor offers
indirect and draught-free ventilation.

S338_078

49

Heater and air conditioner

The Climatic system

22°C

S338_061

In the Climatic system, the vehicle's entire interior is
comprised to form a single climatic zone.
The desired temperature is set at the left
rotary switch.
The rotary switch is linked to a potentiometer,
which passes the temperature commend on to the
Climatic control unit. The control unit then forwards a
calculated flap position value to the temperature flap
positioning motor.

Climatic is able to control the pre-set temperature by
monitoring the vent and interior temperature.

S338_123

The air distribution flaps are actuated via a
flexible shaft in the Climatic system.
The air conditioner is switched on and off via the
ECON button. In ECON mode, the additional heater
is also switched off in vehicles fitted with diesel
engines. The Climatic air conditioner unit is equipped
with a combined fresh air/recirculated air flap.

50

Further information can be found in self-study programme No. 318 "The Golf 2004".

The 2C-Climatronic system

23°C

19°C

S338_060

In the 2C-Climatronic system, the interior is sub­divided into two climatic zones. This means that the
temperaturs desired on the driver and front
passenger side can be set independently of each
other. The climatic zones are separated by two
temperature flaps inside the air conditioner unit.

All flaps, air distribution and the temperature
are actuated via positioning motors with an
integrated feedback potentiometer. Maintenance of
the pre-set interior temperature and optimal air
distribution is thereby controlled and monitored by
the Climatronic control unit.

The 2C-Climatronic system can be operated in
automatic or manual mode.

S338_124

In addition to the Climatic system, 2C-Climatronic is
fitted with a fresh air flow flap, which is closed as of
100km/h as speed increases, in order to keep the
volume of fresh air which is supplied constant.
One further function which is available is speed­dependent blower reduction, which reduces the air
conditioner's flow noises at low speed. In cooling
mode, this is compensated by lowering the vent
temperature and by raising the ventilation tempera­ture in heating mode.

To prevent the windows from misting when the
compressor is switched off and the windscreen wipers
are switched on, the defrost flap is automatically
opened further to conduct more air to the windscreen.

51

Heater and air conditioner

The Thermo Top V auxiliary coolant heater

The Golf Plus can be fitted with the optional Thermo Top V auxiliary coolant heater.
This undertakes the following tasks:

● Acts as an auxiliary heater for heating the vehicle interior and defrosting the vehicle's windows,

● Acts as stationary ventilation to lower the interior temperature when the vehicle is parked in the sun,

● Acts as an additional heater in vehicles with petrol or diesel engines (fitted as standard in diesel engines).

Structure

Combustion air blower

Control unit

Electrical connection

Combustion air
inlet

Ventu ri no z zle

Fuel
inlet

Water outlet

Temperature sensor

S338_045

Heat exchanger

Exhaust gas outlet

52

Special characteristics

- The auxiliary coolant heater control unit is integrated into the heater unit.

- The electrical contacts for the combustion air blower are inserted directly into the control unit.

- The auxiliary coolant heater is fitted with a second NTC temperature sensor for controlling and monitoring the
water temperature.

- The combustion air enters the combustion chamber via a venturi nozzle and thereby draws in the fuel
delivered by the metering pump from the fuel line.

The venturi nozzle

Fuel inlet

Combustion air inlet

Heater element mounting

The fuel pre-heater

PTC heater element

The intaken air is guided through a ceramic housing,
which is shaped as a venturi nozzle. As a result of this,
the air delivered by the combusion air blower is acce­lerated to approx. 50 m/s.
The incoming fuel is therefore drawn from the fuel line
and swirled.

S338_046

The Thermo Top V system is fitted with a PTC element
for pre-heating fuel; this enables the use of RME
(rapeseed methyl ester).
The fuel is heated directly prior to emerging from the
fuel line. To do this, the PTC heater element is switched
on for one minute at ambient temperatures of less
than 5°C.

Fuel supply line

S338_047

53

Heater and air conditioner

Activation of Thermo Top V

There are three ways of activating the Thermo Top V auxiliary coolant heater.
The "heater" or "ventilation" functions can be set in the dash panel insert display.

1. Activation of the auxiliary coolant heater via the
instant heat button on the control panel.

2. Programming the auxiliary coolant heater via the
multi-function indicator (MFI) with the data
display protocol (DDP).
In this case, programming is carried out via the dis­play in the dash panel insert in the "auxiliary heater"
sub-option (personalisation).

3. The separate radio remote control can be used for
switching on and off functions. An indicator lamp
indicates whether the radio signal has been received
by the auxiliary coolant heater.

SETTINGS

Time
Winter tyres
Language
Units
Light & visibility
Comfort

Auxiliary heater

S338_070

AUXILIARY HEATER

Activation 1
Activation 2
Activation 3
Runtime
Operating mode
Weekday
Default setting

S338_069

54

The instant heat button in the control panel shows the
status of the auxiliary coolant heater: if active,
the yellow feedback LED lights up. If a programmed
duty cycle for the auxiliary coolant heater is active,
the feedback LED lights up for approx. 10 seconds
after the ignition has been switched off.

Further information can be found in self-study programme No. 318 "The Golf 2004".

S338_114

Special tools

Tool No. Figure Designation and use

T 10311 Wing underlay

The wing underlays are required when removing and installing
the gearbox. They serve as underlays for support T 10222 A and
its adapters T 10222 A/8.

S338_137

Service

55

338

© VOLKSWAGEN AG, Wolfsburg
All rights and technical changes reserved.

000.2811.53.20 Technical status 01.2005

Vol k swage n AG
Service Training VK-21
Brieffach 1995
D-38436 Wolfsburg

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