Here are some free official Volkswagen factory workshop manuals, and related technical information for the VW Golf and Jetta Mk5 (
typ 1K, platform PQ35) to download (
right clicky > save target/link as - please note: this did not work with early FireFox or Opera web browsers - current Firefox, and Comodo Dragon (a super-fast Chrome based browser) works perfectly). I will update when more become available.
Standard disclaimer: neither I, nor the Owners, Administrators and Moderators of Mk5GolfGTI.co.uk Forum, will be held liable for any bits left on your garage floor, as a result of downloading and reading these manuals, and the subsequent tinkering with said Golfs! Please be aware some information may not be applicable to your particular model, and some may be only relevent to different countries. Proceed only at your own risk.
MAINTENANCE PROCEDURES:
http://vwts.ru/service/g5_service_eng.pdf - Description of work
http://vwts.ru/service/j05_maintenance_01.pdf - Maintenance. Part 1 (for Jetta, but same as Golf V)
http://vwts.ru/service/j05_maintenance_02.pdf - Maintenance. Part 2 (for Jetta, but same as Golf V)
ENGINE OIL STANDARDS:
https://erwin.volkswagen.com/erwin/showApprovedOils.do - you'll need to create an account (free) before downloading oil standards, by either specification or alphabetically -
newENGINES - general:
http://vwts.ru/electro/g5/j05_27_el.pdf - Battery, Starter, Generator - 1.9L TDI-PD engine, 2.5L gasoline engine, 2.0L TFSI engine
ENGINES - Volkswagen 1.4 TSI R4 engine with dual-charging:
http://www.volkspage.net/technik/ssp/ssp/SSP_359.pdf - Self-Study Programme 359 -
newENGINES - Volkswagen 2.0T FSI R4 engine BPY: (BPY is the North American variant [with different emissions gubbins] of the European AAX or BWA variants)
http://www.golfmkv.com/forums/golfgoodies/mk5golfengine.pdf - Self-Study Programme
http://vwts.ru/engine/bpy/bpy_10-00.pdf - Technical data
http://vwts.ru/engine/bpy/bpy_10.pdf - Engine, removing and installing
http://vwts.ru/engine/bpy/bpy_13.pdf - Engine, disassembling and assembling
http://vwts.ru/engine/bpy/bpy_15-1.pdf - Cylinder head
http://vwts.ru/engine/bpy/bpy_15-2.pdf - Valve train
http://vwts.ru/engine/bpy/bpy_17.pdf - Lubrication system components
http://vwts.ru/engine/bpy/bpy_19.pdf - Cooling system components
http://vwts.ru/engine/bpy/bpy_19-01.pdf - Cooling system components
http://vwts.ru/engine/bpy/bpy_20.pdf - Fuel tank, Fuel supply system, EPC
http://vwts.ru/engine/bpy/bpy_21.pdf - Turbocharger, Charge air system
http://vwts.ru/engine/bpy/bpy_24.pdf - Fuel injection system Motronic MED 9.1
http://vwts.ru/engine/bpy/bpy_26.pdf - Exhaust system components, removing and installing
http://vwts.ru/engine/bpy/bpy_28.pdf - Ignition, servicing
ENGINES - Volkswagen 3.2 VR6 engine BJS - R32:
http://vwts.ru/electro/g5/g5_r32_bjs_wd.zip - Electrical Diagrams
TRANSMISSIONS:
http://vwts.ru/vw_doc2/trans/02e/at_02e_dsg_repair.pdf - 02E 6-speed Direct-Shift Gearbox (full service manual)
SUSPENSION:
http://vwts.ru/suspension/g5/g5_40-2.pdf - Front suspension, servicing
http://vwts.ru/suspension/g5/g5_40-3.pdf - Front axle, tightening torques
http://vwts.ru/suspension/g5/g5_40-4.pdf - Subframe, stabilizer bar, control arms
http://vwts.ru/suspension/g5/g5_40-5.pdf - Wheel bearing, assembly overview
http://vwts.ru/suspension/g5/g5_40-6.pdf - Suspension, assembly overview
http://vwts.ru/suspension/g5/g5_40-7.pdf - Drive axle, servicing
http://vwts.ru/suspension/g5/g5_42-02.pdf - Rear suspension, servicing
http://vwts.ru/suspension/g5/g5_42-03.pdf - Rear axle, tightening torques
http://vwts.ru/suspension/g5/g5_42-04.pdf - Subframe, transverse link, tie rod, assembly overview
http://vwts.ru/suspension/g5/g5_42-05.pdf - Wheel bearing housing, trailing link
http://vwts.ru/suspension/g5/g5_42-06.pdf - Shock absorber, coil spring
http://vwts.ru/suspension/g5/g5_42-07.pdf - Stabilizer bar, assembly overview
BRAKES:
http://vwts.ru/brake/g5/g5_45.pdf - Electrical/electronic components and installation locations, Malfunction displayed by warning lamps for level control system, Hydraulic unit, brake booster/brake master cylinder, ABS system components on front and rear axles removing and installing, ESP system components removing and installing
http://vwts.ru/brake/g5/g5_46-01.pdf - Front brakes, servicing
http://vwts.ru/brake/g5/g5_46-02.pdf - Rear wheel brakes, servicing
http://vwts.ru/brake/g5/g5_46-03.pdf - Parking brake lever
http://vwts.ru/brake/g5/g5_46-04.pdf - Brake pedal, assembly overview
http://vwts.ru/brake/g5/g5_47_eng.pdf - Front brake caliper servicing, Rear brake caliper servicing, Bleeding braking system, Brake booster/brake master cylinder assembly overview, Brake master cylinder removing and installing, Brake booster, removing and installing, Brake line repairs
STEERING:
http://vwts.ru/steering/g5/g5_48-02.pdf - General repair notes
http://vwts.ru/steering/g5/g5_48-03.pdf - Steering, torque specifications
http://vwts.ru/steering/g5/g5_48-04.pdf - Steering column, assembly overview
http://vwts.ru/steering/g5/g5_48-05.pdf - Electro-mechanical steering gear, assembly overview
http://vwts.ru/steering/g5/g5_48-06.pdf - Steering gear difference (Generation I and II)
http://vwts.ru/steering/g5/g5_48-07.pdf - Electromechanical steering gear, servicing (Generation I)
http://vwts.ru/steering/g5/g5_48-08.pdf - Electro-mechanical steering gear, servicing (Generation II)
BODY:
http://vwts.ru/body/g5/g5_50-01.pdf - Lock carrier (bonnet slam panel)
http://vwts.ru/body/g5/g5_50-02.pdf - Front wings
http://vwts.ru/body/g5/g5_50-03.pdf - Engine undertray
http://vwts.ru/body/g5/g5_50-04.pdf - Underbody trim
http://vwts.ru/body/g5/g5_50-05.pdf - Plenum chamber bulkhead
http://vwts.ru/body/g5/g5_55-01.pdf - Front hood (bonnet)
http://vwts.ru/body/g5/g5_55-02.pdf - Hatchback
http://vwts.ru/body/g5/g5_55-03.pdf - Fuel filler flap unit
http://vwts.ru/body/g5/g5_57-01.pdf - Front door
http://vwts.ru/body/g5/g5_57-02.pdf - Central locking system
http://vwts.ru/body/g5/g5_58-01.pdf - Rear door
http://vwts.ru/body/g5/g5_60-01.pdf - Sunroof with glass panel (Meritor)
http://vwts.ru/body/g5/g5_63-01.pdf - Front bumper
http://vwts.ru/body/g5/g5_63-02.pdf - Front bumper (GTI)
http://vwts.ru/body/g5/g5_63-03.pdf - Rear bumper
http://vwts.ru/body/g5/g5_64-01.pdf - Flush bonded windows
http://vwts.ru/body/g5/g5_64-02.pdf - Front door window
http://vwts.ru/body/g5/g5_64-03.pdf - Rear door window
http://vwts.ru/body/g5/g5_66-01.pdf - Wheel arch liners
http://vwts.ru/body/g5/g5_66-02.pdf - Exterior rear view mirror
http://vwts.ru/body/g5/g5_66-03.pdf - Radiator grille
http://vwts.ru/body/g5/g5_66-04.pdf - Strips and trim
http://vwts.ru/body/g5/g5_66-05.pdf - Rear roof edge spoiler (tailgate)
http://vwts.ru/body/g5/g5_68_eng.pdf - Interior rearview mirror, Storage compartments, covers and trim, Sill panel trim, Grab handles
http://vwts.ru/electro/g5/g5_69_eng.pdf - Seat belts, Seat belts, inspecting, Airbag, airbag module removing and installing, Crash sensors
http://vwts.ru/electro/g5/g5_70.pdf - Instrument panel, Door trim, Pillar and side trim, Rear lid trim, Luggage compartment trim, Roof trim
http://vwts.ru/body/g5/g5_72_eng.pdf - Front seats, Rear seats
http://vwts.ru/body/g5/g5_74_eng.pdf - Front seat covers and padding, Cover and upholstery for rear seats
ELECTRICAL:
http://vwts.ru/electro/g5/g5_fuse_relays.pdf - Golf5 Relay and fuse arrangements, from October 2005
http://vwts.ru/electro/g5/g5_gti_relay.zip - GTI Relay and fuse arrangements, from October 2005
http://vwts.ru/electro/g5/g5_gti_component.zip - GTI Component locations
http://vwts.ru/electro/g5/g5_gti_ground.zip - GTI Ground connection
http://vwts.ru/electro/g5/g5_90_eng.pdf - Instrument Cluster
http://vwts.ru/electro/g5/g5_91_eng.pdf - In Car Entertainment (Radios, Navigation system, Amplifier, CD Changer, iPod System, Speakers, Antennas, Multi-Function Steering Wheel, Mobile phone kit
http://vwts.ru/body/g5/g5_92_eng.pdf - Front and Rear Wipers
http://vwts.ru/electro/g5/g5_94_eng.pdf - Exterior Lighting systems (all components, including High Intensity Gas Discharge (HID) Lamps, High-Mount Brake Light, Steering Column Switches, Ignition/Starter Switch and Lock Cylinder)
http://vwts.ru/electro/g5/g5_96_eng.pdf - Interior Lighting systems (all components), Horns, Anti-Theft Immobilizer, Anti-theft Alarm System
http://vwts.ru/electro/g5/g5_97_eng.pdf - Fuse Panel, Relay Panels, Electronics Boxes (E-Boxes), Control Modules, Wiring Harness and Connectors, repairing
Rgds, and n-joy.
Oh - if, for whatever reasons, the above links don't work, below are a couple of 'portal' links:
http://vwts.ru/index.php?p=vw_golf5_1k - Volkswagen Golf 5 / Jetta 5 / Bora / GTI / R32 / Rabbit Mk5 (1K) 2004 - 2009
and
http://vwts.ru/index.php?p=pl_a5 - this is a portal for all
A5 (PQ35) platform cars:
Audis: A3 (8P), TT (8J), Q3;
VWs: Eos (1F), Scirocco (13), Tiguan (5N), Touran (1T), Caddy (2K), Golf6 (5K);
SEATs: Leon Mk2 (1P), Toledo Mk3 (5P), Altea (5P);
Škodas: Octavia 2 (1Z), Yeti (5L)
