Volkswagen Golf 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Volkswagen Model: Golf Year: 2002 Codes Platform Code: PQ34 Chassis Designation: Mk4 (Fourth Generation) 👋 Introduction Market Position Segment: Compact Car / Hatchback Target Audience:...

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Sku: 368907

Tags: 2002 Car Cars Golf Volkswagen Volkswagen VW

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Description

🏷️ Basic Information

Identification

Make:

Volkswagen

Model:

Year:

Codes

Platform Code:

Chassis Designation:

Mk4 (Fourth Generation)

👋 Introduction

Market Position

Segment:

Compact Car / Hatchback

Target Audience:

DIY enthusiasts, independent repair shops, and owners seeking detailed maintenance and repair information.

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Ford Focus, Mazda3

Key Features

Design:

Solid build quality, refined interior, practical hatchback design.

Powertrains:

Known for reliable and fuel-efficient engines, particularly the 1.8T.

Handling:

Good balance of ride comfort and sporty handling, especially in GTI variants.

📋 Manual Details

Coverage Areas

Primary Coverage:

North American Market (US/Canada)

Secondary Coverage:

European Market specifications may differ, but general principles apply.

Page Count

Estimated Page Count:

~2000+

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

1.8L Turbo (AGU/AWP), 2.0L naturally aspirated (APK/AZG/AVH/BBW), 2.8L VR6 (AGM/AAA - less common for 2002 NA models, focus on 1.8T/2.0L)

Engine Management:

ECU diagnostics, fuel injection, ignition system, emissions control

Transmission Manual:

5-speed (02J), 6-speed (02M - for 1.8T)

Transmission Automatic:

4-speed automatic (01M, 01N)

Drivetrain:

Front-Wheel Drive (FWD), Haldex All-Wheel Drive (4MOTION - less common for base 2002 models, but applicable for GTI/GLI)

Suspension:

Front McPherson strut, rear independent torsion beam (or multi-link for 4MOTION)

Brakes:

Front ventilated discs, rear solid discs (or drums on base models), ABS system

Steering:

Hydraulic power steering, steering rack

Electrical:

12V system, battery, alternator, starter, lighting, body control module (BCM), fuse box diagrams

HVAC:

Heating, Ventilation, Air Conditioning (including refrigerant R134a)

Body:

Exterior panels, doors, windows, interior trim, body repairs

Body Electrical:

Wiper system, power windows, central locking, power mirrors

Safety Systems:

Airbag system (SRS), seatbelt pre-tensioners

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plugs, fluid checks, belt inspections

Major Repairs:

Engine component removal and installation (e.g., alternator, starter, water pump), clutch replacement

Engine Overhaul:

Cylinder head removal/installation, piston and connecting rod service, crankshaft service

Transmission Service:

Clutch hydraulic system, transmission fluid changes, manual transmission internal inspection/repair, automatic transmission component replacement

Brake Service:

Brake pad and rotor replacement, brake caliper service, bleeding procedure, ABS sensor replacement

Suspension Repair:

Strut and shock absorber replacement, control arm bushing replacement, ball joint service

Electrical Troubleshooting:

Wiring diagrams, component testing, diagnostic trouble codes (DTCs) and procedures

HVAC Service:

Component replacement (compressor, condenser, evaporator), refrigerant system evacuation and recharge, leak detection

Body Repair:

Door panel removal, window regulator repair, mirror replacement, minor body panel alignment

Diagnostic Procedures:

Step-by-step guides for diagnosing common and uncommon faults across all systems.

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics.

Diagnostic Tools:

Information on using OBD-II scanners and specific VW diagnostic tools (e.g., VAG-COM)

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text, allowing quick access to specific topics.

Printability:

Printable pages for workshop use.

Print Quality

Image Clarity:

High-resolution diagrams and images.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1.8T:

1.8L DOHC 20-valve turbocharged inline-4 (AGU/AWP)

Engine 2.0L:

2.0L SOHC 8-valve naturally aspirated inline-4 (APK/AZG/AVH/BBW)

Performance

1.8T Horsepower:

150 hp @ 5700 rpm (approx.)

1.8T Torque:

162 lb-ft @ 1750 rpm (approx.)

2.0L Horsepower:

115 hp @ 5200 rpm (approx.)

2.0L Torque:

122 lb-ft @ 3200 rpm (approx.)

Fuel System

Injection Type:

Multi-point fuel injection (MPI) or Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (91 octane or higher recommended for 1.8T)

🔧 Transmission

Standard

Manual Transmission:

5-speed manual (02J) for 2.0L, 6-speed manual (02M) for 1.8T

Optional

Automatic Transmission:

4-speed automatic (01M, 01N)

Features

Clutch:

Hydraulically actuated single dry plate clutch

Transmission Fluid Manual:

VW G 052 171 A2 (or equivalent GL-4 75W-90)

Transmission Fluid Automatic:

VW G 052 162 A2 (or equivalent ATF type)

📐 Dimensions

Exterior

Length:

~160.2 inches

Width:

~68.1 inches

Height:

~58.2 inches

Wheelbase:

~101.5 inches

Cargo

Cargo Volume Seats Up:

~15.1 cubic feet

Weights

Curb Weight Base:

~2750 lbs

Curb Weight 1.8T:

~2900 lbs

🛡️ Safety Features

Ratings

NHTSA Front Impact:

NHTSA Side Impact:

IIHS Front Offset:

Active Features

Standard

Traction Control:

Optional (ASR)

Passive Features

Airbags Front:

Standard dual front airbags

Airbags Side:

Optional front side airbags

Seatbelts:

Three-point seatbelts with pre-tensioners

💡 Technology Features

Infotainment

Audio System:

Factory radio with AM/FM, CD player. Premium sound systems available (e.g., Monsoon).

Navigation:

Optional factory navigation system (less common on base models).

Driver Assistance

Cruise Control:

Standard on most models.

Connectivity

Power Features:

Power windows, power door locks, power mirrors (heated).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 7,500 miles or 12 months (whichever comes first), depending on driving conditions and oil used.

Timing Belt Replacement:

100,000 miles or 10 years for 1.8T (and some 2.0L engines with interference design), check manual for specific engine code. **Critical:** Failure to replace can cause catastrophic engine damage.

Coolant Flush:

Every 30,000 miles or 2 years.

Fluid Specifications

Engine Oil:

SAE 5W-40 or 5W-30, meeting VW 502.00/505.00 specifications (synthetic recommended).

Coolant:

G12 (pink) or G12+ antifreeze (Volkswagen Genuine Coolant).

Brake Fluid:

DOT 4

Known Issues

Ignition Coils:

Coil-on-plug ignition coils are prone to failure, causing misfires. Often replaced as a set.

Mass Air Flow Sensor:

Can become dirty or fail, leading to poor idling and performance issues.

Window Regulators:

Plastic components within the regulator mechanism can break, causing power windows to fail.

Rear Main Seal:

Can leak oil over time, requiring transmission removal for replacement.

ABSorbent Glass Mat Battery:

Early Mk4 models may have used conventional batteries; later ones often came with AGM types. Ensure correct replacement type.

📚 Vehicle History

Brand Heritage

Volkswagen Legacy:

Volkswagen has a long history of producing reliable and practical European cars, dating back to the Beetle.

Model Evolution

Golf Legacy:

The Golf is Volkswagen's flagship hatchback, known for its versatility and refinement, evolving through multiple generations since its 1974 debut.

Mk4 Generation:

The Mk4 (1997-2006) represented a significant step up in interior quality and refinement for the Golf line.

Production

Manufacturing Locations:

Primary production in Wolfsburg, Germany; also produced in Mexico, Brazil, and South Africa.

🏆 Awards & Recognition

Recognitions

Car Of The Year:

While the 2002 model itself may not have specific 'Car of the Year' awards, the Mk4 Golf platform was generally well-received for its blend of European driving dynamics and practicality.

Ratings

Consumer Reports:

Consumer Reports typically rated the Golf as average to above average in its class for reliability and performance during this period, with specific praise for the 1.8T engine.