Volkswagen Golf IV and Bora 1.6 Petrol — Electrical and Mechanical Schema 1999

Auto-Volt schema card N°757 (June 1999) covering the Volkswagen Golf IV (4th generation, launched January 1998) and Bora (launched October 1998) with the 1.6L petrol engines AEH and AKL (4 cylinders in line, 1595 cm³, 81×77.4 mm, 74 kW/101 hp at 5600 rpm, 14.5 daN.m torque at 3800 rpm), aluminium cylinder block and head, A-platform shared with Audi A3, Seat Toledo, Skoda Octavia and Volkswagen Beetle. Includes full mechanical documentation (single overhead camshaft with toothed belt replaced every 90,000 km and semi-automatic tensioner, pressure lubrication with gear pump and oil/water heat exchanger, cooling with thermostat opening at 87–102°C, two-speed electric fan controlled by staged thermocontact at 92–97°C and 99–105°C, 55-litre petrol tank), complete engine management documentation (Siemens Simos 2 system with 80-pin ECU in 2 connectors placed at the centre of the scuttle compartment, sequential phased multipoint injection, variable-volume intake manifold controlled by pneumatic capsule and solenoid valve switching at 4000 rpm, throttle body with integrated potentiometer, idle speed micro-motor regulator and coolant heating, hot-film mass airflow sensor with integrated air temperature sensor, Hall-effect camshaft position sensor, inductive crankshaft speed sensor on 120-tooth ring, piezoelectric knock sensor, heated lambda sensor, coolant and air temperature CTN sensors, jumostatique lost-spark ignition with dual coil module and 4 HT outputs, NGK BKUR 6 ET 10 spark plugs at 0.9–1.1 mm, canister solenoid valve), complete automatic transmission documentation (4-speed 01M gearbox with 68-pin ECU, hydraulic block type QEB with 7 solenoid valves, torque converter with lock-up clutch type QADC, fuzzy logic DSP sport/economy gear selection, kickdown, CAN bus communication with engine and ABS ECUs), complete ABS documentation (ITT Mark 20 IE, 4 channels, 8 solenoid valves plus 2 for optional EDS electronic differential lock, EBV brake pressure distribution function, ventilated front discs 256 mm, solid rear discs 232 mm), complete electrical documentation (Bosch alternators 40/70A, 50/90A or 70/120A, Bosch starters type DBL/DWL 12V, 44Ah/220A battery, Golf H7/H1 or Bora H4 headlights, LED third brake light — 32 diodes on Golf, 18 on Bora), 12 wiring diagrams covering Simos 2 engine management, automatic transmission management, ABS with EDS, ignition and charge circuits, lighting, signalling, wipers, interior lighting, heating and ventilation, fuse and relay tables for three fuse boxes (cabin with 44 fuses, engine compartment with 8 fuses, and relay board with 13-relay and 6-relay panels), and a Volkswagen Golf IV 1595 cm³ repair time schedule.