VOLKSWAGEN GOLF 2004 (08) PDF Document

To move the lock carrier to the service position, follow these steps:

1. Remove the front bumper.

2. Unhook the Bowden cable at the coupling.

3. If the vehicle has a charge air cooler, disconnect the pressure hoses.

4. Unscrew the horn with its bracket on the right side of the longitudinal member.

5. Remove the bolts from the left and right longitudinal members.

6. Attach the special tool guide pins T 10093 to the left and right longitudinal members.

7. Remove the bolts on the left and right from the upper part of the lock carrier.

8. The lock carrier can now be pulled forwards about 10 cm on the guide pins.

When moving the lock carrier, ensure that the charge air cooler pressure hoses are properly engaged again, and ensure that all hoses and lines are not pinched.

To remove the lock carrier, follow these steps:

1. Set the lock carrier with add-on parts to the service position.

2. Disconnect all electrical connectors.

3. Drain the coolant and disconnect the coolant lines.

4. Disconnect the wiring for the condenser.

5. Together with a second mechanic, unscrew the guide pins T 10093 from the left and right longitudinal members and lift the lock carrier out.

WARNING: Do not start the engine if the air conditioning system and/or the coolant system lines are disconnected.

To remove the wing, follow these steps:

1. Remove the front bumper.

2. Remove the wheel housing liners.

3. Remove the guide.

4. Loosen the hexagon nut and remove the bolts.

5. Pull out the moulded plastic part between the wing and the longitudinal member.

6. Lightly heat the outside of the wing in the area of the moulded foam part using the hot air blower V.A.G 1416.

7. The bonding on the moulded foamed plastic part will release, allowing the wing to be removed.

To remove the noise insulation, remove the bolts as shown in the assembly overview. Note that procedures may vary slightly depending on the engine fitted.

To remove the bonnet, follow these steps:

1. Remove the left and right washer jets.

2. Unclip the line from the hinge and bonnet.

3. Pull the line out through the aperture in the bonnet.

4. Loosen the hexagon nuts on the left and right, but do not remove them.

5. With the help of a second mechanic, disconnect the gas strut at the bonnet.

6. Remove the hexagon nuts and lift the lid out of the hinges.

To safely release gas from the gas strut:

1. Clamp the gas strut in a vice only within the area x = 50 mm from the end.

2. WARNING: Clamp the gas strut only within this area to avoid danger of accident.

3. Saw through the cylinder of the gas strut within the first third of the cylinder’s overall length, using the piston rod end of the cylinder as a reference point.

4. Wear eye protection, cover the area of the saw cut with a cloth, and dispose of the oil and cloth via existing disposal channels.

To remove the bonnet lock, follow these steps:

1. Open the bonnet.

2. Remove the appropriate radiator grille (standard, GTI, or R32 version).

3. Separate the Bowden cable and disconnect the connector for the bonnet contact switch F 266 (located over the right headlight).

4. Remove the three bolts on the lock carrier and remove the bonnet lock upwards.

5. To unclip the Bowden cable, press the tab and cable together, release the fastening, and remove it from the lock.

For initial adjustment, the vehicle must be on the ground and the latch hook must be removed. Follow these steps:

1. Disconnect the gas strut at the bonnet.

2. Loosen the hexagon nuts and the bolt on both bonnet hinges to align the bonnet between the wings.

3. Adjust the rear part of the bonnet on both sides to the wing height using the adjustment screws.

4. The front part of the bonnet can be adjusted to the wing height using the adjustment buffers.

5. After adjustment, install and adjust the arrester.

1. Support the open rear lid.

2. Position a small screwdriver beneath the spring clip.

3. Raise the spring clip until it can be moved over the ball socket.

4. Pull the gas strut from the ball-head pins.

WARNING: Proceed with care if the gas strut is reused. The spring clip must not be levered completely out of the ball socket. The gas strut will spring out of the mounting, causing damage or injury.

If the fuel tank filler flap does not open, open it by hand using the release rod. The side trim must be removed to do this. The removal steps are:

1. Open the fuel tank flap and remove the fuel filler cap.

2. Remove the bolt.

3. Pull the rubber part off the fuel tank filler neck.

4. Pull the fuel tank flap unit with the drain hose to the rear and swing it out of the side panel.

5. Unclip the assembly part out of the side panel and pull it off the release rod.

To remove the front door outer panel, follow these steps:

1. Lever out the clips from the bottom, starting on the door, and remove the cover.

2. Remove the lock cylinder and the door handle.

3. Remove the bolt from the mounting bracket located behind the door outer panel.

4. Remove all bolts securing the panel.

5. Carefully remove the door outer panel.

CAUTION: Bolts of different types are used to secure the door outer panel. If they are fitted in the wrong positions, the door outer panel will be damaged.

To remove the door lock, perform the following:

1. Remove the door outer panel.

2. Remove the mounting plate.

3. Disconnect the connector.

4. Remove the bolts.

5. Release the cable from the relay lever and remove the door lock.

1. Insert a screwdriver in the slot between the transmitter unit and the key, and twist to separate them.

2. Press the transmitter unit apart using the profile section of the key.

3. Unclip the battery from the retainers with a screwdriver.

4. Before installing the new battery, press any key once to reset the transmitter unit.

5. Lay the new battery with the positive terminal downwards in the sender unit (positive is marked on the housing).

6. Engage the battery, fit the cover, and clip the transmitter unit back onto the key.

To remove the front bumper cover:

1. Remove the radiator grille.

2. Remove the bolts from the top.

3. Remove the bolts from below.

4. Remove the bolts on the left and right in the area of the wheel housing liner.

5. With the help of a second mechanic, press the locking devices downwards on both sides and pull the cover parallel out of the guides.

6. Disconnect all electrical connections and separate hoses.

To adjust the door window, follow these steps:

1. Remove the front door trim.

2. Lever out the caps.

3. Lower the door window until the clamping bolts for the mounting are accessible.

4. Loosen the bolts from inside by turning to the right and press the clamping jaws apart.

5. Apply light pressure to the window, press it into the clamping jaws, and align the door window tension-free at the rear window guide.

6. Ensure the window is parallel to the guide, then tighten the clamping jaws by turning the bolts to the left from the interior.

The torque settings for the standard front bumper cover are: