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Volkswagen Golf 4 Mk4 1997-2006 Service Repair Manual
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Basic Information Identification Make: Volkswagen Model: Golf Generation: Mk4 Production Years: 1997-2006 Introduction Market Position Market Segment: Compact car (C-segment) Competitive Analysis Key Competitors: Ford Focus, Opel/Vauxhall Astra, Renault Megane,...
Type: Cars
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Sku: 427926
Tags:
Golf
Volkswagen
Volkswagen VW
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| Basic Information | |
| Identification | |
| Make: | Volkswagen |
| Model: | Golf |
| Generation: | Mk4 |
| Production Years: | 1997-2006 |
| Introduction | |
| Market Position | |
| Market Segment: | Compact car (C-segment) |
| Competitive Analysis | |
| Key Competitors: | Ford Focus, Opel/Vauxhall Astra, Renault Megane, Peugeot 307, Toyota Corolla, Honda Civic. |
| Key Features | |
| Design Philosophy: | Solid build quality, practical interior, refined driving dynamics, wide range of engine options, strong safety credentials. |
| Target Audience: | Families, young professionals, budget-conscious buyers seeking a reliable and versatile hatchback. |
| Manual Details | |
| Coverage Areas | |
| Coverage Summary: | Comprehensive service, maintenance, and troubleshooting for all Golf Mk4 models, engines, trims, and transmissions. |
| Page Count | |
| Estimated Page Count: | Thousands (typical for a complete factory service manual) |
| Manual Type | |
| Type: | Factory Service Repair Manual / Workshop Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | |
| Manual Coverage | |
| Systems Covered | |
| Engine Systems: | Engine mechanical (cylinder head, block, pistons, crankshaft), lubrication, cooling, fuel injection, ignition, emissions control, turbocharging (where applicable). |
| Transmission Systems: | Manual transmission (gearbox, clutch, linkage), Automatic transmission (torque converter, valve body, internal components, control systems). |
| Drivetrain Systems: | Front-wheel drive, all-wheel drive (4MOTION), CV joints, driveshafts, differential. |
| Suspension Steering Systems: | Front and rear suspension components (struts, shocks, control arms, bushings, springs), steering rack, power steering system, alignment specifications. |
| Brake Systems: | Front and rear disc brakes, ABS system (modulator, sensors, control module), brake fluid, parking brake. |
| Electrical Systems: | Battery, charging system, starting system, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module (BCM), comfort electronics. |
| HVAC Systems: | Heating, ventilation, and air conditioning (AC compressor, refrigerant, evaporator, condenser, blower motor, controls). |
| Body Interior Exterior: | Body panel removal and installation, interior trim, seats, airbags, glass, doors, locks, bumpers, exterior trim, paint codes. |
| Procedures Included | |
| Maintenance Procedures: | Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, belt inspection/replacement, tune-ups. |
| Repair Procedures: | Engine rebuilds, transmission overhaul, suspension component replacement, brake caliper/rotor replacement, electrical component diagnosis and replacement, AC system service. |
| Troubleshooting Diagnostics: | Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, component testing procedures, electrical schematics for fault finding. |
| Special Procedures: | Timing belt replacement, fuel system bleeding, airbag system service, ECU/module coding and adaptation, diagnostic tool usage. |
| Technical Depth | |
| Depth Of Coverage: | Complete disassembly and reassembly, detailed torque specifications, special tool requirements, component tolerances, diagnostic flowcharts. |
| Manual Specifications | |
| File Format | |
| File Format: | |
| Print Quality | |
| Printability: | Printable without restriction |
| Binding Type | |
| Binding: | Digital Download (PDF) |
| Paper Type | |
| Paper Type: | Not Applicable (Digital) |
| Requirements | |
| Software Requirements: | Adobe PDF Reader |
| Engine Specifications | |
| Primary Engine Options | |
| Gasoline Engines: | 1.4L (AEX, APQ), 1.6L (AEH, AKL, APF, AUR), 1.8L (AGN, AGU, ARZ, AUM, AUQ, APY, AQC), 2.0L (AZJ, AWX, AVU, BCB), 2.3L V5 (AGZ, AQN), 2.8L VR6 (AAA, AQP, AQQ, BDE). |
| Diesel Engines: | 1.9L TDI (AGR, ALH, AHF, ASV, AJM, AUY, BXE, BKC, BJB, BLS), 1.9L SDI (AQM, AGD). |
| Performance | |
| Horsepower Range: | Approximately 60 hp (1.4L) to 204 hp (2.8L VR6). |
| Torque Range: | Approximately 115 Nm (1.4L) to 270 Nm (2.8L VR6). |
| Fuel System | |
| Fuel Delivery: | Electronic Multi-Point Fuel Injection (MPI) or Direct Injection (TDI, FSI on later models not specified here). |
| Fuel Type: | Unleaded gasoline (RON 91-98 depending on engine), Diesel (Euro 3/4 standards). |
| Engine Codes Explained | |
| Engine Code Examples: | AGU (1.8T 150hp), ALH (1.9 TDI 90hp), AGZ (2.3 V5 150hp). |
| Transmission | |
| Standard Transmission | |
| Manual: | 5-speed Manual Transmission (02A/02J family) |
| Optional Transmission | |
| Automatic: | 4-speed Automatic Transmission (01M family), 5-speed Tiptronic (01N/01M variants), 6-speed Manual Transmission (02M for performance models like R32). |
| Features | |
| Clutch Type: | Dry single-plate clutch (manual), torque converter (automatic). |
| Gear Ratios | |
| Typical Ratios: | Varies by engine and transmission. Manual transmissions typically feature close-ratio gearing for sportier variants. |
| Dimensions | |
| Exterior | |
| Length: | Approx. 4025 mm |
| Width: | Approx. 1710 mm |
| Height: | Approx. 1440 mm |
| Wheelbase: | Approx. 2515 mm |
| Interior | |
| Seating Capacity: | 5 |
| Cargo | |
| Cargo Volume Seats Up: | Approx. 330 liters |
| Cargo Volume Seats Down: | Approx. 1230 liters |
| Weights | |
| Curb Weight: | Approx. 1150-1400 kg (depending on engine and equipment) |
| Safety Features | |
| Ratings | |
| Euroncap Rating: | 4 Stars (for early models, later updates may vary slightly) |
| Active Features | |
| ABS: | Standard on most models, Anti-lock Braking System. |
| Traction Control: | Optional (ASR/EDL on some models) |
| Passive Features | |
| Airbags: | Front airbags (driver/passenger) standard, optional side airbags and curtain airbags on later models. |
| Seatbelts: | Pre-tensioned seatbelts with force limiters, ISOFIX child seat anchor points. |
| Technology Features | |
| Infotainment | |
| Audio Systems: | Factory radio/cassette or CD players. Optional upgrades included premium sound systems, CD changers, and later touchscreen head units in some trims. |
| Driver Assistance | |
| Cruise Control: | Available on higher trims or as an option. |
| Parking Assistance: | Rear parking sensors were an option on later models. |
| Connectivity | |
| Bluetooth: | Rarely factory-fitted, typically an aftermarket addition or available via accessory kits on later models. |
| Lighting | |
| Headlights: | Halogen headlights standard, optional Xenon HID headlights on some higher trims or with specific packages. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Typically 15,000 km or 1 year (whichever comes first), or 30,000 km / 2 years with LongLife service intervals, depending on oil specification and driving conditions. |
| Timing Belt Interval: | Varies significantly by engine. For most belt-driven engines (e.g., 1.6L, 1.8T, 1.9 TDI), typically every 90,000-120,000 km or 5-7 years. Chain-driven engines (V5, VR6) require less frequent major service but may need tensioner checks. |
| Fluid Specifications | |
| Engine Oil: | API SN/SP or ACEA C3/C4/C5, viscosity 5W-40 or 5W-30 (depending on engine and VW specification like VW 502 00, VW 504 00, VW 505 00, VW 507 00). Refer to manual for exact spec. |
| Coolant: | G12 or G12+ (Pink/Red) ethylene glycol based coolant, mixed 50/50 with distilled water. |
| Brake Fluid: | DOT 4 (DOT 5.1 may be specified for certain ABS systems). |
| Transmission Fluid Manual: | GL-4 or GL-4/5 gear oil, SAE 75W-90 or 75W-80. |
| Transmission Fluid Automatic: | VW G 052 162 (or equivalent ATF like Dexron III for older units). Critical to use correct fluid. |
| Known Issues | |
| Common Problems: | Coil pack failure (1.8T), Mass Air Flow (MAF) sensor issues (1.8T, TDI), ABS sensor failure, window regulator failure, door lock actuator issues, minor oil leaks from valve cover/oil pan, catalytic converter failure (especially on earlier models), catalytic converter failure on early models, glow plug issues (TDI). |
| Vehicle History | |
| Brand Heritage | |
| Volkswagen Heritage: | Volkswagen's reputation for robust engineering, practical design, and long-term durability. |
| Model Evolution | |
| Mk4 Development: | The Mk4 Golf represented a significant step forward in refinement, build quality, and technology over its Mk3 predecessor. It shared its platform (PQ34) with other VW Group models like the Audi A3 and SEAT Toledo. |
| Production | |
| Production Period: | Introduced in 1997, production continued globally until 2006, with some variations and facelifts (e.g., the 'R32' performance variant). |
| Manufacturing Locations: | Primary production in Wolfsburg, Germany, with assembly plants in Mexico, Brazil, South Africa, and China. |
| Awards & Recognition | |
| Recognitions | |
| European Car Of The Year: | While the Golf Mk4 itself wasn't a winner, the Golf lineage has a strong history of awards, including European Car of the Year for earlier generations. |
| Ratings | |
| Consumer Reports Ratings: | Ratings varied by year and specific model. Generally regarded as reliable with some common electrical and suspension wear items. |
| Certifications | |
| Manufacturing Standards: | Produced under strict Volkswagen AG quality control and ISO 9001 standards. |