Service

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Workshop Manual
Golf 2004 ➤ Golf Plus 2005 ➤
Engine ID

4-cylinder diesel engine (1.9 l engine)
BJB BKC BRU BLS BXE BXF BXJ Edition 01.2009
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Service Department. Technical Information

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List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups
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Repair Group
00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling
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21 - Turbocharging/supercharging
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26 - Exhaust system

28 - Glow plug system

Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2010 Volkswagen AG, Wolfsburg K0059000420

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23 - Mixture preparation - injection

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20 - Fuel supply system
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Service

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Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1.1 1.2 1 1.1 1.2 1.3 1.4 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 4 4.1 4.2 4.3 4.4 4.5 1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.4 2.5 1 1.1 1.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - sealingn flangesswagen AG . Volk and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ge AG d Renewing crankshaftooilwa - pulley end . . .o.es no.t g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . lks seal yV u b Removing and iinstalling sealing flange - pulley end . a.ra.nt. . . . . . . . . . . . . . . . . . . . . . . . . . . ed rs e ho t Renewing crankshaft sealing flange - flywheel end . . . . .e or . . . . . . . . . . . . . . . . . . . . . . . . .a au c s Removingsand installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1 1 1

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
2 2 7 7 10 12 12 13 15 19 20 20 21 23 25 31 33 33 38 39 39 40 41 42 42 44 45 48 50 67 71 74 74 76 78 80 84 86 86 86

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents

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Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 2 2.1 2.2 3 3.1 3.2 3.3 3.4 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1 2 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1 4.2 4.3 4.4 4.5 4.6 5 5.1 5.2 5.3 5.4 5.5 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

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Parts of lubrication system . . . . . . . . . . . . Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter bracket, oil pressure, engine oil cooler and oil supply line . . . . . . . . . . . . . . . . . . Assembly overview - oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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87 88 92 92 93 94 95

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
97 98 99 101 102 105 106 108 110 112 114 115 116 116 117 121 123 124 125 127 127 128 132 135 137 138 140 140 141 142 143 147 151 151 151 152 156 158 161 162 164

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel tank, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

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Contents

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. . . . .2 1. . . . . . . . . . . . . . . . . . in part or in wh ole. . . . . . .2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine control unit . . . . . . . . . . . . . . . .1 2. .9 l engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1. . . . . Prote cted by c o py rig ht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading and erasing engine control unit fault memory . . . . . . . . . . . Golf . . . . Cleaning the intake manifold flap support. . . . . . . . cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng 23 . . . . . . . . . . . . . . . . . . .4 1. . . . . . Safety precautions . . . . . . . .1 1. . . . . . . . . . . . . 198 ht rig py Co t. . . . . . . . . . .Glow plug system . . . . . . .5 2. . . . . . . . .8 1. . . . . .4 1. . . . Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing. . . . .3 2. . .2009 db ran e tee ris ho t or ac au ss 166 166 167 167 169 171 172 174 176 177 178 178 179 180 180 183 183 186 186 187 189 191 192 193 193 198 198 199 200 26 . . . . . . . . . . . . . . . . Adjusting non-contact gap of unit injectors . . . . . . . . . . . . . . . . . .front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . .3 1. . . . . . . . . . . . rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en urposes. . . . . . . . . . . . . Contents iii . . . . . . . . . . . . . .parts of exhaust gas recirculation . . . . . . . . . . . . Engine code BLS and BXJ . . .5 1. . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 2.9 2 2. . . . . . .1 1. . Removing and installing unit injector . . . . . . . . . .Mixture preparation . . . . . . . . . . . . . . . . . . . . . .7 1. Assembly overview . . . . . . . . . . . . . . Removing and installing engine control unit.2 1. . . . Golf . . . . . . . . . . . . . . . . . . . . . Assembly overview . . agen lksw Vo by AG. . . . . . . Removing and installing anti-theft engine control unit. . . . Adapting functions and components . . . . . . . . . . Volkswagen AG do es n Golf 2004 ➤ . Removing and installing anti-theft engine control unit. . Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aligning exhaust system free of stress . . . . . . . . . . . Removing and installing O-rings for unit injector . . . . . . . . . . . . . . .front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . . . . .3 Diesel direct injection system . . Assembly overview . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . Characteristics of ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . 166 ility ab y li an pt ce n AG. . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . Checking glow plug system .6 1 1. . . . installing and checking glow plugs . . . . . . . . . . . . . . . . . .air filter . . . . . Co py i 28 . .1 1. . . . . . . . . . . . . . . . . Removing. . . . . . . . . . . Golf Plus . . . . . . . . . . . . . .intake manifold . . . . . . . . . . . .Exhaust system . . . . . . .1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . installing and checking ceramic glow plugs . . . Golf Plus 2005 ➤ wage o g olks yV ua 4-cylinder diesel enginet (1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .silencer with mountings (vehicles with front wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .unit injector . . . . . . . . Assembly overview . . . . . . . . . . . . . . .3 1. . . . . . . .6 1. . . . . . . . . . Assembly overview . . . . . . . . .Edition 01. . . . . . . . .injection . . . . . . . . . . . .5 2 2. . . . . . .silencer with mountings (vehicles with four-wheel drive) . . . . . . . . . . . . . . Removing and installing engine control unit. . . . . . . . . . . . . . . . . . . . . . .

9 l engine) .2009 urposes. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n AG.Golf 2004 ➤ . agen lksw Vo by AG.C op yi . Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his do cu m en iv Contents ht rig py Co t. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. in part or in wh ole. Prote cted by c op yri gh t .Edition 01.

5 79.06 11.5 2 2 2 19.5 2 19.5 95.9 77/ 4000 250/ 1900 79.Golf 2004 ➤ .5 DIN EN 590 1-3-4-2 yes yes yes yes no 03.5 2 2 19. Technical data 1 .5 95.5 2 18.9 66/ 66/ 4000 4000 210/ 210/ 1800 1800.9 l engine) . Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or BJB BKC BRU BLS th orBXE ac au ss BXF BXJ l kW at rpm Nm at rpm 10.9 1.9 77/ 66/ 77/ 4000 4000 4000 250/ 210/ 250/ 1900 1800..5 95. AG.9 77/ 4000 250/ 1900 79. 1.5 95.03 ▸ EU3 standard 1. The engine code is also included on the vehicle data sticker. Prote cted by cop yri gh t .1 Engine number The engine number (“code letters” and “serial number”) can be found at the joint between engine and gearbox.0 19.9 1.0 DIN EN 590 1-3-4-2 yes yes yes yes no yes yes no yes yes no yes agen lksw Vo by yes yes ht rig py Co t.03 ▸ 04.2009 00 – 1 Technical data Technical data Engine number ⇒ page 1 Engine data ⇒ page 1 1.0 DIN EN DIN EN 590 590 1-3-4-2 1-3-4-2 yes yes yes yes yes yes no yes yes no ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en 1...Edition 01. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 1.06 EU4 standard 1..5 95.07 EU4 EU4 standard standard 1.06 ▸ EU4 EU4 EU4 standard standard standard 1.250 1900 0 79.0 18.04 ▸ 02.C op yi Bore ∅ mm Stroke mm Valves per cylinder Compression ratio Fuel accord‐ ing to Firing order Catalytic converter Exhaust gas recircu‐ lation Turbocharging/super‐ charging Charge air cooler Particulate filter r fo ng 10.250 0 79.5 79. in part or in w l purpos hole ercia . Additionally there is a sticker on the toothed belt guard with “en‐ gine code” and “serial number”.5 DIN EN DIN EN DIN EN 590 590 590 1-3-4-2 1-3-4-2 1-3-4-2 yes yes yes yes yes yes 03. is n mm ot p co erm or te itte va ri d p Manufactured Emissions fulfil Capacity Output Torque n AG.5 95.0 19.5 79.5 95.2 Engine data un le Engine code es.

Prote cted by c o py rig ht.9 l engine) . cial p is n mer ot com pe rm itte d rrectness of i t to the co nform spec a tion h re wit in t his or ate riv p or gf n do cu m en 2 Rep.A.G 1306- n AG. Assembly mountings ⇒ page 10 .Golf 2004 ➤ .Removing and installing engine ht rig py Co t. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce urposes. agen lksw Vo by AG.G 1202 A♦ Drip tray -V.A.1 Removing engine Special tools and workshop equipment required ♦ Lifting tackle -2024 A♦ Engine bracket -T10012♦ Support clamp -VW 313♦ Engine and gearbox sup‐ port -VW 540un le ♦ Workshop crane -V.10 . 1. Co py i . in part or in wh ole. Gr.Edition 01.2009 10 – 1 Removing and installing engine Removing and installing engine Removing engine ⇒ page 2 Securing engine to assembly stand ⇒ page 7 Notes on installing ⇒ page 7 .

Prote cted by cop yri gh t . disconnect battery earth strap. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit Note ♦ Before carrying out further work.C op yi removed must be replaced in the same position when engine is installed. First check whether a coded radio is fitted.Golf 2004 ➤ .9 l engine) . in part or in wh ole. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. ♦ All cable ties which are opened or cut through when engine is ht rig py Co t. Obtain antitheft coding first if necessary. ♦ The engine is removed downwards together with the gearbox.2009 ♦ Torque wrench -V.G 1383 A♦ Spring-type clip pliers -VAS 5024♦ Stepladder -VAS 5085♦ Guide rods -T10093♦ Cable ties urposes.A.A.Edition 01.G 1332♦ Engine and gearbox jack V.G 1331♦ Torque wrench -V. Removing and installing engine 3 . 1.A. agen lksw Vo by thi sd oc um en AG.

disconnect earth strap from battery. then pull inner engine coverkswa abruptly up‐ not Vol gu by ara wards at -arrows-. 50 . Procedure – With ignition switched off.front. pull engine cover abruptly upwards at front and right -arrows A-.th⇒ General body repairs. especially in the engine compart‐ ment. ♦ Ensure that there is sufficient clearance to all moving or hot components. coolant. hydraulics. brake fluid and vacuum) and electrical wiring in their original po‐ sitions. – Remove air filter housing with air mass meter and connecting pipe. in part or in w l purpos hole ercia .C op yi . Two-piece engine cover For two-piece engine cover. is n mm ot p co erm or te itte va ri d p is or nte eo ra c ility ab y li an pt ce un le rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng 4 Rep.10 .Removing and installing engine ht rig py Co t.2009 WARNING When doing any repair work. agen lksw Vo by AG. Rep. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. pay attention to the following due to the cramped condi‐ tions: ♦ Route all the various lines (e.g. Volkswagen AG d abruptly gen oes upwards at -arrows-.Golf 2004 ➤ . es.Edition 01. refrigerant. Body . for fuel. au ss exterior. One-piece engine cover For one-piece engine cover. Gr. first pull outer engine cover AG. then pull forwards out of rear fas‐ tening -arrow B-. acti‐ vated charcoal filter system. Prote cted by c op yri gh t .9 l engine) . d e – Remove plenum chamber bulkhead. plenum chamber bulk‐ head . Gr.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Remove bolt -arrow A- and pull air filter housing upwards out of mounting. – Remove battery and battery tray. – Disconnect fuel supply and return lines as well as coolant line on cylinder head. WARNING

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– Remove insulation tray ⇒ General body repairs, exterior; Rep. Gr. 50 ; Body - front; Assembly overview

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– Bring lock carrier into service position ⇒ General body repairs, exterior; Rep. Gr. 50 ; Body - front; Lock carrier - service po‐ sition . – Drain coolant ⇒ page 102 . Vehicles with air conditioner Note

To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
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– Remove poly V-belt ⇒ page 13 .
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– Remove air conditioner compressor ⇒ Heating, air condition‐ ing; Rep. Gr. 87 ; Removing and installing compressor brack‐ et . – Secure air conditioner compressor to lock carrier so that re‐ frigerant lines are free of stress. – Remove alternator ⇒ Electrical system; Rep. Gr. 27 ; Re‐ moving and installing alternator and poly V-belt . Continuation for all vehicles – Remove connecting pipes between charge air cooler and en‐ gine. – Unbolt left and right-hand drive shafts from gearbox ⇒ Run‐ ning gear, axles, steering; Rep. Gr. 40 ; Removing and installing drive shaft . – Remove front exhaust pipe ⇒ page 186 . – Release connectors on engine control unit and pull them off.
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Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Open all cable guide fasteners -arrows-. –
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– Pull off or disconnect all other electrical connections from en‐ gine and gearbox as necessary and lay to side. – Separate all connecting, coolant, vacuum and intake hoses from engine. Vehicles with manual gearbox – Remove slave cylinder for hydraulic clutch. ⇒ 6-speed manual gearbox 02S; Rep. Gr. 30 ; Repairing clutch mechanism; As‐ sembly overview - hydraulics . – Unbolt gear selector mechanism from gearbox. ⇒ 6-speed manual gearbox 02S; Rep. Gr. 34 ; Repairing selector mech‐ anism . Vehicles with four-wheel drive: – Remove selector mechanism from gearbox ⇒ 6-speed man‐ ual gearbox 02Q, four-wheel drive; Rep. Gr. 34 ; Repairing selector mechanism . – Separate pressure line for hydraulic clutch control. – Remove front propshaft ⇒ Final drive 02D, 0AV; Rep. Gr. 39 ; Assembly overview - repairing propshaft .
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Continuation for all vehicles: – Unbolt pendulum support -arrows-. Vehicles with particulate filter

– Remove subframe ⇒ Running gear, axles, steering; Rep. Gr. 40 ; Removing and installing subframe . – Remove right drive shaft ⇒ Running gear, axles, steering; Rep. Gr. 40 ; Removing and installing drive shafts . – Remove steering box ⇒ Running gear, axles, steering; Rep. Gr. 48 ; Removing and installing steering box . Continuation for all vehicles: – Insert engine bracket -T10012- in engine and gearbox jack V.A.G 1383 A- . Note

Support pins must be secured to engine bracket -T10012- as shown.
– Fit engine bracket -T10012- to cylinder block with M10 x 25/ 8.8 bolt and tighten to approx. 40 Nm. – Raise engine and gearbox slightly using engine and gearbox jack -V.A.G 1383 A- .

6

Rep. Gr.10 - Removing and installing engine

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Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Unbolt assembly mounting on engine side from engine bracket -arrows-. Note
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Engine with gearbox must be guided carefully when lowered to prevent damage to bodywork.

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– Disconnect gearbox.

– Attach lifting tackle -2024 A- as shown and raise engine out of engine and gearbox jack -V.A.G 1383 A- using workshop hoist -V.A.G 1202 A- . Pulley end: 2nd hole in hook rail at position 1 Flywheel end: 4th hole in hook at position 8 WARNING

The hooks and locating pins must be secured with locking pins.

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♦ The holes in the hook rails are counted up from the hook. – Secure engine on support clamp -VW 313- using engine and gearbox jack -VW 540- .

1.3

Notes on installing

Installation is carried out in the reverse order. When installing, note the following:

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Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Check clutch release bearing for wear and renew if necessary. – Lubricate splines of input shaft lightly with G 000 100. – Check whether dowel sleeves for centring engine and gearbox are in cylinder block and install if necessary. When installing engine, ensure correct position of assembly mountings: – On belt pulley side, ensure that there is a distance -a- of at least 10 mm between engine support and right longitudinal member. – The side surface of the engine support -2- should be located parallel to the support arm -1-. Dimension -x- must be identical at top and bottom. Note

Distance -a- = 10 mm can also be checked with a metal rod of suitable size, or similar.
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exterior. Rep. – Install engine control unit ⇒ page 178 . Body . – Install insulation tray ⇒ General body repairs. 34 . Gr. – On vehicles with particulate filter install subframe ⇒ Running gear. – Install air conditioner compressor ⇒ Heating. nte i 40 . 40 c op yri gh t . – Fill cooling system with coolant ⇒ page 102 . Rep.2009 – Ensure that the edges of the support arm on the gearbox as‐ sembly mounting -2. Gr. Removing and installing compressor bracket.C op yi 9 . Repairing clutch mechanism. Gr. Note ♦ Torque specifications for assembly mounting ⇒ page 10 . Rep. Plenum chamber bulk‐ head .s o eo th u ra a c ss . – – urposes. four-wheel drive. Removing and installing alternator and poly V. in part or in wh ole. Assembly overview.repairing propshaft . Gr.must be identical at top and bottom. Removing and installing drive shafts r. Install front exhaust pipe ⇒ page 186 ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his do cu m en – Install poly V-belt ⇒ page 13 . Rep. 30 .front. – Install plenum chamber bulkhead ⇒ General body repairs. Gr. 50 . – Install front propshaft ⇒ Final drive 02D. Rep. Dimension -x. ed steering. Prote cted by 1. Gr. Repairing selector mecha‐ nism . Rep. axles. steering. – Remove selector mechanism from gearbox ⇒ 6-speed man‐ ual gearbox 02S. axles. ♦ Electrical connections and routing. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Gr.belt . Assembly overview . 97 – Install pendulum support. – Carry out road test and then read fault memory ⇒ page 178 .Golf 2004 ➤ . air conditioning. agen lksw Vo by – Install alternator ⇒ Electrical system.9 l engine) . – Install pressure line for hydraulic clutch control. cial p is n mer ot com – Install slave cylinder for hydraulic clutch ⇒ 6-speed manual gearbox 02S. Rep. Gr. exterior. Rep.hydraulics . Removing and installing engine ht rig py Co t. 0AV. Continuation for all vehicles: or ate riv p or gf n pe rm itte d Vehicles with manual gearbox un le AG. 50 . 87 . Body . Rep. Vehicles with four-wheel drive: – Install selector mechanism on gearbox ⇒ 6-speed manual gearbox 02Q. 39 . Repairing se‐ lector mechanism .Edition 01. ⇒ Electrical system.are parallel. Volkswagen AG d agen oes not lksw Vo gu by ara Install drive shafts ⇒ Running gear. Rep. Gr. Rep. Gr. AG.and gearbox support -1. As‐ sembly overview . Gr.front. 27 . 34 .

Golf 2004 ➤ .9 l engine) . nuts M6 M8 M10 M12 Specified torque 10 Nm 20 Nm 45 Nm 60 Nm 1.10 . Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his or ate riv p or gf n do cu m en 10 Rep. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.2009 Specified torques Threaded connection Bolts. Gr.4 Assembly mountings Engine assembly mounting A = 20 Nm + 90° (1/4 turn) further 1) B = 40 Nm + 90° (1/4 turn) further 1) C = 60 Nm + 90° (1/4 turn) further 1) 1) Renew urposes.C op yi . in part or in wh ole. cial p is n mer ot com B = 60 Nm + 90° (1/4 turn) further 1) 1) pe rm itte d A = 40 Nm + 90° (1/4 turn) further 1) Renew un le Gearbox assembly mounting AG. Prote cted by c op yri gh t .Edition 01. agen lksw Vo by AG.Removing and installing engine ht rig py Co t.

Removing and installing engine 11 .5 x 70 100 Nm + turn 90° further Tighten only if pendulum support is bolted to gearbox Always renew after removing rrectness of i t to the co nform spec at ion h re wit in t his do cu m en ht rig py Co t.9 must be used.9: turn 50 Nm + 90° further Always renew after removing Bolt -ByV db d M10 x 75 strength class 8. Co py i 1.8:oturnag Nm + 90° furtheroes not lksw 40 olkswagen AG en AG. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.2009 Pendulum support Always note the size and strength class of bolt. Bolt -AM10 x 35 strength class 8. Different specified torques are valid. use bolts with strength class 8.8 and the specified torques. Caution From model year 08. V M10 x 75 strength class 10. in manual gearboxes 02Q Heli Coil in‐ serts are installed in the threaded connections to pendulum support.Golf 2004 ➤ .9: turn 50 Nm + 90° further ise or Bolt -Curposes.9 l engine) . agen lksw Vo by AG. in part or in wh ole. Prote cted by c op yri gh t. 34 For these and all other gearboxes bolts with strength class 10. Gr. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n a Always renew after removing ss h ut gu ara nte eo ra c ility ab y li an pt ce M14 x 1.Edition 01.8: turn 40 Nm + 90° further M10 x 35 strength class 10. Difference ⇒ Rep. If Heli Coil inserts are not fitted in manual gearboxes 02Q.

Edition 01.crankcase ⇒ page 19 Note n AG.25 Nm 9 .poly V-belt drive 1 .2009 13 – 1 Crankshaft group Dismantling and assembling engine Assembly overview . agen lksw Vo by AG.1 Assembly overview .C op yi .Crankshaft group ht rig py Co t.Dowel sleeves 10 . Gr.Poly V-belt ❑ Mark direction of rota‐ tion before removing.Alternator 4 . thi sd oc um en 12 Rep. by partial seizure of the crankshaft or conrod bearings) are found in the engine oil when making repairs.25 Nm 7 . clean the oil passages thoroughly and renew the engine oil cooler in order to prevent further damage from occurring later.Bracket ❑ For alternator and air conditioner compressor. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng rrectness of i t to the co nf orm spec atio h re n in wit 1. for example.Belt pulley and vibration damper ❑ Can only be installed in one position. Prote cted by cop yri gh t .poly V-belt drive ⇒ page 12 Removing and installing poly V-belt ⇒ page 13 Assembly overview . ❑ Check for wear. 6 . holes are offset. 5 .Air conditioner compressor 8 .toothed belt drive ⇒ page 15 Assembly overview . ❑ Removing and installing ⇒ page 13 . ❑ Do not kink.Poly V-belt tensioning ele‐ ment ❑ Swing with ring spanner to slacken poly V-belt.Golf 2004 ➤ . Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce If large quantities of metal particles or other deposits (caused. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.25 Nm 3 . 2 .13 . urposes.9 l engine) . in part or in wh ole.

Golf 2004 ➤ . Dismantling and assembling engine ht rig py Co t. The open-end spanner 16 mm -T 10241. exterior.is particularly well suited to relieve tension.front. in part or in wh ole. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his – Swing tensioning element in direction of arrow to remove ten‐ sion from poly V-belt. Gr. Body . 50 .C op yi 13 . – Pull fuel filter out of bracket and lay it with hoses to side.2 Removing and installing poly V-belt Special tools and workshop equipment required ♦ Locking pin -T10060 A- ♦ 16 mm open-end spanner -T 10241- 1.Edition 01. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.2009 1. Rep. agen lksw Vo by AG.1 Removing poly V-belt pe rm itte d – Remove insulation tray. un le AG. Prote cted by c op yri gh t . ⇒ General body repairs. urposes.9 l engine) . or ate riv p or gf n do cu m en 1. Assembly overview .2. cial p is n mer ot com – Mark direction of rotation of poly V-belt.

13 .C op yi .Edition 01. agen lksw Vo by AG. Belt drive without air conditioner compressor AG.. After completing repairs always: – Start engine and check belt running. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng rrectness of i t to the co nf orm spec atio h re n in wit Belt drive with air conditioner compressor thi sd oc um en 14 Rep. ensure proper seating of belt in pulleys. check direction of belt rotation and ♦ Lastly. – Remove poly V-belt.2 Installing poly V-belt – Installation is carried out in the reverse sequence of removal. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) . place poly V-belt over alternator.Crankshaft group ht rig py Co t. in part or in wh ole. ♦ When fitting poly V-belt. air conditioner compressor) are secured tightly. Note ♦ Before installing poly V-belt.2.2009 – Lock tensioning element in position with locking pin -T10060 A. 1.Golf 2004 ➤ . Prote cted by c op yri gh t . Gr. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce urposes. ensure that all ancillaries (alter‐ nator.

pe rm itte d un le rrectness of i t to the co nform spec a tion h re wit in t his 11 .2009 1.Camshaft pulley 5 .Coolant pump ❑ Removing and installing ⇒ page 106 . removing and installing camshaft. 21 .yuse ua db ran T10052-e s tee ri ho t or ❑ Removing and installing ac au s ⇒ spage 80 .Rear toothed belt guard 9 . holes are offset.Edition 01. cial p is n mer ot com ility ab y li an pt ce 6 .9 l engine) .to loosen and tighten.25 Nm 4 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.10 Nm ❑ Renew 7 . Volkswagen AG do es n wage ot g olkspuller V ❑ To remove.toothed belt drive 1 . urposes.Sealing grommet ❑ Renew if damaged.Golf 2004 ➤ .20 Nm + 1/8 turn (45°) fur‐ ther or ate riv p or gf n 12 .3 Assembly overview . Dismantling and assembling engine agen lksw Vo by c op yri gh t. Turning further can be done in several stages.to loosen and tighten.25 Nm 10 . do cu m en 15 .Crankshaft toothed belt pulley 17 . 14 .120 Nm + 1/4 turn (90°) further ❑ ❑ ❑ ❑ AG. 16 .Stud ❑ 15 Nm 8 .Toothed belt guard lower part 20 .Tensioning roller ❑ Remove engine support in order to remove and install ⇒ page 16 .100 Nm 3 .20 Nm 15 .15 Nm 19 .Hub ❑ With sender wheel ❑ Use counterhold tool T10051.Belt pulley and vibration damper ❑ Can only be installed in one position. Co py i 13 . in part or in wh ole. 18 .Idler roller ht rig py Co t.10 Nm + 1/4 turn (90°) further ❑ Renew 1. Prote cted by Renew Use counterhold tool -3099.Toothed belt guard upper part 2 . n AG. Do not additionally oil or grease thread and shoulder.

3.2009 22 . Gr. urposes.C op yi do cu m en 16 Rep. installing and tensioning ⇒ page 50 .40 Nm + 1/2 turn (180°) further ❑ Renew 25 .Toothed belt ❑ Mark direction of rotation before removing.Edition 01.Cover 23 .A.Golf 2004 ➤ .Engine bracket 1. . ❑ Do not kink.and then pull forwards out of rear fastening -arrow B-. 24 .auth – Remove engine cover. cial p is n mer ot com pe rm itte d – To do this. Prote cted by cop yri gh t . Volkswagen AG doe n AG support wage olks is or ♦ Support bracket -10 .Crankshaft group agen lksw Vo by AG. in part or in wh ole.222 A. ❑ Removing.9 l engine) . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. ❑ Check for wear. un le ♦ Torque wrench -V.1 V by Special tools and workshop equipmentdrequired e Removing and installing engine. pull engine cover upwards abruptly at front and right -arrows A. ht rig py Co t.13 . first pull outer engine cover abruptly upwards at -arrows-.G 1331- ss s no t gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his Two-piece engine cover or ate riv p or gf n For two-piece engine cover.Toothed belt guard centre part 26 . then pull inner engine cover abruptly up‐ wards at -arrows-.

WARNING urposes. Assembly overview . cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng ♦ The assembly mounting may only be removed if the engine is supported with support bracket 10-222A! n AG. Note ♦ The engine support must only be loosened when the assembly mounting has been removed. – Disconnect coolant hose from top of expansion tank. exteri‐ or. Gr. agen lksw Vo by AG. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) . Body .noise insulation . Dismantling and assembling engine 17 . – Remove noise insulation tray ⇒ General body repairs. thi sd oc um en ht rig py Co t..with adapters -10-222A/ 13.and take up weight of engine in installation position. – Remove securing bolts from assembly mounting/engine sup‐ port -arrows. – Lay fuel filter with hoses to side. – Remove expansion tank and lay it to side.and remove complete assembly mounting. 50 . Rep. ♦ Ensure that no fuel escapes (use a cloth).Edition 01.C op yi 1. Golf Plus and Touran: – Fit engine support bracket -10-222A. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit When raising and lowering engine using support bracket -10-222A.front. – Remove charge air pipe between charge air cooler and turbo‐ charger. Golf. – Remove front right wheel housing liner.2009 – Separate push-on connectors of fuel lines -arrows-. Note ♦ Do this by pressing in catch of push-on connectors. Prote cted by cop yri gh t .Golf 2004 ➤ . ensure that no components or hoses are damaged or torn off. – Carefully cover or seal open ends. in part or in wh ole.

exterior.C op yi thi sd oc um en Before installing assembly mounting. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Prote cted by cop yri gh t . Body . Further assembly is basically the reverse of the dismantling se‐ quence. supply line black). tighten all engine support bolts to prescribed torque. or t au ss Lower engine with support bracket -10-222A. Assembly overview .Crankshaft group agen lksw Vo by AG.Edition 01.13 . raise or lower engine using support bracket -10 .. ♦ Do not interchange supply line and return line (return line blue or with blue marking.to 40 Nm + 1/2 turn (180 °) further. – Tighten bolts for engine support in the sequence shown -1…3. . Rep.by both upper d until ise bolts of engine support can be loosenedhand removed. V G do es n ot g ua ran tee or ac ility ab y li an pt ce can be loosened and removed. – Insert new bolts and tighten hand-tight.front. Gr. – Install noise insulation tray ⇒ General body repairs. Installing urposes.by bringing contact surfaces together using support bracket -10-222A. note the following: ♦ Ensure that fuel hose connections are tight. Specified torque: 60 Nm + 90° (1/4 turn) further. ♦ When installing charge air pipes.222 A. – Bolt engine assembly mounting to engine support -arrows. ensure that locking lugs en‐ gage correctly. In the process. To do this. – Install assembly mounting between engine and body. Gr. rrectness of i t to the co nf orm spec atio h re n in wit – Position engine support from above on cylinder block. Caution The tightening sequence and specified torques for the engine support securing bolts must always be followed.– – – Remove engine support upwards.noise insula‐ tion 18 Rep.. 50 . I : Engine support with less clearance to engine II: Engine support with greater clearance to engine Note ht rig py Co t. – Install wheel housing liner.2009olkswagen A AG.until lower bolt Golf 2004 ➤ . cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng agen ksw Vol Raise engine with support bracket -10-222A. renew securing bolts ⇒ page 10 . Otherwise the engine support can be stressed and it can break.9 l engine) . in part or in wh ole.

Rep. ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng 16 . 105 °C ❑ Opening lift at least 7 mm.Bracket ❑ For alternator. in part or in w l purpos hole ercia . Removing and installing compressor bracket .15 Nm + 1/4 turn (90°) fur‐ ther ❑ Renew ❑ First fit upper left and lower right bolts and then tighten all four bolts diagonally.Hexagon bolt ❑ Tightening sequence and torque specifications ⇒ Heating. ❑ Observe installation position ⇒ page 108 .Connection ❑ For thermostat.Oil filter bracket ❑ Dismantling and assem‐ bling ⇒ page 92 . removing and installing thermostat. Dismantling and assembling engine ht rig py Co t. 85 °C ❑ Ends at approx.4 Assembly overview . AG.Gasket ❑ Renew 3 . Gr.20 Nm 7 .Sump ❑ Clean sealing surface before fitting.9 l engine) . ❑ Install with silicone sealant -D 176 404 A2.Cylinder block ❑ Removing and installing sealing flange and fly‐ wheel ⇒ page 20 . Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss 11 .Edition 01.15 Nm 9 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. 4 .Poly V-belt tensioning element 14 . is n mm ot p co erm or te itte va ri d p 10 . 87 . ❑ Removing and installing crankshaft ⇒ page 33 ❑ Dismantling and assem‐ bling pistons and con‐ rods ⇒ page 33 2 ..crankcase 1 .2009 1.15 Nm 1. un le n AG. 5 . 8 .Thermostat ❑ Removing and installing ⇒ page 108 .Bracket 6 . agen lksw Vo by Prote cted by c o py rig ht. if air conditioner compressor is fitted 13 .25 Nm 15 . ❑ Check: Heat thermostat in water ❑ Opening begins at approx.O-ring ❑ Renew es. 12 . air conditioning.Golf 2004 ➤ . Co py i 19 .

Prote cted by cop yri gh t . Renewing crankshaft sealing flange .pulley end ⇒ page 21 .Cylinder block ❑ Removing and installing crankshaft ⇒ page 33 ❑ Dismantling and assem‐ bling pistons and con‐ rods ⇒ page 33 4 .pulley end ⇒ page 21 .2009 2 Removing and installing sealing flange and flywheel Assembly overview . in part or in wh ole. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his do cu m en 6 .Intermediate plate ❑ Must be positioned on dowel sleeves. ❑ Renewing crankshaft oil seal . ❑ Do not damage or bend when assembling. 2.Edition 01.sealing flanges and flywheel n AG.1 Note Assembly overview . Rep.Seal ❑ Do not additionally oil or grease the oil seal seal‐ ing lip. 20 Rep.13 . re‐ move oil residue from crankshaft journal using a clean cloth. ran ed is tee or th or ac au ss Repairing clutch ⇒ 6-speed manual gearbox 1 . Repairing clutch.C op yi . agen lksw Vo by AG. ❑ Before installing.Flywheel ❑ To remove and install flywheel.Sealing flange ❑ Must be positioned on dowel sleeves. counterhold with 3067. ility ab y li an pt ce urposes.pulley end ⇒ page 21 .flywheel end ⇒ page 25 . Gr. Removing and installing sealing flange . 3 .sealing flange and flywheel ⇒ page 20 Removing and installing engine speed sender ⇒ page 31 Renewing crankshaft oil seal . Gr.Crankshaft group ht rig py Co t.Golf 2004 ➤ . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. 2 .by30 . Volkswagen AG do es n wage ot g olks V ua 02S.60 Nm + 1/4 turn (90°) fur‐ ther ❑ Renew 5 . ❑ Install with silicone seal‐ ant -D 176 404 A2⇒ page 23 . ❑ Removing and installing ⇒ page 23 .9 l engine) .

2 Renewing crankshaft oil seal .Golf 2004 ➤ .Sealing flange with oil seal ❑ Renew complete with oil seal and sender wheel only.G 1331♦ Torque wrench V.2009 7 . ❑ Loosen and tighten using commercially available ball-ended hexagon key socket ❑ Specified torque: 5 Nm. cial p is n mer ot com pe rm itte d un le n AG.G 1332- urposes. 2. do cu m en agen lksw Vo by AG.1 Removing or ate riv p or gf n – Remove toothed belt.Edition 01. in part or in wh ole.9 l engine) . 9 . Removing and installing sealing flange and flywheel 21 . ❑ Removing and installing ⇒ page 25 . ⇒ page 50 ht rig py Co t.A.A.Removing and installing engine speed sender -G28. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Co py i 2..15 Nm ❑ Renew 8 .2.⇒ page 31 . Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his 2.pulley end Special tools and workshop equipment required ♦ Counterhold tool -3099♦ Oil seal extractor -3203♦ Assembly tool -T10053♦ Torque wrench V. Prote cted by c op yri gh t.

Edition 01. To do this. Co py i .. – Place guide sleeve -T10053/1. screw central bolt by hand into crankshaft to stop.2 Installing Note thi sd oc um en The oil seal sealing lip must not be additionally oiled or greased. Volkswagen – Oil threadedho ut head of oil seal extractor. urposes.2. – Loosen knurled screw and turn inner part against crankshaft until oil seal is pulled out. A n – Unscrew inner part ofkoilaseal extractor twoG does n(approx. place two washers between toothed belt pulley and counterhold tool. c op yri gh t.2009 – Remove crankshaft toothed belt pulley. screw oil seal extractor as far as possi‐ ble into seal. 22 Rep.9 l engine) . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – To guide oil seal extractor -3203. Gr. rrectness of i t to the co nf orm spec atio h re n in wit 2.Crankshaft group ht rig py Co t.onto crankshaft journal. Note When bolting on counterhold tool.Golf 2004 ➤ . in part or in wh ole.13 . lock tooth‐ ed belt pulley using counterhold tool -3099.t gua part d AG. – Remove oil residue from crankshaft journal using clean cloth.. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng a ss e ris ran tee or ac ility ab y li an pt ce – Using great pressure. Prote cted by – Slide oil seal over guide sleeve onto crankshaft journal. agen lksw Vo by AG. 3 turns w ge o ol s mm) out of outer by V and lock with knurled screw.

Edition 01. 2.G 1332♦ Hand drill with plastic brush attachment ♦ Silicone sealant -D 176 404 AG.2009 – Press oil seal in to stop using assembly tool -T10053.G 1331♦ Torque wrench V.A. Removing and installing sealing flange and flywheel 23 .C op yi 2.9 l engine) . ht rig py Co t.1 Removing 2. ⇒ page 50 agen lksw Vo by AG. – Install and tighten toothed belt ⇒ page 50 .Golf 2004 ➤ .A. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n ss ksw Vol by ed ris tho au es n ot g ua ran tee or ac ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his do cu m en – Remove toothed belt.3. in part or in wh ole. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.and centre bolt. Volkswagen AG d Aagen o ♦ Flat scraper urposes. Prote cted by cop yri gh t .pulley end Special tools and workshop equipment required ♦ Counterhold tool -3099♦ Assembly tool -T10053♦ Torque wrench V.3 Removing and installing sealing flange .

place two washers between toothed belt pulley and counterhold tool. – Drain engine oil.2 urposes. . To do this. – Remove sealant residue from cylinder block with a flat scraper. They must be free of oil and grease. erwise excess sealant can enter sump and clog strainer in oil pump suction pipe as well as drip onto crankshaft oil seal. – Remove sump ⇒ page 88 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. in part or in wh ole.. 24 Rep. – Remove residual sealant from sealing flange using a plastic rotary brush (wear eye protection). – Clean sealing surfaces. – Pull off front sealing flange. ♦ Install sealing flange within 5 minutes of applying the silicone sealant. – Cut off tube nozzle at forward marking (approx. – Remove sealing flange. 3 mm nozzle ∅)..13 . lock tooth‐ ed belt pulley using counterhold tool -3099. Gr. cover sealing surface of oil seal AG. ht rig py Co t. because oth‐ Prote cted by cop yri gh t . n AG. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng Installing rrectness of i t to the co nf orm spec atio h re n in wit Note ♦ Observe expiry date of sealing compound.Edition 01.3 mm. if necessary. Note When bolting on counterhold tool.C op yi with a clean cloth.9 l engine) . Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce 2.Golf 2004 ➤ .3.2009 – Remove crankshaft toothed belt pulley. Note thi sd oc um en ♦ Sealant bead must not be wider than 2.Crankshaft group agen lksw Vo by ♦ Before applying sealant bead.. loosen by applying light blows with a rubber-headed hammer.

AG.Edition 01.. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Note When fitting sealing flange with oil seal installed use guide sleeve -T10053/1. in part or in wh ole. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng ksw Vol by ed ris tho au es n ot g ua ran tee or ac ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit ♦ Three hexagon bolts M6 x 35 mm ♦ Two hexagon bolts M7 x 35 mm 2.C op yi – Remove intermediate plate. 1 cylinder ⇒ page 50 . 30 minutes. – Install sump ⇒ page 88 . ♦ The procedure is identical whether the engine is installed or – Remove flywheel.2009 – Apply silicone sealant bead as shown to the clean sealing sur‐ face of sealing flange.A.Golf 2004 ➤ . 25 .G 1332/11♦ Vernier gauge urposes. Note After fitting.4 Renewing crankshaft sealing flange flywheel end AG. allow sealant to dry for approx. Removing and installing sealing flange and flywheel agen lksw Vo by – Set engine to TDC No. ⇒ page 50 2. Prote cted by cop yri gh t . Installing toothed belt and adjusting valve timing. 2. – Install sealing flange immediately and tighten all bolts lightly. – Tighten securing bolts for sealing flange to 15 Nm using alter‐ nate and diagonal sequence.G 1331♦ Socket -V.9 l engine) .1 Pressing out sealing flange with sender wheel Note ♦ For the sake of clarity. removed. the work is performed with the engine removed. thi sd oc um en – Remove sump ⇒ page 88 . Only then fill with engine oil.A. Removing and installing toothed belt.4. ht rig py Co t. Volkswagen AG d agen o ss Special tools and workshop equipment required ♦ Assembly tool -T10134♦ Torque wrench -V.

urposes.Clamping surface B . Note Sealing flange and sender wheel are pressed off the crankshaft together using three M6 x 35 mm bolts. renewed together with the sender wheel.Assembly housing D . This support ring serves as a fitting sleeve and must not be removed prior to installation.Edition 01.-arrow.by a locating pin. lip support ring.Golf 2004 ➤ . Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his 2.of sealing flange. 1/2 turn 180° for each bolt) into sealing flange and press sealing flange together with sender wheel off crankshaft.is held in its position relative to the crankshaft by a guide pin inserted into a hole in the crankshaft.13 .Guide pin for petrol engines (red knob) 26 Rep.Hexagon nut C . n AG. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Unscrew sealing flange securing bolts. ♦ The sender wheel is held in its installation position on the as‐ sembly device -T10134.4. – Screw bolts alternately (max.Hexagon socket head bolt F .using a commer‐ cially available ball-ended hex key socket ⇒ page 31 .2 Pressing in sealing flange with sender wheel Note do cu m en ♦ The sealing flange with a PTFE seal is equipped with a sealing ♦ Sealing flange and sender wheel must not be separated or ht rig py Co t. Assembly tool -T10134A . AG.Crankshaft group agen lksw Vo by Prote cted by cop yri gh t .2009 – Remove engine speed sender -G28.Locating pin E . cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n – Screw three M6 x 35 mm bolts into threaded holes -arrows. in part or in wh ole. ♦ Sealing flange and oil seal form one unit and must only be ♦ The assembly device -T10134.C op yi . turned after removal from packaging.9 l engine) .Guide pin for diesel engines (black knob) G . Gr.

in a vice on clamping sur‐ face -A. 2. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Prote cted by cop yri gh t . Note The sender wheel must not be taken out of the sealing flange or twisted.9 l engine) . agen lksw Vo by AG.Assembling seallkwith sender wheeloes not gu Vo by ara d nte on assembly tool -T10134ise or e . h ut or ac ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his – Clamp assembly device -T10134.downwards so that it lies on hex‐ agon nut -B. Removing and installing sealing flange and flywheel ht rig py Co t.to just before clamping surface -Ass of threaded spindle. Volkswagen AG gen AG d urposes.4.3 swa A . cial p is n mer ot com pe rm itte d un le a – Screw in hexagon nut -B.of threaded spindle.Golf 2004 ➤ . Note or ate riv p or gf n do cu m en – Remove securing clip -arrow.-arrow-. – Locating hole -A. – Place sealing flange with front side downwards on a clean flat surface. in part or in wh ole.2009 2. – Press assembly housing -C.C op yi 27 .on sealing flange.Edition 01. Inner part of assembly tool and assembly housing must be at same height.must align with marking -B.from new sealing flange.on sender wheel -C.

do cu m en • • Crankshaft flange must be free of oil and grease.4 B .2009 – Push sealing lip support ring -A.so that locating pin cannot slide out of sender wheel hole.can be inserted in sender th u ra a -A-. Engine positioned at TDC No. ensure that sender wheel remains fixed in assembly device.Golf 2004 ➤ . – Note Ensure sealing flange lies flat on assembly device.whilst tightening the three knurled screws -A. – Upper edge of sender wheel and front edge of sealing flange must align -arrows-. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n AG.downwards in direction of ar‐ row until it lies on flat surface. in part or in wh ole.Edition 01.13 .C op yi . c ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his – Push sealing flange and support ring for sealing lip -B. Volkswagen AG d agen oes not lksw Vo gu by-T10134ara Place sealing flange with front side on assemblyised tool nte or wheel hole eo so that locating pin -A.4. 1 cylinder 28 Rep. Prote cted by 2. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Attaching assembling tool -T10134with sealing flange on crankshaft flange agen lksw Vo by c op yri gh t . Note When installing sealing flange. Gr.Crankshaft group AG. urposes.against surface of assembly device -T10134. ht rig py Co t.9 l engine) .

into hole in crankshaft. – Secure assembly tool -T10134.5 C . e wage olks yV db e ris ho ut a ss s no t gu ara nte eo ra c ility ab y li an pt ce urposes.into crankshaft flange (ap‐ prox.must not be inser‐ ted in threaded hole of crankshaft.C op yi 29 .2009 – Screw hexagon nut -B. until hexagon nut -B. – Press threaded spindle of assembly tool -T10134.Bolting assembly tool -T10134. Volkswagen AG do cylinder block. – To guide sealing flange. Note or ate riv p or gf n do cu m en – Screw hexagon nut -E.to crankshaft flange using hexagon socket head bolts -A-. agen lksw Vo by c op yri gh t .9 l engine) . 5 full turns).lies against assembly housing -A-.by hand in direction of arrow until sealing lip support ring -B. – Hand-tighten both hexagon socket head bolts of assembly tool.onto crankshaft flange – Push assembly housing -C. Removing and installing sealing flange and flywheel AG. 2. This ensures that the sender wheel reaches its fi‐ nal installation position. – Push guide pin for diesel engines (black knob) -D.4. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Prote cted by ht rig py Co t.onto threaded spindle by hand until it lies on assembly housing -C-. in part or in wh ole.Edition 01. The guide pin for petrol engines (red knob) -F.Golf 2004 ➤ .to end of threaded spindle. – Align flat side of assembly housing on sump side of crankcase sealing surface. screw two M7 × 35 mm bolts -A.contacts crankshaft flange -A-.into n AG. cial p is n mer ot com pe rm itte d un le rrectness of i t to the co nform spec a tion h re wit in t his 2.in direction of arrow. Note Screw hexagon socket head bolts -A.

6 D .5 mm exists between crankshaft flange -A.A. thi sd oc um en 2.13 .7 – Screw hexagon nut -E.C op yi .to 35 Nm us‐ ing torque wrench -V. in part or in wh ole. 24 mm -V. – Remove the two bolts -A.to end of threaded spindle.2009 or ac au ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit – Tighten hexagon nut of assembly tool -T10134. – Measure distance -a.between crankshaft flange and sender wheel.Pressing sender wheel onto crank‐ shaft flange using assembly tool T10134- n AG.from cylinder block. ht rig py Co t. Golf Plus 2005 ➤ ran ed is tee or diesel engine (1. If measurement -a.4.G 1332/11. a small air gap must be present between cylinder block and sealing flange. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng 2. – Screw the three knurled screws -B.. – The sender wheel is in the correct installation position on the crankshaft if a gap -a.Checking sender wheel installation position on crankshaft agen lksw Vo by Prote cted by cop yri gh t .out of sealing flange.= 0. ⇒ page 31 If dimension -a.and sender wheel -B-.9 l engine)th Edition 01.is too small: – Press sender wheel further. – Set vernier gauge on crankshaft flange.Crankshaft group AG. 30 Rep.A. Volkswagen AG do es n wage ot g olks V ua by ➤ .Golf 2004 4-cylinder urposes. – Remove assembly tool -T10134.and tool insert.is attained: – Tighten new securing bolts for sealing flange to 15 Nm using alternate and diagonal sequence. Note After hexagon nut is tightened to 35 Nm. – Remove sealing lip support ring.4.G 1331. Gr. E ..

Co py i 31 . – Check installation position of sender wheel on crankshaft again. ⇒ page 30 If dimension -a. n AG. – Check installation position of sender wheel on crankshaft again.onto threaded spindle by hand until it lies on assembly housing -C-.and tighten secur‐ ing bolt to 5 Nm.to crankshaft flange using hexagon socket head bolts -A-. – Install sump ⇒ page 88 .2009 – Install engine speed sender -G28.and tool insert. – Hand tighten both hexagon socket head bolts. Removing and installing sealing flange and flywheel ht rig py Co t.Golf 2004 ➤ . agen lksw Vo by AG.8 F .4. 24 mm -V.by hand to sealing flange.. – Install flywheel using new bolts.A. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng – Screw hexagon nut -E. urposes. 2. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit – Tighten hexagon nut of assembly tool -T10134. Prote cted by c o py rig ht.G 1331.-arrow.9 l engine) . – Install intermediate plate. ⇒ page 30 thi sd oc um en 2.to 40 Nm us‐ ing torque wrench -V. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.is too small again: – Tighten hexagon nut for assembly tool -T10134.G 1332/11.A.to 45 Nm. in part or in wh ole.Re-pressing sender wheel – Secure assembly tool -T10134. – Push assembly tool -T10134. Tighten securing bolts to 60 Nm +1/4 turn (90°).5 Removing and installing engine speed sender -G28- Special tools and workshop equipment required 2.Edition 01.

un le ss k Vol by ed ris tho au not gu ara nte eo ra c ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng 32 Rep. observing the fol‐ lowing: specified torque for engine speed sender -G28. 4 mm -T10370- ♦ Or commercially available ball-ended hexagon key socket. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.C op yi . – Clamp off coolant hoses at engine oil cooler using hose clip and pull off hoses.. – Remove noise insulation tray ⇒ General body repairs. Prote cted by cop yri gh t .Edition 01.13 .front. exteri‐ or.noise insulation . Rep. – Remove securing bolt -arrow.securing bolt: 5 Nm.Crankshaft group ht rig py Co t.and pull out engine speed send‐ er -G28. check which tool is to be used. 50 . Body .2009 ♦ Hexagon key extension. – Remove oil filter bracket.Golf 2004 ➤ .9 l engine) . Assembly overview . Gr. Gr. 5 . is n mm ot p co erm or te itte va ri d p Two different bolts are installed. in part or in w l purpos hole ercia . Installation is performed in the reverse order. agen lksw Vo by AG. Volkswagen AG mm gen AG does swa Note es.

tighten to 65 Nm but not further.Edition 01. 6 .07…0.Bearing shell 3 ❑ For bearing cap without oil groove. 3. ❑ Note fixing arrange‐ ment..Crankshaft ❑ Axial clearance new: 0. 2.Thrust washer ❑ For cylinder block.17 mm ❑ Do not rotate crankshaft when checking radial clearance.crankshaft 2 . Prote cted by c op yri gh t . ❑ Bearing shell retaining lugs in cylinder block and bearing caps must align. 3. ❑ Crankshaft dimensions ⇒ page 38 .Thrust washer ❑ For bearing cap 3. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng 1 . ❑ For cylinder block with oil groove.0. wear limit: 0. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en 5 . ❑ Bearing cap 3 with re‐ cesses for thrust wash‐ ers.1 Assembly overview . 3 .37 mm ❑ Check radial clearance with Plastigage new: 0.65 Nm + 1/4 turn (90°) fur‐ ther ❑ Renew ❑ To measure radial clear‐ ance.. Crankshaft 33 .C op yi 4 . wear limit: 0.17 mm.9 l engine) . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. in part or in wh ole. ❑ For cylinder block with oil groove. agen lksw Vo by AG.Golf 2004 ➤ . urposes.crankshaft ⇒ page 33 Crankshaft dimensions ⇒ page 38 .Bearing shells 1. AG. 7 . bearing 3 ht rig py Co t.2009 3 Crankshaft Assembly overview .03. 4 and 5 ❑ For bearing cap without oil groove.Bearing cap ❑ Bearing cap 1: pulley end. ❑ Do not interchange used bearing shells (mark).08 mm.

If it is damaged or tarnished blue. check needle bearing in crankshaft.1.vehicles with dual clutch gearbox 6-speed dual clutch gearbox: If the engine or gearbox has to be removed during repairs.2009 3. – If it is not damaged.. 7-speed dual clutch gearbox: Always renew needle bearing when removing engine or gearbox.Crankshaft group ht rig py Co t. it must be renewed. lightly grease with high-temperature grease -G052133A2.Golf 2004 ➤ .Edition 01. Co py i . testers. in part or in wh ole.1 Renewing needle bearing in crankshaft .9 l engine) .13 . Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce urposes. Prote cted by c op yri gh t. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng rrectness of i t to the co nf orm spec atio h re n in wit This gearbox can be identified by the gearbox oil cooler Special tools. agen lksw Vo by AG. measuring instruments and auxiliary items required thi sd oc um en 34 Rep. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. 6-speed dual clutch gearbox n AG. Gr.

Golf Plus 2005 ➤ 4-cylinder diesel engine (1. AG. Co py i 3. Crankshaft 35 .2009 1 .Drift -VW 207 C- urposes.-1.Centring mandrel -31763 .Golf 2004 ➤ .with adapter -T10055/3Procedure • Gearbox is unscrewed from engine. agen lksw Vo by c op yri gh t. cial p is n mer ot com pe rm itte d un le n AG.Kukko 21/2 2 . in part or in wh ole.9 l engine) . Prote cted by Pulling needle bearing out: ht rig py Co t.Edition 01. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his or ate riv p or gf n do cu m en Puller -T10055.

Volkswagen AG d oes not gu ara auxiliary items nte eo ra c ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng 36 Rep. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. 7-speed dual clutch gearbox No gearbox oil cooler is installed. testers.. measuring instruments and ris required tho u V by es.13 .and puller -T10055. agen lksw Vo by AG. Prote cted by cop yri gh t .9 l engine) . in part or in w l purpos hole ercia . Always renew needle bearing when removinglkswagen or gearbox.C op yi .Crankshaft group ht rig py Co t.Edition 01. adapter T10055/3. is n mm ot p co erm or te itte va ri d p un le a ss AG. Gr.Golf 2004 ➤ . engine o ed Special tools.2009 – Pull out needle roller bearing using Kukko 21/2.

Edition 01. agen lksw Vo by AG. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce es.g.Drift -VW 207 Cun le n AG. in part or in w l purpos hole ercia .Centring mandrel -31763 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Golf 2004 ➤ . Crankshaft ht rig py Co t.Kuk‐ ko 22/1 2 . Kukko 21/2 and Kukko 22/1. e. is n mm ot p co erm or te itte va ri d p rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng Procedure • Gearbox is unscrewed from engine. Installing 3. Pulling needle bearing out: – Pull out using commercially available puller -A-.2009 1 .-1. Co py i 37 . Prote cted by c o py rig ht.9 l engine) .Kukko 21/2 and -4.

80 r fo ng -0. is n mm ot p co erm or te itte va ri d p un le rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en 3.2009 – Drive needle bearing in with drift -VW 207 C..022 -0.13 .042 .5 to 1.022 -0. (Dimensions in mm) Honing dimen‐ sion 38 Rep. n AG.00 47. Gr.Golf 2004 ➤ . Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce • Driving depth: Dimension -a.8 mm. if driving depth is too deep.042 Conrod journal ∅ ht rig py Co t.2 Crankshaft dimensions Crankshaft bearing journal ∅ -0. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. es. Co py i Basic dimension 54.= 1. Prote cted by c o py rig ht. in part or in w l purpos hole ercia . – Carefully drive needle bearing in.or with centring mandrel -3176. – Always measure the driving depth when driving in. Renew bearing.9 l engine) .Edition 01.Crankshaft group agen lksw Vo by AG.

2 .Edition 01.Conrod ❑ Mark cylinder allocation -A.Piston ❑ With combustion cham‐ ber. Prote cted by c o py rig ht. ❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. 4. heat piston to 60 °C.pistons and conrods ⇒ page 39 . ❑ Installation position: Marking -B. cylinder bore and piston installation position ⇒ page 42 n AG.Piston pin ❑ If difficult to remove.Bearing shell ❑ Note installation position.2009 4 Pistons and conrods Assembly overview . 6 .Circlip rrectness of i t to the co nform spec at ion h re wit in t his do cu m en 5 . ❑ Checking piston ring gap ⇒ page 42 . ❑ Cracks on piston skirt. ❑ Use piston ring pliers to remove and install. ❑ With industrially cracked conrod cap. ❑ Arrow on piston crown points to belt pulley end.. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n ility ab y li an pt ce 1 . ❑ Installation position and allocation of piston to cylinder ⇒ page 43 . renew piston. in part or in wh ole. agen lksw Vo by AG.pistons and conrods urposes. Co py i 39 . ❑ Checking ring-to-groove clearance ⇒ page 42 .1 Assembly overview . Piston rings.9 l engine) . Separating new conrod ⇒ page 40 .Golf 2004 ➤ .faces towards pulley end. ❑ Remove and install us‐ ing drift -VW 222. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Piston rings ❑ Offset gaps by 120°. Identifi‐ cation: Black line on bearing surface in area of joint. Checking piston projection at TDC ⇒ page 41 Piston and cylinder dimensions ⇒ page 42 . 4 . Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss 4.with coloured pen. ❑ Mark installation posi‐ tion and cylinder num‐ ber. ❑ Checking piston projec‐ tion at TDC ⇒ page 41 3 . ❑ “TOP” faces towards piston crown. Pistons and conrods ht rig py Co t. ❑ Install using piston ring clamp.

♦ Clamp conrod in below the marked line. – Using a plastic hammer.2 Separating new conrod y db ise or th au ss ua ran tee or ac ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en ♦ To prevent damage to the conrod.Oil spray jet ❑ For piston cooling Note 10 .Conrod bearing cap ❑ Note installation position. Check for secure seating. Gr.until it is loose.Cylinder block ❑ Checking cylinder bore ⇒ page 43 .08 mm.C op yi . do not rotate crankshaft when checking radial clearance. in part or in w l purpos hole ercia . separating the cap from conrod. only clamp conrod in lightly.Conrod bolt.37 mm. – Unscrew the two bolts -arrows. is n mm ot p co erm or te itte va ri d p un le 4. 9 . 5 turns. Check radial clearance with Plastigage: Wear limit: 0.Golf 2004 ➤ .ksw Vo g – Mark cylinder allocation of conrod ⇒ Item 5 (page 39) – Lightly clamp the conrod in a vice using aluminium vice clamps. 7 . ❑ Piston and cylinder dimensions ⇒ page 42 .Crankshaft group ht rig py Co t. as shown in the illustration. AG.13 . carefully knock against conrod bear‐ ing cap -arrow. Insert bearing shells centrally. 30 Nm + 1/4 turn (90°) further ❑ Renew ❑ Oil threads and contact surface. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. 8 . wear limit: 0.approx. Axial clearance. r fo ng 40 Rep. agen lksw Vo by AG.9 l engine) . 11 . Note es.Edition 01. ❑ The cap only fits in one position and only on the appropriate conrod due to the breaking procedure (cracking).2009 ❑ ❑ ❑ ❑ ❑ Do not interchange used bearing shells.25 Nm ❑ Insert without sealant. Volkswagen AG d agen oes not l ❑ Use old bolt for measuring radial clearance. Prote cted by c op yri gh t .

11 mm .9 l engine) .00 mm 1.2009 4. 1. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Pistons and conrods 41 ...Edition 01.91 mm .. use the largest dimension for selecting the gasket. 1.10 mm 1. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his ♦ Dial gauge Test procedure Note If different values are determined during the projection measure‐ ment. Piston projection at TDC must be measured when installing new pistons or a short engine..01 mm . according to following table: do cu m en or ate riv p or gf n Note ht rig py Co t. Install the appropriate cylinder head gasket depending upon piston projection. Turn engine clockwise to measure piston projection at TDC. cial p is n mer ot com pe rm itte d un le AG. in part or in wh ole.3 Checking piston projection at TDC Special tools and workshop equipment required ♦ Measuring bridge -VW 382/7- ♦ End dimension plate -VW 385/17- urposes.C op yi Identification Holes/notches 1 2 3 4. 1.Golf 2004 ➤ . c op yri gh t .20 mm agen lksw Vo by AG... Prote cted by Piston projection 0.

compression ring 2..47 79.20. cial p is n mer ot com pe rm itte d ♦ Production control code = arrow 2 (can be disregarded) un le Vo by ed Cylinder head gasket identification horis t au ♦ Part number = arrow 1 ss Golf 2004 ➤ .51 79. in part or in wh ole. Co py i 4. Prote cted by c o py rig ht..0 1.0 1.0 Checking ring-to-groove clearance Special tools and workshop equipment required ♦ Feeler gauges 42 Rep. Golf Plus 2005 ➤ AG.40 0.2009 AG does n lks ot g ua ran tee or ac ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his 4. Honing dimension Basic dimen‐ sion Stage I Stage II mm mm mm or ate riv p or gf n do cu m en Special tools and workshop equipment required ♦ Feeler gauges – Push piston ring squarely from above down to approx.76 80.♦ Holes = arrow 3 urposes.72 79. Gr. compression ring Oil scraper ring New 0.0..4 Piston and cylinder dimensions Piston ∅ 79.20. Volkswagen 4-cylinder diesel engine (1.. 15 mm from bottom end of cylinder. Piston ring dimensions in mm 1.01 ht rig py Co t.50 Wear limit 1.40 0.13 .5 Piston rings.25.97 Cylinder bore ∅ 79. cylinder bore and piston in‐ stallation position .9 l engine)w-agen Edition 01..0.Crankshaft group agen lksw Vo by Checking piston ring gap AG.0..

olks mounted on a repair stand with V engine support bracket -VW 540.25 0. compression ring Oil scraper ring Checking cylinder bores New 0.06 Wear limit 0.Golf 2004 ➤ ... in part or in wh ole. Note urposes..10 mm.0.. Difference between actual and nominal diameter max.and longitudinal -B..0. Piston in cylinders 3 and 4: Larger inlet valve chamber towards belt pulley side -arrows-.. ♦ Piston for cylinders 1 and 2: marked 1/2 ♦ Piston for cylinders 3 and 4: marked 3/4 or ate riv p or gf n do cu m en ht rig py Co t. compression ring 2. agen lksw Vo by AG. Pistons and conrods 43 .2009 – Clean ring groove before checking. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.u g by ara e as measurements may thend be incorrect.03.0. Vcylinder AG do is Cylinder bores must not be measuredewhen olkswagenblockes wag not .15 Special tools and workshop equipment required ♦ Cylinder gauge 50. 0. nt ris un le Piston installation pe rm itte d ho ut sa s position and allocation of piston to cylinder ee or ac ility ab y li an pt ce Piston in cylinders 1 and 2: Larger inlet valve chamber towards flywheel -arrows-. Piston ring dimensions in mm 1.Edition 01. Co py i 4.25 0.directions. cial p is n mer ot com rrectness of i t to the co nform spec a tion h re wit in t his ♦ New piston allocation to cylinders is shown by a coloured marking on piston crown.06.09 0..100 mm – Take measurements at 3 positions in both transverse -A. Prote cted by c o py rig ht..05.9 l engine) . as illustrated.08 0. Note n AG.

15 . the contact surfaces between the bucket tappets and the cam must be oiled before installing the cylinder head cov‐ er. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Cylinder head. valve gear Cylinder head ♦ When installing an exchange cylinder head with fitted cam‐ shaft. Gr. removed only immediately before the cylinder head is fitted. valve gear ht rig py Co t. ♦ The plastic protectors fitted to protect the open valves must be ♦ If the cylinder head is replaced.2009 15 – 1 Note Cylinder head.Golf 2004 ➤ . Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his or ate riv p or gf n do cu m en 44 Rep. agen lksw Vo by AG.Edition 01. cial p is n mer ot com pe rm itte d un le n AG. all the coolant in the system urposes.9 l engine) . Prote cted by c o py rig ht. in part or in wh ole. must also be renewed. Co py i .

2009 Removing and installing cylinder head cover ⇒ page 48 .Fuel return line ht rig py Co t. place washers in cylinder head ⇒ Item 4 (page 74) . Co py i 1.Camshaft pulley 7 n AG. installing and tensioning ⇒ page 50 . ❑ Do not kink. c op yri gh t.to loosen and tighten. 1. Volkswagen AG do es n wage ot g olks yV ua .Edition 01.Stud ❑ 15 Nm 12 .Sealing grommet ❑ Renew if damaged.Cylinder head cover ❑ Before fitting.Cylinder head bolt ❑ Observe sequence when loosening and tightening ⇒ page 67 . thoroughly clean sealing surface of cylinder head with clean cloth.Toothed belt guard upper part 2 . ❑ Removing. ❑ To remove. ❑ Before installing. in part or in wh ole. 10 .10 Nm ❑ Renew 4 . agen lksw Vo by Prote cted by 13 .25 Nm 5 . installing and tensioning toothed belt ⇒ page 50 Removing and installing cylinder head ⇒ page 67 Checking compression ⇒ page 71 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) .1 Assembly overview .cylinder head 1 . Removing. 3 . do cu m en 14 .100 Nm 6 .Toothed belt ❑ Mark direction of rota‐ tion before removing.Hub db ran se tee ri ho ❑ With sender wheel t or ac au ss ❑ Use counterhold tool - ility ab y li an pt ce urposes. use puller T10052❑ Removing and installing pe rm itte d un le rrectness of i t to the co nform spec a tion h re wit in t his 8 .Fuel supply line 15 . AG. ❑ Check for wear. cial p is n mer ot com T10051. unbutton sealing grommet ⇒ Item 9 (page 45) from rear toothed belt guard.Golf 2004 ➤ . Cylinder head 45 .Rear toothed belt guard 9 .Coolant line 16 . or ate riv p or gf n 11 .Hall sender -G40❑ For camshaft position ❑ To remove.

seal transitions with “AMV 174lkswa 01” ⇒ page 48 004 Vo n AG.20 Nm 24 . ❑ Removing and installing ⇒ page 147 .Return hose ❑ To fuel filter ❑ Blue or with blue marking. 22 .Tandem pump ❑ For fuel and vacuum supply ❑ Checking ⇒ page 147 .Gasket ❑ Renew 33 . Prote cted by 31 . ht rig py Co t. ❑ Check for secure seating.Pressure regulating valve ❑ For crankcase ventilation.Cylinder head ❑ Removing and installing ⇒ page 67 . thi sd oc um en 32 .Lifting eye 26 . Co py i . in part or in wh ole. valve gear agen lksw Vo by AG.Cylinder head. renew entire coolant 46 Rep.To turbocharger.20 Nm 35 . 21 .Sealing cap ❑ Renew seal if damaged 20 .10 Nm ❑ Observe tightening sequence ⇒ page 48 . wage olks V by ed ris ho ut sa s 23 .From brake servo urposes.Unit injector ❑ Removing and installing ⇒ page 169 .Cylinder head gasket ❑ Renew ❑ Note marking ⇒ page 47 ❑ After renewing. ❑ After renewing. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng 25 .Central connector ❑ For unit injector 28 . ❑ Secure with spring-type clips. ❑ Before fitting.Golf 2004 ➤ .15 . ❑ Check for secure seating. ❑ White or with white marking.Edition 01. c op yri gh t. renew entire coolant 36 .Seal ❑ Renew if damaged.2009 17 . 18 . ❑ Must not be dismantled. 19 . ❑ Secure with spring-type clips.10 Nm 27 . gen AG does not gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit 29 . 30 .9 l engine) .Supply hose ❑ From fuel filter. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Gasket for cylinder head cover ❑ Renew together with cylinder head cover only. Gr.Bracket 34 .

⇒ page 41 agen lksw Vo by AG. 38 .Glow plug ❑ 15 Nm ❑ Checking ⇒ page 198 .Tensioning roller ❑ Remove engine support in order to remove and install ⇒ page 16 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) . Note urposes. permissible distortion: 0. 39 .C op yi pending on the piston projection.Golf 2004 ➤ . Cylinder head 47 .2009 37 .Edition 01.20 Nm + 1/8 turn (45°) further Checking cylinder head for distortion Special tools and workshop equipment required ♦ Straight edge ♦ Feeler gauges Max. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng n AG. When renewing gasket. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit Reworking diesel cylinder heads is not permissible. in part or in wh ole. install new gasket with same identification. new pistons or a short engine. Cylinder head gasket identification ♦ Part number = arrow 1 ♦ Holes = arrow 3 Note ♦ Production control code = arrow 2 (can be disregarded) thi sd oc um en ♦ Different thicknesses of cylinder head gasket are fitted de‐ ♦ Piston projection at TDC must be determined when installing ht rig py Co t.1 mm. 1. Prote cted by cop yri gh t .

Edition 01. first pull outer engine cover abruptlyy Volksw upwards at -arrows-.2 Removing and installing cylinder head cover Special tools and workshop equipment required ♦ Torque wrench -V. tho – Disconnect crankcase breather hose at union of rear of charge air pipe.9 l engine) . Co py i . Volkswagen AG d agen oes – Remove upper toothed belt guard. in part or in wh ole. au ss not gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his do cu m en 48 Rep.G 1331♦ Sealant -AMV 174 004 01⇒ page 4 Removing – Remove engine cover.2009 1. Prote cted by c op yri gh t. then pull inner engine cover abruptly up‐ed b ris wards at -arrows-.and then pull forwards out of rear fastening -arrow B-. pull engine cover upwards abruptly at front -arrows A. agen lksw Vo by AG.15 . To do this. – Unbolt bracket from exhaust gas recirculation valve. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. urposes. valve gear ht rig py Co t.Cylinder head.A. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n AG. Two-piece engine cover For two-piece engine cover.Golf 2004 ➤ . Gr.

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Cylinder head cover, engine codes: BLS, BXJ Installing for all engine codes

Installation is carried out in the reverse sequence of removal. In the process, note the following:
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♦ Renew cylinder head cover gasket and seal for bolts if dam‐ ♦ Renew seal for intake manifold flap. Engine codes BLS, BXJ – Place a drop of sealant -AMV 174 004 01- (∅ approx. 5 mm) -arrows- on edges of both sealing surfaces of bearing cap and cylinder head at front of engine.
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1.3

Removing, installing and tensioning toothed belts
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♦ To change the tensioning roller, for both versions the engine

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50

Rep. Gr.15 - Cylinder head, valve gear

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1.3.1

Removing and installing toothed belt (vehicles with engine support bolted close to engine)

Special tools and workshop equipment required ♦ Pin wrench -T10020- or hexagon wrench ♦ Crankshaft stop -T10050AG.
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♦ Locking pin -3359-

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Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ♦ Support bracket -10-222Awith adapters -10-222A/1♦ Counterhold tool -T10172with pins -T10172/4♦ Crankshaft stop -T10100(on vehicles with oval crankshaft belt pulley)

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Removing Note

Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature.
– Remove engine cover. ⇒ page 4 – Remove poly V-belt ⇒ page 13 . – Remove front right wheel housing liner.
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– Remove lower and centre parts of toothed belt guard.

52

Rep. Gr.15 - Cylinder head, valve gear

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– Remove belt pulley with vibration damper.

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AG. Note If toothed belt is to be removed in order to remove cylinder head.. in part or in wh ole. Co py i 1. Cylinder head 53 .! mounting has been removed. es n lksw Vo by ed ris tho au ot g ua ran tee or ac ility ab y li an pt ce urposes. ♦ The engine bracket must be loosened only when the assembly do cu m en – Remove engine bracket rearwards. This will provide the space necessary for removing the cyl‐ inder head. When installing this toothed belt pulley.9 l engine) .until both upper bolts of engine bracket can be loosened. the crankshaft stop T10100.and remove complete assembly mountings.Edition 01. Observe identification characteris‐ tics -arrows-. Note Gradual introduction of oval crankshaft toothed belt pulleys.2009 – Set up support bracket -10-222A. ht rig py Co t. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n ss rrectness of i t to the co nform spec at ion h re wit in t his – Remove securing bolts between assembly mounting and en‐ gine bracket and between assembly mounting and body -arrows. V AG do agen connected). – Unscrew filler neck for window wash system. 1 cylinder. – Remove refrigerant line securing clamp from longitudinal member. – Raise engine with support bracket -10-222A.until both lower bolts of engine bracket can be loosened. – Unbolt fuel filter bracket from engine mounting -arrows-. set up support bracket -10-222A.must be installed to determine the TDC position instead of crankshaft stop -T10050. agen lksw Vo by – Lower engine with support bracket -10-222A. Note ♦ The assembly mounting may only be removed if the engine is supported with support bracket -10-222A. – Turn crankshaft to TDC No.with adapters -10-222A/22and support engine in installation position.Golf 2004 ➤ . – Pull fuel filter out of bracket. Prote cted by c o py rig ht. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.. – Unbolt coolant expansion tank and lay to side (hoses remainolkswagen AG.with higher adapters -10-222A/ 13.

do cu m en 54 Rep.15 . Vehicles with oval crankshaft belt pulley – Turn crankshaft to TDC No. lock using crankshaft stop -T10100. Prote cted by cop yri gh t . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. The markingaonnthe.C op yi . To do this.Golf 2004 ➤ . When doing this. TDC marking at 12 o'clock B = Oval belt pulley. Note Turn crankshaft until marking on crankshaft pulley and tooth seg‐ AG Volk wagen AG ment of camshaft pulley is on top.2009 Characteristics of crankshaft toothed belt pulley A = Round belt pulley. TDC marking at 1 o'clock Vehicles with round crankshaft belt pulley – Turn crankshaft to TDC No...Cylinder head. Gr. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n – Lock hub using locking . in part or in wh ole. ran ise urposes.rearstoothed do w ge belt guard must line up with the markingVonsthe camshaft sender es not g olk y ua db wheel -arrow-. the pin of the crankshaft stop must insert in the drilling of the sealing flange. 1 cylinder. 1 cylinder. lock using crankshaft stop -T10050. Note r tho au pinss-3359- tee or ac ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his The marks on the crankshaft toothed belt pulley and the crank‐ shaft stop must align. agen lksw Vo by AG.9 l engine) .Edition 01.. To do this. push crankshaft stop into teeth of belt pulley from face side. – Lock crankshaft toothed belt pulley with crankshaft stop T10050. valve gear ht rig py Co t. slide locking pin through the free elongated hole on left into hole in cylinder head.

Golf Plus 2005 ➤ 4-cylinder diesel engine (1.2009 Note Turn crankshaft until marking on crankshaft pulley and tooth seg‐ ment of camshaft pulley is on top. Cylinder head 55 . – Lock hub using locking pin -3359. in part or in w l purpos hole ercia . – Loosen securing bolts -1. un le ss k Vol by ed ris tho au not gu ara nte eo ra c ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng Note A hexagon key can be used to tension or relieve tension on the tensioner. AG. – Loosen tensioning roller securing nut..Edition 01. The marking on the rear toothed belt guard must align with the marking on the camshaft sender wheel -arrow-.9 l engine) . slide locking pin through the free elongated hole on left into hole in cylinder head. Continuation for all vehicles – Mark direction of rotation of toothed belt. agen lksw Vo by – Turn pin wrench -T10020.anti-clockwise until toothed belt tensioning roller can be locked with locking pin -T10115. Co py i 1. To do this. To do this. At the same time. is n mm ot p co erm or te itte va ri d p The marks on the crankshaft toothed belt pulley and the crank‐ shaft stop must align.Golf 2004 ➤ .of camshaft toothed belt pulley until camshaft pulley can be moved within the elongated holes. ht rig py Co t. – Lock crankshaft toothed belt pulley with crankshaft stop T10100. Prote cted by c o py rig ht. swa Note es. push crankshaft stop into teethsof toothed .. Volk wagen AG gen AG does belt pulley from its face side. the crankshaft stop pin must engage in the drilling in the sealing flange..

Cylinder head. ris un le au Tensioning roller locked with locking pin ss cured to right stop.clockwise to stop and tighten securing nut -1. Co py i . camshaft toothed belt pulley and idler roller. cial p is n mer ot com pe rm itte d rrectness of i t to the co nform spec a tion h re wit in t his Adjustment work on toothed belts must be performed only on cold engines. valve gear AG. in part or in wh ole. tensioning roller.Edition 01. – Then fit toothed belt on coolant pump toothed belt pulley. – Now carefully turn tensioning roller clockwise using pin wrench -T10020. tho n AG. Prote cted by Note ht rig py Co t. olk The crankshaft is locked with crankshaft stops-T10050. Volkswagen AG do es n wage ot g ua ran tee or ac -T10115. agen lksw Vo by c op yri gh t.2009 – Now turn pin wrench -T10020. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Gr. or ate riv p or gf n do cu m en Ensure that tensioning roller seats correctly in rear toothed belt guard -arrow-.. as the indicator position on the tensioning element varies depending on the engine temperature. – Loosen tensioning roller securing nut and pull out locking pin -T10115.or yV db e crankshaft stop -T10100..Golf 2004 ➤ .15 . Ensure that securing nut does not turn as well. – Turn camshaft pulley in its elongated holes to centre position -arrows-.and se‐ ility ab y li an pt ce Note urposes. Installing • • • Camshaft locked with locking pin -3359. 56 Rep. – Remove toothed belt first from coolant pump and then from remaining pulleys.9 l engine) .. – Fit toothed belt onto crankshaft toothed belt pulley.hand tight.until indicator is in middle of gap in the base plate -arrow-. – Hold tensioning roller in this position and tighten tensioning roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.

Co py i 1.for camshaft toothed belt pulley. Press counterhold tool -T10172. Vehicles with oval crankshaft belt pulley ht rig py Co t.Edition 01. – Remove locking pin -3359. t gu yV b ed r Vehicles with round crankshaft beltispulley ho urposes. Prote cted by – Turn crankshaft slightly against engine direction of rotation until the pin of the crankshaft stop is positioned just before the hole in the sealing flange -arrow-.and crankshaft stop -T10050. Cylinder head 57 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. in part or in wh ole. – In this position.in direction of arrow. agen lksw Vo by AG. – Now turn crankshaft in engine direction of rotation until crank‐ shaft stop pin engages in sealing flange whilst turning. l1scylinder.oforotation AG doe wage s no ok until crankshaft is just before TDC No.. n AG V lkswagen – Turn crankshaft two rotations in engine direction . keeping camshaft toothed belt pulley under tension.9 l engine) . tighten camshaft toothed belt pulley securing bolts -1.2009 – Fit counterhold tool -T10172.whilst turning engine in di‐ rection of rotation..Golf 2004 ➤ .as shown.with pins -T10172/4. c op yri gh t.to 25 Nm. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n t au ss ara nte e or ac ility ab y li an pt ce – Lock hub with locking pin -3359. If crankshaft cannot be locked rrectness of i t to the co nform spec at ion h re wit in t his do cu m en – Loosen securing bolts -1. – Check whether crankshaft can be locked with crankshaft stop -T10050.

If crankshaft cannot be locked: – Loosen securing bolts -1.in direction of arrow. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Gr. in part or in wh ole. 58 Rep.whilst turning engine in di‐ rection of rotation. Press counterhold tool -T10172.. – Check whether the crankshaft can be locked with crankshaft stop -T10100.as shown. agen lksw Vo by Prote cted by cop yri gh t .and crankshaft stop -T10050. toothed belt is tee or th or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his – Turn crankshaft against engine direction of rotation slightly until pin of crankshaft stop is located just before hole in sealing flange -arrow-.. or ate riv p or gf n Continuation for all vehicles do cu m en – In this position. cial p is n mer ot com pe rm itte d un le n AG.to 25 Nm.for camshaft urposes.9 l engine) .Edition 01. ht rig py Co t. valve gear AG. Volkswagen AG do es n wage ot g olks V ua by ran ed pulley. 1 cylinder. – Turn crankshaft two rotations in engine direction of rotation until crankshaft is just before TDC No.15 . keeping camshaft toothed belt pulley under tension. – Fit counterhold tool -T10172. – Repeat check.Golf 2004 ➤ .2009 – Lock hub with locking pin -3359. – Now turn crankshaft in engine direction of rotation until crank‐ shaft stop pin engages in sealing flange from rotational move‐ ment.C op yi . – Remove locking pin -3359.with pins -T10172/4. tighten camshaft toothed belt pulley securing bolts -1.Cylinder head.

– Fit engine cover.to 40 Nm + 1/2 turn (180 °) further. Specified torque. – Install toothed belt guard upper part. – Engage fuel filter in bracket. – Bolt on filler neck for window wash system. Prote cted by c op yri gh t . tighten all engine bracket bolts to prescribed torque. Cylinder head ht rig py Co t. agen lksw Vo by AG. Note Before installing assembly mounting.Golf 2004 ➤ .V ed Specified torque: 60 Nm + 90° (1/4 turn) urposes. M10 bolts: 40 Nm + 90° (1/4 turn) – Bolt engine assembly mounting to engine bracket by bringing lkswag o b contact surfaces together using support bracket -10-222A-y. V does not gu ara nte eo ra c ility ab y li an pt ce – Install centre and lower parts of toothed belt guard. rrectness of i t to the co nform spec at ion h re wit in t his – Install front right wheel housing liner. in part or in wh ole.Edition 01. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n olkswagen AG en AG. – Install assembly mounting between engine and body (renew securing bolts). Specified torque: 10 Nm + 90° (1/4 turn) – Install poly V-belt ⇒ page 13 . do cu m en 1. – Bolt fuel filter bracket to engine mounting to 8 Nm torque -arrows-. ris ho ut a ss – Install belt pulley vibration damper (renew securing bolts). – Install coolant expansion tank.9 l engine) .2009 – Set engine bracket against cylinder block and tighten securing bolts -arrows.C op yi 59 . M8 bolts: 20 Nm + 90° (1/4 turn) Specified torque.

⇒ page 4 To do this. Special tools and workshop equipment required ♦ Diesel injection pump lock‐ ing pin -3359♦ Locking pin -T10060 A♦ Crankshaft stop -T10100♦ Counterhold tool -T10172♦ Special wrench. in part or in w l purpos hole ercia . Prote cted by c op yri gh t.15 . r fo ng ht rig py Co t. installing and tensioning toothed belt”. Gr.and then pull forwards out of rear fastening -arrow B-.Golf 2004 ➤ .Edition 01. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en Removing – Remove engine cover.3.Cylinder head. long reach -T10264♦ Locking tool -T10265- es. valve gear agen lksw Vo by AG. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. for both versions the engine support must be removed.9 l engine) .2009 1. pull engine cover upwards abruptly at front -arrows A. ♦ To change the tensioning roller.2 Removing and installing toothed belt (vehicles with engine support bolted further away from engine) Note ♦ A revised engine support has been introduced gradually and it is no longer necessary to remove the engine support and to support the engine for the procedure “removing. Co py i . 60 Rep. is n mm ot p co erm or te itte va ri d p un le n AG.

2009 – Remove two-piece engine cover ⇒ page 4 WARNING ♦ In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector en‐ gine. – Remove connecting pipe between charge air cooler and intake connecting pipe. in part or in w l purpos hole ercia . Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng agen lksw Vo by – Disconnect fuel supply line -3.by pulling release tabs. Prote cted by c op yri gh t.danger of scalding. ♦ Wear protective gloves. is n mm ot p co erm or te itte va ri d p un le n AG. – Pull off coolant line -3-.and fuel return hose -2. lightly lift retaining clips -arrows-.Golf 2004 ➤ .9 l engine) . Co py i 61 . AG. – Remove bolt -1-. – Pull fuel supply hose -1. ♦ Wear eye protection.Edition 01. 1. Allow the fuel to cool down before disconnecting the lines . es. Cylinder head ht rig py Co t.and return line -2.off fuel lines. to do this. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.

– Remove front right wheel housing liner. – Remove tensioning element for poly V-belt. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Co py i .Golf 2004 ➤ . – Remove upper toothed belt guard. n AG. – Disconnect electrical connector on coolant expansion tank -1-. – Remove coolant expansion tank. loosen retaining clips -arrows-.Cylinder head. – Unscrew bracket -3. – Remove poly V-belt ⇒ page 13 . valve gear AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce es. is n mm ot p co erm or te itte va ri d p un le rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng Rep. – Remove belt pulley with vibration damper. in part or in w l purpos hole ercia . agen lksw Vo by Prote cted by c op yri gh t. to do this.9 l engine) .for fuel filter. coolant hoses remain con‐ nected.Edition 01. 62 ht rig py Co t.for windscreen washer system reservoir.2009 – Pull fuel filter out of bracket -arrow-. – Remove lower and centre parts of toothed belt guard. Place it on engine. – Turn crankshaft to TDC No. – Unscrew bolt at filler neck -2.15 . 1 cylinder. Gr.

To do this.C op yi 63 .9 l engine) . slide locking pin through the free elongated hole on left into hole in cylinder head.. in part or in w l purpos hole ercia .. agen lksw Vo by AG. until the tensioning roller can be locked with locking tool -T10265. When doing this. is n mm ot p co erm or te itte va ri d p ility ab y li an pt ce un le rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en – Loosen tensioning roller securing nut -1-. Volkswagen AG d agen oes not lksw o Loosen securing bolts -1.Edition 01. To do this.. Cylinder head ht rig py Co t. – Turn eccentric of tensioning roller anti-clockwise -arrow. – AG. The marking on the rear toothed belt guard must line up with the marking on the camshaft sender wheel -arrow-. r fo ng 1. Note The marks on the crankshaft toothed belt pulley and the crank‐ shaft stop must align. – Mark direction of rotation of toothed belt. Prote cted by c op yri gh t . the pin of the crankshaft stop must insert in the drilling of the sealing flange.of camshaft toothed belt pulleyVuntil gu by ara d camshaft pulley can be moved within the elongatedisholes.Golf 2004 ➤ .. – Lock crankshaft toothed belt pulley with crankshaft stop T10100. push crankshaft stop into teeth of belt pulley from face side.2009 Note Turn crankshaft until marking on crankshaft pulley and tooth seg‐ ment of camshaft pulley is on top. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Lock hub using locking pin -3359.using socket -T10264. e nte or eo th u ra a c ss es.

Note Ensure that securing nut does not turn as well. Gr.C op yi Note .hand-tight. Volkswagen AG does not olks cured to right stop with securing nut. tensioning roller. Tensioning roller locked with locking pin -T10265. valve gear agen lksw Vo by AG. – Hold tensioning roller in this position and tighten tensioning roller nut to 20 Nm + 45° (1/8 turn). – Then fit toothed belt on coolant pump toothed belt pulley. in part or in wh ole.onto stop and tighten securing nut -1..until indicator -2. – Turn camshaft pulley in its elongated holes to centre position -arrows-. Prote cted by Ensure that tensioning roller seats correctly in rear toothed belt guard -arrow-.Edition 01.. – Loosen tensioning roller securing nut -1-. – Remove toothed belt first from coolant pump and then from remaining toothed belt pulleys. 64 Rep. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en – Remove locking pin -T10265.Cylinder head.15 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. ht rig py Co t.is in middle of gap in base plate. – Fit toothed belt onto crankshaft toothed belt pulley. – Turn eccentric of tensioning roller clockwise -arrow. long reach -T10264. – Guide toothed belt through gap between engine support and engine.Golf 2004 ➤ .and se‐ wagen AG. urposes.from tensioning roller. Crankshaft locked with crankshaft stop -T10100. camshaft toothed belt pulley and idler roller.using special wrench. as the indicator position on the tensioning element varies depending on the engine temperature.9 l engine) . Installing • • • Camshaft locked with locking pin -3359. gu yV Note db ise or th au ss ara nte e or ac ility ab y li an pt ce Adjustment work on toothed belts must be performed only on cold engines. c op yri gh t .2009 – Now turn tensioning roller eccentric clockwise -arrow.

Prote cted by c op yri gh t .for camshaft toothed belt pulley. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce es.Edition 01. is n mm ot p co erm or te itte va ri d p un le rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en – Loosen securing bolts -1. – Lock hub of camshaft with locking pin -3359. agen lksw Vo by AG.and crankshaft stop -T10100. – Turn crankshaft two rotations in engine direction of rotation until the crankshaft is just before TDC again. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. and keep the toothed belt under tension on pulling side.of camshaft toothed belt pulley to 25 Nm.9 l engine) . If crankshaft cannot be locked AG.2009 – Fit counterhold tool -T10172. by pressing in -direction of arrow-. – Check whether crankshaft can be locked with crankshaft stop -T10100. – Tighten bolts -1. – Remove locking pin -3359. Cylinder head 65 . r fo ng ht rig py Co t.C op yi 1. in part or in w l purpos hole ercia .whilst turning engine in direction of rotation..with pin -T10172/4..Golf 2004 ➤ .as shown in illustration.

– In this position. valve gear agen lksw Vo by .9 l engine) . Specified torque: 10 Nm + 90° (1/4 turn) – Install toothed belt guard upper part. Prote cted by cop yri gh t .C op yi do cu m en – Install centre and lower parts of toothed belt guard.and crankshaft stop -T10100.15 . – Bolt on filler neck for window wash system.as shown. – Install connecting pipe between charge air cooler and intake connecting pipe. tighten camshaft toothed belt pulley securing bolts -1..in direction of arrow. Gr.with pins -T10172/4. 1 cylinder. not gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his – Fit counterhold tool -T10172. – Install belt pulley vibration damper (renew securing bolts). Volkswagen AG d agen oes urposes.Cylinder head. in part or in wh ole. – Remove locking pin -3359. – Turn crankshaft two rotations in engine direction of rotation until crankshaft is just before TDC No.to 25 Nm. – Install coolant expansion tank. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Fit engine cover. AG. – Engage fuel filter in bracket. ht rig py Co t. tho au AG.Edition 01. keeping camshaft toothed belt pulley under tension.Golf 2004 ➤ . cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n ss – Now turn crankshaft in engine direction of rotation until crank‐ shaft stop pin engages in sealing flange whilst turning. – Bolt fuel filter bracket to engine mounting to 8 Nm torque -arrows-. – Install front right wheel housing liner. 66 Rep.2009 ks – Turn crankshaft slightly against engine directionoof w V l rotation by until the pin of the crankshaft stop is positioned just before the ed ris hole in the sealing flange -arrow-. – Repeat check and adjustment if necessary. – Install poly V-belt ⇒ page 13 . Press counterhold tool -T10172.

A.(only vehicles ▸ 05.with adapters -10-222A/13.G 1390- rrectness of i t to the co nf orm spec atio h re n in wit ♦ Water drainage container V.A.2009 s n ot g ua ran tee or ac ility ab y li an pt ce Special tools and workshop equipment required ♦ Drip tray -V.4 Removing and installing cylinder head urposes.05) thi sd oc um en Special tools and workshop equipment required ♦ Support bracket -10-222A. Volkswagen AG n does 4-cylinderkdiesel AG wage engine (1.05) ht rig py Co t.A.C op yi 1.(only ve‐ hicles ▸ 05.G 1332♦ Hand vacuum pump with accessories -V.G 1306. Prote cted by cop yri gh t .9 l engine) . in part or in wh ole. Cylinder head 67 .Edition 01.G 1331♦ Torque wrench V. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng ss Vol by ed ris tho au Golf 2004 ➤ .A. Golf Plus 2005 ➤ .or drip tray -VAS 6208♦ Torque wrench V.G 1390/1- ♦ Retainer -T10014.A.1. agen lksw Vo by AG.

– Remove two-piece engine cover ⇒ page 4 Prote cted by agen lksw Vo by – Remove engine cover panel ⇒ page 4 . refrigerant. Gr. valve gear AG.g.Golf 2004 ➤ . Co py i . exterior. 50 . ♦ Ensure that there is sufficient clearance to all moving or hot components. ht rig py Co t. do cu m en – Remove plenum chamber bulkhead.and water drainage container -V. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.and then pull for‐ wards out of rear fastening -arrow B-. brake fluid and vacuum) and electrical wiring in their original po‐ sitions. V wag olks yV db ise WARNINGthor au ss ♦ Route all the various lines (e. acti‐ vated charcoal filter system. urposes. To do this. Rep.1 Removing Note Before removing cylinder head. Gr.G 1390/1. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n When doing any repair work. especially in the engine compart‐ ment.15 .⇒ page 147 . coolant.9 l engine) . c op yri gh t.front.4. pull engine cover upwards abruptly at front -arrows A. plenum chamber bulk‐ head . hydraulics.A.A. pay attention to the following due to the cramped condi‐ tions: does not gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his 1. for fuel. olkswagen AG en AG. Body .2009 Note All cable ties which are opened or cut through when cylinder head is removed must be replaced in the same position when cylinder head is installed.Edition 01. 68 Rep.Cylinder head. – Remove air filter housing with air mass meter and connecting pipe. extract fuel using hand-operated vacuum pump with accessories -V. in part or in wh ole. ⇒ General body repairs.G 1390.

Golf 2004 ➤ .front. – Before removing cylinder head.and -4-.-3-. Removing and installing camshaft. Assembly overview . cial p is n mer ot com – Remove toothed belt. Rep. in part or in wh ole. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or From 05. – Remove turbocharger support and oil return from turbocharg‐ er. so an additional bracket for supporting the engine must be se‐ cured on the cylinder block. Gr. 50 . – Drain coolant. – Remove exhaust gas recirculation connecting pipe. – Install hub for camshaft pulley ⇒ page 80 .A. Only vehicles ▸ 05. Body .2009 – Remove bolt -arrow A. Cylinder head 69 . vacuum and intake hoses from cylinder head. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. AG. – Remove front exhaust pipe ⇒ page 186 . extract fuel from tandem pump using hand-operated vacuum pump with accessories -V. coolant.05 a modified engine support has been introduced. ⇒ page 102 – Disconnect fuel supply and return lines as well as coolant line on cylinder head. installing and tensioning toothed belt” ⇒ page 50 un le ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his – Remove rear toothed belt guard securing bolts -2. eit ris th o u ac a no longer necessary to remove the engine support and supporting ss Note urposes.05) Note ht rig py Co t. – Remove oil supply line and lay it to side ⇒ page 95 . – Unscrew Hall sender -G40. Prote cted by c op yri gh t .Edition 01. pe rm itte d the engine for the procedure “removing. exterior. agen lksw Vo by AG.A.and pull air filter housing upwards out of mounting. – Pull off or disconnect all other electrical connections as nec‐ essary from cylinder head and lay to one side.C op yi 1.and water drainage container -V. or ate riv p or gf n – Separate all connection. ⇒ General body repairs. – Pull fuel filter module upwards out of bracket and lay it with hoses to side.9 l engine) . do cu m en Both lifting eyes for the support are located on the cylinder head. – Remove insulation tray. ⇒ page 50 – Remove toothed belt tensioning roller.G 1390.G 1390/1⇒ page 147 .

2009 – Screw retainer -T10014. valve gear AG. – Fit cylinder head gasket. ♦ Handle gasket very carefully. 70 Rep. Note es.Golf 2004 ➤ . ♦ In cases of repair carefully remove gasket remains from cyl‐ c op yri gh t. ♦ Carefully remove remains of emery and abrasives.Edition 01. in part or in w l purpos hole ercia .15 .Cylinder head.into threaded hole above coolant pump and tighten to 20 Nm. Continuation for all vehicles – Remove cylinder head cover. ⇒ page 48 – Lift cylinder head slightly and remove from engine laterally past toothed belt guard. – Lift engine slightly using spindle -A. agen lksw Vo by inder head and cylinder block. un le n AG.and push it to side. – Unhook spindle -B.4. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en The cylinder head must be guided carefully to prevent damage. When using abrasive paper do not use a grade less than 100. Ensure that no long scores or scratches are created. . Note Note identification on cylinder head gasket ⇒ page 47 .2 Note Installing ♦ Do not remove new cylinder head gasket from packaging until it is ready to be fitted. – Turn crankshaft to TDC marking before fitting cylinder head.is relieved. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.until spindle -B. is n mm ot p co erm or te itte va ri d p – Maintain sequence when loosening cylinder head bolts. – Turn crankshaft opposite engine direction of rotation until all pistons are approximately equally placed below TDC. Gr. Co py i r fo ng ♦ Always renew cylinder head bolts. 1. Prote cted by ht rig py Co t.9 l engine) . Damage to the silicone coating or the indented area will lead to leaks.

exterior. Before fitting toothed belt.2009 – Fit cylinder head and tighten all cylinder head bolts hand-tight. 50 . – Install toothed belt ⇒ page 50 . testing and information system -VAS 5051B.front. Assembly overview. Body . Cylinder head 71 . Gr. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce urposes. – Tighten cylinder head in four stages in sequence as shown as follows: 1Tighten initially with torque wrench: Stage I = 35 Nm Stage II = 60 Nm 2Stage III = 1/4 turn (90°) Stage IV = 1/4 turn (90°) Note Turn further with rigid spanner: n AG. 1. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.5 Note Checking compression If ceramic glow plugs are fitted. ht rig py Co t. installing and tightening toothed belt.9 l engine) . note the following: – After tightening cylinder head.front. – Install insulation tray ⇒ General body repairs. agen lksw Vo by AG. Rep. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his After repair work it is not necessary to retighten the cylinder head bolts. Rep. The compression test is warranted only if one or more cylinders are conspicuous in this idling speed check. before removing check idling speed smooth running control using vehicle diagnostic.Edition 01. exterior. 1 cylinder equally point upwards. Gr. Prote cted by cop yri gh t . Body . – Install plenum chamber bulkhead ⇒ General body repairs. 1. 50 . – Install oil supply line ⇒ page 95 . – Carry out road test and then read fault memory ⇒ page 178 . Further installation is carried out in the reverse order. in part or in wh ole.C op yi do cu m en – Install hub for camshaft toothed belt pulley ⇒ page 147 . – Install poly V-belt ⇒ page 13 . In the proc‐ ess. Plenum chamber bulk‐ head .Golf 2004 ➤ . turn camshaft so that cams for No.. – Fill cooling system with coolant ⇒ page 102 . Re‐ moving and installing camshaft. turn crankshaft in engine direction of rotation ⇒ page 50 . removing.

Golf Plus 2005 ➤ 4-cylinder diesel engine (1. in part or in wh ole.A.oris tee h t or ac au Torque wrench ss urposes.15 . Volkswagen AG do es n wage ot g olks yV ua db ran e Jointed spanner -3220. Co py i . Prote cted by c o py rig ht.A.2009 Special tools and workshop equipment required ♦ ♦ n AG. Note If ceramic glow plugs are fitted.9 l engine) . 72 Rep.G 1381/12♦ Compression tester V.G 1763- rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en Test prerequisite • Engine oil temperature min.Golf 2004 ➤ . valve gear ht rig py Co t.A.Cylinder head.G 1331- ility ab y li an pt ce ♦ Adapter -V.Edition 01. Test procedure – Pull off central connector for unit injectors. always observe notes on remov‐ ing and installing ceramic glow plugs ⇒ page 198 . 30 °C.. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng V. Gr. agen lksw Vo by AG. – Remove all glow plugs or ceramic glow plugs using jointed extension and socket -3220.

– Read fault memory of engine control unit. AG en AG. agen lksw Vo by Prote cted by Specified torque: 15 Nm. always observe notes on remov‐ ing and installing ceramic glow plugs ⇒ page 198 .2009 engine no – Screw in adapter -V.Edition 01. in part or in wh ole.G 1381/12. ⇒ page 178 Note Disconnecting the central connector for unit injectors causes faults to be stored. do cu m en – Remove glow plugs or ceramic glow plugs using jointed ex‐ tension and socket -3220.31 bar. – Operate starter until tester shows no further pressure in‐ crease.Golf 2004w➤ enGolf Plus 2005 ➤ olks ag .G 1763. yV db ise or glowthplugs or au ss t gu ara nte eo ra c ility ab y li an pt ce – Check compression using compression tester -V.. wear limit: 19 bar Maximum permissible difference between all cylinders: 5 bar Note If ceramic glow plugs are fitted.9 l engine) . cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his Using compression tester ⇒ Operating instructions.. Note urposes. read fault memory and clear if nec‐ essary.. V does 4-cylinder diesel olkswag (1.A..A. Therefore.C op yi 1.in place of ceramic glow plugs. ht rig py Co t. Cylinder head 73 . c op yri gh t . Compression pressures: New: 25. AG.

20 Nm + 1/4 turn (90°) fur‐ ther ❑ Renew ❑ Note sequence when loosening and tighten‐ ing ⇒ page 80 . Gr. r fo ng . ❑ Oil contact surfaces.Golf 2004 ➤ . insert washers ⇒ Item 4 (page 74) in cylinder head. ❑ Before removing. Assembly overview . Prote cted by cop yri gh t . ❑ With hydraulic valve clearance compensa‐ tion.Rocker arm shaft ❑ Do not interchange.15 . ❑ Before installing. Volkswagen AG does 4-cylinder diesel engine (1.Washer ❑ For cylinder head bolts.valve gear ⇒ page 74 .valve gear 2 . ❑ Store with cam contact surface downwards ❑ Before installing.5 mm wide. is n mm ot p co erm or te itte va ri d p Cylinder heads with cracks between the valve seats may be used without reducing engine life. remove camshaft bearing caps 74 Rep.Cylinder head bolt ❑ Renew ❑ Note sequence when loosening and tighten‐ ing ⇒ page 67 . Golf Plus 2005 ➤ . provided the cracks are small and not more than 0. Renewing valve stem seals ⇒ page 78 . valve gear ht rig py Co t.2009AG agen ksw n 2 Note Valve gear es. 3 . Remov‐ ing and installing cylin‐ der head.Edition 01.Bucket tappet ❑ Do not interchange. agen lksw Vo by AG. in part or in w l purpos hole ercia . ❑ Insert in cylinder head before installing bearing caps 5 . Checking valve guides ⇒ page 76 . un le ss Vol by ed ris tho au ot g ua ran tee or ac ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en Removing and installing camshaft ⇒ page 80 Removing and installing camshaft seal ⇒ page 84 2.Cylinder head.9 l engine) . 4 .C op yi 1 . check camshaft axial clearance ⇒ page 76 . Re‐ moving and installing camshaft.1 Assembly overview .

13 .Edition 01. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Inner valve spring ❑ Removing and installing: with cylinder head removed.Unit injector ❑ Removing and installing ⇒ page 169 . seal parting surfaces of bearing caps 1 and 5 with sealant -AMV 174 004 01.Valve cotter 7 . Volkswa 10 .C op yi 2.⇒ page 76 19 . use valve spring compressor -2037. 9 .Seal ❑ Do not additionally oil or grease the oil seal sealing lip.g. urposes.Camshaft ❑ Checking axial clearance ⇒ page 76 .Valve spring plate 8 .Golf 2004 ➤ .01 mm.Outer valve spring ❑ Removing and installing: with cylinder head removed. ❑ Removing and installing ⇒ page 84 . ❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head ht rig py Co t. Prote cted by cop yri gh t .Bearing cap ❑ Installation sequence ⇒ page 80 ..Valve stem seal ❑ Renewing ⇒ page 78 n AG. Valve gear 75 . in part or in wh ole. wear limit: 0. 0.Bearing shell ❑ Do not interchange used bearing shells (mark). wage olks V by ed ris tho au gen AG does not gu ara nte eo ra c 12 . cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n 11 . using Sellotape). 15 . with cylinder head installed ⇒ page 78 . Renewing valve stem seals. ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his 14 .11 mm. with cylinder head installed ⇒ page 78 . tape over groove in taper of camshaft (e. ❑ Runout: max. do cu m en 18 .Cylinder head ❑ See note ⇒ page 74 . Renewing valve stem seals. use valve spring compressor -2037.. 17 . ❑ Removing and installing ⇒ page 80 .2009 6 . removing and installing camshaft ❑ To install.Valves ❑ Valve dimensions ⇒ page 76 16 .Valve guide ❑ Checking ⇒ page 76 . ❑ To install. remove residual oil from camshaft journal using a clean cloth.8 Nm + 1/4 turn (90°) further ❑ Renew agen lksw Vo by AG.9 l engine) . ❑ Before installing. ❑ Check radial clearance with Plastigage.

15 . Gr.95 6.980 89.2 Checking valve guides Special tools and workshop equipment required 76 Rep. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. 0. Wear limit: max. Note urposes. valve gear AG.Golf 2004 ➤ . Prote cted by cop yri gh t .15 mm n AG.thinly and evenly on the sur‐ faces -1-. mm mm mm ∠° 31.9 l engine) . Only grinding-in is permissible.Cylinder head. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his Be careful that no sealant gets into grooves -arrows-. third and last with is tee or th or ac au ss ility ab y li an pt ce Seal parting surfaces of bearing caps 1 and 5 with sealant -AMV 174 004 01– Apply sealant -AMV 174 004 01.95 45 .Edition 01.C op yi do cu m en Dimension ∅a ∅b c α Inlet valve 35. ht rig py Co t. Valve dimensions Note Valves must not be reworked. Volkswagen AG do es n wage ot g olks V ua by ran removed and ed first.95 45 Exhaust valve agen lksw Vo by 2.2009 Checking camshaft axial clearance Special tools and workshop equipment required ♦ Universal dial gauge bracket -VW 387♦ Dial gauge Check with bucket tappets bearing caps fitted.956 89.45 6. in part or in wh ole.

r fo ng ht rig py Co t. Wear limit: max.Golf 2004 ➤ . Due to slight differences in stem di‐ ameters. The end of the valve stem must be flush with the guide.2009 ♦ Universal dial gauge bracket -VW 387- es. Prote cted by c op yri gh t. in part or in w l purpos hole ercia . – Determine rock. 1. Co py i 2. use only an inlet valve in inlet guide and an exhaust valve in exhaust guide. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. agen lksw Vo by AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en ♦ Dial gauge Test procedure – Insert new valve into guide.Edition 01.9 l engine) .3 mm – Cylinder head must be renewed if the rock is greater than the wear limit. Valve gear 77 . is n mm ot p co erm or te itte va ri d p un le n AG.

Edition 01. is n mm ot p co erm or te itte va ri d p rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng 2.3 Renewing valve stem seals n AG. Prote cted by c o py rig ht. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. 78 Rep. in part or in w l purpos hole ercia .15 .9 l engine) .1 Removing (With cylinder head installed) – Remove camshaft.Golf 2004 ➤ . agen lksw Vo by AG. When doing this. ensure that tappets are not interchanged. Co py i . Gr. – Set piston of respective cylinder to top dead centre (TDC).3. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss Special tools and workshop equipment required ♦ Assembly tool -2036♦ Fitting tool -3129un le ♦ Puller -3047 A♦ Valve lever -VW 541/1A♦ Thrust piece -VW 541/5- ility ab y li an pt ce es.2009 2. ⇒ page 80 – Remove bucket tappets and place them with the contact sur‐ face downwards.Cylinder head. valve gear ht rig py Co t.

– Insert new valve stem seal in fitting tool -3129.. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng rrectness of i t to the co nf orm spec atio h re n in wit 2.. in part or in wh ole.. thi sd oc um en 2. AG. – Pull off valve stem seals using puller -3047 A. This will prevent the new valve stem seal -B. Valve gear ht rig py Co t. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Remove valve springs using valve lever -VW 541/1A.2 Installing – Place the plastic sleeve -A.3.C op yi 79 .supplied on the respective valve stem. Note The valves are supported by the piston crown. – Lubricate sealing lip of valve stem seal and carefully push on valve guide. Prote cted by c op yri gh t . Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce urposes.9 l engine) .and adjust mounting to height of studs. agen lksw Vo by AG.and press tool -VW 541/5.2009 – Insert valve assembly device -2036.being damaged.Edition 01.Golf 2004 ➤ .

9 l engine) .Cylinder head.A. Volkswagen AG d agen oes 4-cylinder diesel engine (1. agen lksw Vo by AG. valve gear ht rig py Co t.15 .Golf 2004 ➤ . 80 Rep.4.C op yi .4 Removing and installing camshaft urposes.G 1332- ♦ Sealant -AMV 174 004 01- thi sd oc um en 2. in part or in wh ole. Golf Plus 2005 ➤ AG.2009 no lks o 2. Gr.1 Removing – Remove toothed belt.G 1331♦ Torque wrench (40…200 Nm) -V.A. – Pull camshaft toothed belt pulley off hub. ⇒ page 50 – Remove securing bolts for camshaft toothed belt pulley -1-.Editionw01. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng yV db ise r tho au ss t gu ara nte eo ra c ility ab y li an pt ce Special tools and workshop equipment required ♦ Puller -T10052- ♦ Counterhold tool -T10051- rrectness of i t to the co nf orm spec atio h re n in wit ♦ Torque wrench (5…50 Nm) -V. Prote cted by c op yri gh t .

2009 – Loosen hub securing bolt -1-. This will prevent having to perform ba‐ sic settings of unit injectors -arrows-.9 l engine) . hold puller with 30 mm spanner.Golf 2004 ➤ .and screw securing bolts -1. Note First loosen both outer and then inner securing bolts respectively. Volkswa w olks yV db e ris tho au s no t gu ara nte eo ra c ility ab y li an pt ce urposes. AG. 1 and 3. Co py i 2. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n ss rrectness of i t to the co nform spec at ion h re wit in t his – Apply puller -T10052. – Loosen hub securing bolt agen AG2 turns. Note When doing this.Edition 01. – Remove cylinder head cover. – First remove bearing caps 5. Valve gear 81 . – Remove hub from taper of camshaft. Prote cted by c o py rig ht. in part or in wh ole.gen AG doe about .into hub. – Remove tandem pump ⇒ page 147 .. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Remove camshaft. Then loosen bearing caps 2 and 4 alternately and diagonally. – To do this. agen lksw Vo by do cu m en – Remove rocker arm shafts. use counterhold tool -T10051. – Apply tension to hub by evenly tightening puller until hub sep‐ arates from taper of camshaft. – Mark rocker arm shafts using a permanent felt tip marker to prevent interchanging. ht rig py Co t.

do cu m en – Tighten bearing caps 5.2009 2.Edition 01. AG. ss ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his ♦ Seal parting surfaces of bearing caps 1 and 5 with sealant - AMV 174 004 01. 1 cylinder cams must point upwards. Note pe rm itte d ♦ Before installing bearing caps. 1 and 3 using new bolts. ⇒ page 84 – Install rocker arm shafts and tighten securing bolts.thensure proper seating of retain‐ u ra a c ing lugs in bearing caps and cylinder head.. shells ara nte ise or eo When installing the camshaft. agen lksw Vo by – Install camshaft oil seal. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Fit hub onto camshaft.2 Note Installing ♦ When camshaft is installed. ensure that cylinder head bolt un le AG. – Install bearing caps 5. ♦ ♦ washers are inserted in the cylinder head. 82 Rep. – Tighten hub securing bolt -1. No.4. in part or in wh ole. cial p is n mer ot com – Oil bearing shell running surfaces. 1 and 3 likewise to 8 Nm +1/4 turn (90°). Gr.⇒ page 76 . evenly and diagonally to 20 Nm + 1/4 turn (90°). first the inner -2.Cylinder head. valve gear Prote cted by c op yri gh t . Volkswagen AG d agen oes not lksw gu Do not interchange used bearing d by Vo (mark). ht rig py Co t. use counterhold tool -T10051. – Tighten bearing caps 2 and 4 diagonally and alternately to 8 Nm + 1/4 turn (90°). because otherwise leaks can develop at tandem pump.15 . urposes.9 l engine) .C op yi .Golf 2004 ➤ . – To do this.and then the outer -1-. – Install bearing caps 2 and 4 using new bolts.to 100 Nm. or ate riv p or gf n ♦ Bearing cap 5 must align flush with outer edge of cylinder head.

– Hold adjuster screw in this position and tighten lock nut to 30 Nm. AG. – Remove dial gauge.Edition 01.C op yi When new tappets have been installed the engine must not be started for about 30 minutes. – Hand tighten securing bolts -1. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. es.2009 – Push camshaft toothed belt pulley onto hub. Volkswagen A . Valve gear 83 . Note ht rig py Co t.to camshaft toothed belt pulley so that there is no play.9 l engine) . – Align camshaft toothed belt pulley at centre of elongated holes. agen lksw Vo by 2. ss c ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en – Turn adjustment screw 180° back off stop. r fo ng – Install cylinder head cover. un le G do es n ot g ua ran ed is te or Screw new adjustment screws into rocker arms hand-tight and e o th ra au fit lock nut. – Install tandem pump ⇒ page 147 . Roller side -arrow A. in part or in w l purpos hole ercia . hydraulic compensation elements must settle (otherwise valves will strike pistons). – Now turn the adjuster screw into rocker arm until significant resistance can be felt (unit injector is at limit stop). by ge swa – – Turn crankshaft in direction of engine rotation until roller of rocker arm is located at tip of drive cam.is positioned at highest point and dial gauge -arrow B. is n mm ot p co erm or te itte va ri d p – Fit the dial gauge onto the adjustment screw of the unit injector as shown. Prote cted by cop yri gh t .Golf 2004 ➤ .is positioned at lowest point. Note The toothed segment -arrow.of the camshaft toothed belt pulley must be on top. nA Vol – Install and tighten toothedk belt ⇒ page 50 . – Lock hub using locking pin -3359-G.

. place it in position and exerting firm pressure. ⇒ page 50 – Remove camshaft toothed belt pulley and hub ⇒ page 80 .A.two turns (ap‐ prox.5 Removing and installing camshaft oil seal Special tools and workshop equipment required ♦ Fitting sleeves -10-203♦ Oil seal extractor -3240♦ Torque wrench -V. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit 2.Cylinder head.2009 2.Golf 2004 ➤ . cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng n AG. – Lubricate threaded head of oil seal extractor -3240. in part or in wh ole.1 Removing – Remove toothed belt.15 .A. – Loosen knurled screw and turn inner part against camshaft until oil seal is pulled out. Co py i thi sd oc um en 84 Rep. .G 1331♦ Torque wrench -V.9 l engine) . 3 mm) out of outer part and lock with knurled screw. Removing and installing camshaft.5.G 1332♦ Bolt M12×1. valve gear agen lksw Vo by AG. Prote cted by c o py rig ht. ht rig py Co t. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Unscrew inner part of oil seal extractor -3240.Edition 01. Gr. screw it as far as pos‐ sible into oil seal.5 × 65 urposes.

with Sellotape).2009 ut ra c sa s ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit The oil seal sealing lip must not be additionally oiled or greased. Co py i 2. agen lksw Vo by AG.2 Installing n AG. in part or in wh ole. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng 2.9 l engine) . – Tape over groove in taper of camshaft (e.and bolt M12 5x65 onto stop.Note urposes. – Remove oil residue from camshaft journal using a clean cloth. Valve gear 85 . thi sd oc um en ht rig py Co t.Edition 01. ara db nte se ri eo ho 4-cylinder diesel engine (1. Volkswagen AG do es n wage ot olks yV Golf 2004 ➤ guGolf Plus 2005 ➤ .5. Prote cted by c op yri gh t.g. – Install and tighten toothed belt ⇒ page 50 . – Press in oil seal with press piece of fitting tool -10-203. – Fit oil seal carefully on camshaft.

Area above hatched field up to max.Area from min.danger of damage to catalytic converter! Markings. BRU.Edition 01.17 .1 Oil capacities With oil filter change: 3.3 l Engine codes BLS and BXJ With oil filter change: 4. 0. max.2009 n AG.8 l 1.C op yi Engine codes BJB. Engine oil specification ⇒ Maintenance . agen lksw Vo by AG.3 l Without oil filter change: 3. BKC.17 – 1 Note Lubrication Engine oil urposes. Booklet 38 Oil capacities ⇒ page 86 Checking engine oil level ⇒ page 86 thi sd oc um en 1. Prote cted by cop yri gh t .2 Checking engine oil level 1 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. in part or in wh ole. mark 2 . c .Min. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng Golf 2004 ➤ .5 l of engine oil! 86 Rep. mark up to hatched field: Must be topped up.8 l Without oil filter change: 3.Oil level within hatched field: Can be topped up with engine oil. Gr.Max. BXE and BXF . mark: Do not top up with engine oil! b .Lubrication ht rig py Co t. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit The oil level must not be above the max. mark a . mark .9 l engine) .

O-ring ❑ Renew agen lksw Vo by AG.15 Nm Assembly overview . is n mm ot p co erm or te itte va ri d p Caution Finding metal shavings or a large quantity of small metal par‐ ticles during engine repair could indicate that the crankshaft bearings or conrod bearings are damaged. Parts of lubrication system 87 .Chain tensioner with ten‐ sioning rail.1 1 . ❑ Do not additionally oil or grease the oil seal seal‐ ing lip. ❑ Install with silicone seal‐ ant -D 176 404 A2⇒ page 23 . 2. To prevent this from causing further damage. sump ⇒ page 87 Removing and installing sump ⇒ page 88 un le n AG. Volkswagen AG do engine (1. sump r fo ng ht rig py Co t.Dipstick ❑ The oil level must not be above the max. 3 . ❑ Must be positioned on dowel sleeves.Guide tube 7 . Co py i 2 .Dowel sleeves 8 . mark! ❑ Markings ⇒ page 86 5 .oil pump.Edition 01. preten‐ sion spring and fit 4 . in part or in w l purpos hole ercia . Renew oil filter element Assembly overview . ❑ Removing and installing ⇒ page 23 .2 Parts of lubrication system es. Golf Plus 2005 ➤ .oil pump.pulley end ⇒ page 21 . Prote cted by c o py rig ht.9 l engine) 4-cylinder dieseles n wage ot g olks yV ua db ran e tee ris ho t or ac au ss Golf 2004 ➤ . ❑ Renewing crankshaft oil seal . perform the following repairs: Thoroughly clean oil channels. Renew oil cooler.Dipstick guide 6 . ❑ Before installing.2009 ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en 2. re‐ move oil residue from crankshaft journal using a clean cloth.Sealing flange ❑ With seal. 15 Nm ❑ When installing.

20 Nm + 1/4 turn (90°) further ❑ Renew r fo ng rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en 23 .25 Nm ❑ Insert without sealant.Oil level and oil temperature sender -G266❑ Black connector.9 l engine) .Edition 01.Oil drain plug. 18 .Seal ❑ Renew un le ss does not gu ara nte eo ra c ility ab y li an pt ce 19 . in part or in w l purpos hole ercia .2 Removing and installing sump Special tools and workshop equipment required 88 Rep. 3-pin.Chain sprocket for oil pump 21 . Volkswagen AG is or 17 . is n mm ot p co erm or te itte va ri d p .15 Nm 14 .C op yi 24 .Sump ❑ Clean sealing surface before fitting.Oil pump ❑ With 12 bar pressure relief valve ❑ Before installing. ❑ Install with silicone sealant -D176404A2❑ Removing and installing ⇒ page 88 .Suction line ❑ Clean strainer if soiled 11 . Prote cted by cop yri gh t .Bracket ❑ For oil level/temperature sender wiring harness.15 Nm 13 .Chain ht rig py Co t. 25 .10 Nmauth es. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.15 Nm 10 .17 . 22 .Golf 2004 ➤ . 30 Nmagen AG ksw Vol ❑ Renew ed by 16 . .Oil spray jet ❑ For piston cooling Note 2.2009 9 . check that both dowel sleeves for centring oil pump on cylinder block are fitted. ❑ Renew if running surfaces and gears are scored 20 .Lubrication agen lksw Vo by AG. Gr.Baffle plate 12 . 15 .

⇒ General body repairs.2009 ♦ Torque wrench -V. 5 mm -3249- urposes. agen lksw Vo by Prote cted by cop yri gh t .Edition 01.C op yi AG. 89 . exterior.2.front. – Pull 3-pin connector off oil level and oil temperature sender G266.A. – Remove sump. – Remove sealant residue from cylinder block with a flat scraper.. in part or in wh ole. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Loosen sump with light blows of a rubber headed hammer if necessary. 50 .1 Removing do cu m en – Drain engine oil. Parts of lubrication system ht rig py Co t. Rep. cial p is n mer ot com pe rm itte d un le n AG. Note Observe environmental regulations for disposal.G 1331- ♦ Hexagon key extension. Gr. Body .9 l engine) . – Remove insulation tray. 2.Golf 2004 ➤ . Assembly overview . Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his ♦ Hand drill with plastic brush attachment ♦ Silicone sealant -D176404A2♦ Hand drill with plastic brush attachment ♦ Eye protection ♦ Flat scraper or ate riv p or gf n 2.

no olks ss V by ed ris tho au t gu ara nte eo ra c ility ab y li an pt ce urposes. 3 mm nozzle ∅). ♦ The oil sump must be installed within 5 minutes of applying silicone sealing compound. Volkswablock the oil suction and may gen AG n does wage line strainer. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. otherwise excess sealing compound will enter the oil sump AG.g.2009 – Remove sealant residue on sump using a rotating brush.2 Note Installing ♦ Observe expiry date of sealing compound. as shown. 90 Rep.9 l engine) .Lubrication ht rig py Co t. an electric drill with a plastic brush attachment (wear safety goggles). in part or in wh ole.17 . Co py i .2. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en AG. ♦ Run bead along inner side of bolt holes -arrows-. e. Note The sealant bead must not be thicker. – Apply silicone sealing compound. They must be free of oil and grease. – Clean sealing surfaces. agen lksw Vo by Prote cted by c o py rig ht. 2. – Cut off tube nozzle at forward marking (approx.Edition 01.Golf 2004 ➤ . to clean sealing surface on sump. Gr. Sealing compound bead must be: ♦ 2…3 mm thick.

Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss Golf 2004 ➤ . – Tighten sump bolts diagonally to 15 Nm.9 l engine) . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.– Apply silicone sealing compound bead as shown to the clean sealing surface of the sump. Let sealing compound dry for approx. Ensure that sump is flush against intermediate plate and gear‐ box flange. 30 minutes after installing sump.2009 ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit When installing sump with engine out of vehicle. in part or in wh ole. Only then fill with engine oil. ht rig py Co t. AG. ensure that sump is flush with cylinder block at flywheel end.) – Install sump immediately and tighten all sump bolts lightly. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng n AG. Note thi sd oc um en Further assembly is basically the reverse of the dismantling se‐ quence. Co py i 2. agen lksw Vo by Prote cted by c o py rig ht.Edition 01. Parts of lubrication system 91 . – Tighten bolts securing sump to gearbox to 45 Nm. (The figure shows the position of the sealant bead on the cylinder block. Note urposes.

Engine oil cooler ❑ Ensure clearance to adjacent components. engine oil cooler and oil supply line Assembly overview .Seal ❑ Renew 11 .7 bar switch: brown.17 .Plug. oil pressure. nip open and renew. 25 Nm 13 . nip open and renew.Connection.oil filter bracket and oil cooler ⇒ page 92 Checking oil pressure and oil pressure switch ⇒ page 93 Assembly overview . Gr. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his 5 . 14 . in part or in wh ole. 12 .Seal ❑ Renew AG. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. c op yri gh t .Golf 2004 ➤ . Prote cted by 10 .oil supply line to turbocharger ⇒ page 94 Removing and installing oil supply line to turbocharger ⇒ page 95 3. ht rig py Co t.Oil filter bracket 2 .Oil filter element ❑ Ensure "Top" is upper‐ most when fitting do cu m en . 10 Nm ❑ If seal is leaking. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce urposes.1 Assembly overview .C op yi 9 .9 l engine) . 35 Nm 6 .Sealing cap.oil filter bracket and engine oil cooler 1 .Edition 01.Plug.Seal ❑ Renew.Gasket ❑ Renew 4 .Oil supply line. ❑ See note ⇒ page 87 . ❑ Removing and installing ⇒ page 95 .2009 3 Oil filter bracket.Oil pressure switch -F1❑ 0. 22 Nm ❑ To turbocharger. ❑ If seal is leaking. 7 . ❑ Checking ⇒ page 93 .15 Nm + 1/4 turn (90°) fur‐ ther ❑ Renew ❑ First fit upper left and lower right bolts and then tighten all four bolts diagonally.Lubrication agen lksw Vo by AG. ❑ Tighten to 20 Nm. 25 Nm 8 . 92 Rep. 3 .

Prote cted by c o py rig ht.10 Nm n AG.A.9 l engine) .G 1594 A- un le rrectness of i t to the co nform spec a tion h re wit in t his or ate riv p or gf n do cu m en 3.Edition 01. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. agen lksw Vo by AG.G 1527 B♦ Auxiliary measuring set V. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss 3. in part or in wh ole. 3.Gasket ❑ Renew. engine oil cooler and oil supply line ht rig py Co t. cial p is n mer ot com pe rm itte d ility ab y li an pt ce Special tools and workshop equipment required ♦ Oil pressure tester V.Bracket 17 .Golf 2004 ➤ . Co py i 93 . oil pressure.A. Electrical fault finding and Fit‐ ting locations Guided fault finding with VAS 5051.2.G 1342♦ Voltage tester V.2009 ❑ Checking engine oil cooler for leaks ⇒ page 112 15 .1 Note Test procedure Functional check and repair of optical and acoustic oil pressure warning: ⇒ Current flow diagrams.A. 16 .2 Checking oil pressure and oil pressure switch urposes. Oil filter bracket.

– Screw tester into oil filter bracketlkswagen of oil pressure in place AG. If necessary renew oil filter bracket.10 Nm r fo ng 6 . Vo AG do agen switch.10 Nm ht rig py Co t. in part or in w l purpos hole ercia . ris o yV es.Retaining clamp 2 . 22 Nm 94 Rep. Prote cted by cop yri gh t . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. 5 .A. LED must not light up.Union nut. un le tho ot g ua ran tee o ac battery positive r(+) At higher engine speed.oil supply line to turbocharger 1 . es n lksw b e – Connect brownd wire of tester to earth (-). At 2000 rpm and an oil tem‐ perature of 80 °C the oil pressure should be at least 2.C op yi 4 .85 bar the LED must light up.Oil supply line ❑ To turbocharger. – Increase engine speed further.Bracket 7 .0 bar.Golf 2004 ➤ .Edition 01.. – At 0.3 Assembly overview .A.9 l engine) . ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en 3. otherwise renew oil pressure switch.Union nut.17 . 22 Nm 8 .G 1527 B.G 1594 A.55…0. . Gr. oil pressure must not exceed 7.25 Nm 3 .Lubrication agen lksw Vo by AG. – Start engine and increase speed slowly.to s and oil pressure switch using cables from auxiliary measuring set -V.2009 – Remove oil pressure switch -F1. is n mm ot p co erm or te itte va ri d p – Connects au voltage tester -V.and screw into tester.0 bar.

and pull air filter housing upwards out of mounting. pull gu yV ara d bpull forwards out e upwards abruptly at front -arrows A. AG. – Loosen securing bolts for retaining clips. un le AG. ⇒ page 4 To do this. Gr. in part or in w l purpos hole ercia .G 1331- 3. Co py i 95 . Prote cted by c o py rig ht. t ra au c s s Removing ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en – Remove bolt -arrow A.front. – Remove oil supply line.Edition 01.Golf 2004 ➤ . ⇒ General body repairs. Oil filter bracket. 3.4. engine oil cooler and oil supply line agen lksw Vo by 3. 50 . Body . Assembly overview . r fo ng Note The procedure must be followed to ensure that oil supply line is installed tension-free.A. exterior. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Rep.4. is n mm ot p co erm or te itte va ri d p – Remove air filter housing with air mass meter and connecting pipe.and then nte ris eo ho of rear fastening -arrow B-.1 – es.2009 3.4 Removing and installing oil supply line to turbocharger Special tools and workshop equipment required ♦ Torque wrench -V. Volkswagen AG d agen oes ksw not olengine cover Remove engine cover. – Remove insulation tray.2 Installing ht rig py Co t. – Loosen oil supply line union nuts on oil filter bracket and tur‐ bocharger.9 l engine) . oil pressure.

17 .Edition 01.Golf 2004 ➤ . – First tighten union nut -8. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce urposes.on turbocharger hand-tight.on oil filter bracket and then union nut -6. 96 Rep.to 25 Nm.Lubrication ht rig py Co t. – Tighten securing nut -2. – Tighten union nut -6. – Attach retaining clips -1.on oil filter bracket hand tight.to brackets and tighten securing bolts to 10 Nm. – Start union nuts for oil supply line on connections.2009 n AG. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Further installation is basically the reverse of the removal proce‐ dure.9 l engine) . Co py i . – Tighten union nut -8. in part or in wh ole. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en – Loosen securing nut -2.from retainer -5-. Gr. agen lksw Vo by AG. Prote cted by c o py rig ht.on turbocharger to 22 Nm.

A.Golf 2004 ➤ .are recommended for fitting spring-type clips.or hose clip pliers un le V. If necessary. cial p is n mer ot com do not come into contact with other components (observe markings on coolant connection and hose). brake fluid and vacuum) and electrical wiring in their original po‐ sitions. Volk wage s no olks work. Co py i 1. for fuel. Parts of cooling system 97 . route stress-free so that they urposes. Prote cted by c o py rig ht. release pressure before beginning repairswagen AG doe n AG. ho b ed sure. rrectness of i t to the co nform spec a tion h re wit in t his or ate riv p or gf n do cu m en ht rig py Co t. the cooling system is under pres‐ ris ♦ Hoses are secured with spring-type clips. in part or in wh ole. Note ♦ When the engine is warm. In case of repair. refrigerant. hydraulics.9 l engine) . agen lksw Vo by AG. especially in the engine compart‐ ment. ♦ Ensure that there is sufficient clearance to all moving or hot components. t au ss ara nte e or ac ility ab y li an pt ce ♦ When installing coolant hoses.G 1921.2009 19 – 1 Cooling Parts of cooling system WARNING When doing any repair work. pay attention to the following due to the cramped condi‐ tions: ♦ Route all the various lines (e.Edition 01. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. coolant. pe rm itte d ♦ Spring-type clip pliers -VAS 5024.g. t gu yV only use spring-type clips. acti‐ vated charcoal filter system.

G 1274/9.Sealing cap ❑ Check using cooling system tester V.6 bar.G 1274/8.Connector 6 .9 l engine) .Golf 2004 ➤ .Upper coolant hose ❑ Coolant hose schematic diagram ⇒ page 101 or ate riv p or gf n 2 . 8 .Cooling ht rig py Co t.G 1274/8.4.A.5 Nm 9 .5 Nm 7 . agen lksw Vo by AG. Removing and installing thermostat ⇒ page 108 Checking cooling system for leaks ⇒ page 110 Checking engine oil cooler for leaks ⇒ page 112 urposes.1.G 1274/9...A.A.Connector 14 .and adapters adapter -V. Gr.engine sideth⇒i page 99 Removing and installing radiator ⇒ page 105 .A. Parts of cooling system .. n AG.and adapt‐ er -V. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Expansion tank ❑ Check using cooling system tester V.1 Parts of cooling system.G 1274.10 Nm 10 .Additional fan ❑ Vehicles with optional equipment only. Prote cted by c op yri gh t.2009 Perform leakage test of cooling system using cooling system test‐ er -V.A. Co py i 3 ..Radiator fan 13 . renew entire coolant .19 . ❑ After renewing. 12 . Volkswagen A Vo .and adapt‐ er -V. in part or in wh ole.O-ring ❑ Renew if damaged.A. cial p is n mer ot com pe rm itte d Draining and filling with coolant ⇒ page 102 un le ss Coolant hose schematic diagram ⇒ page 101 au G do es n ot g ua ran tee or ac ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his 1.body side ⇒ page y98lk b d se ge swa or Parts of cooling system .. do cu m en 4 . Removing and installing coolant pump ⇒ page 106 . 5 .Fan support 11 .G 1274. ❑ Test pressure: 1. body side 1 .A.Cooler ❑ Removing and installing ⇒ page 105 .and adapt‐ er -V.Edition 01.Lower coolant hose ❑ Coolant hose schematic diagram ⇒ page 101 98 Rep.G 1274.

Retaining clip ❑ Check for secure seat‐ ing.Golf 2004 ➤ .To top of radiator ❑ Coolant hose schematic diagram ⇒ page 101 16 . 5 . engine side 1 .To heat exchanger ❑ Coolant hose schematic diagram ⇒ page 101 11 .Retaining clip ❑ Check for secure seating.40 Nm 12 .Radiator outlet coolant temperature sender -G83- 1.Edition 01.T-piece 15 .2 Parts of cooling system.To bypass flap ❑ Coolant hose schematic diagram ⇒ page 101 14 .To bottom of radiator ❑ Coolant hose schematic diagram ⇒ page 101 1. 16 .To top of expansion tank ❑ Coolant hose schematic diagram ⇒ page 101 2 .T-piece urposes. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n n AG.9 l engine) . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.2009 15 . agen lksw Vo by AG.15 Nm 17 .To exhaust gas recircula‐ tion cooler ❑ Coolant hose schematic diagram ⇒ page 101 8 . Parts of cooling system ht rig py Co t.O-ring ❑ Renew.To bottom of expansion tank ❑ Coolant hose schematic diagram ⇒ page 101 18 .10 Nm 10 . in part or in wh ole. 6 . Prote cted by c op yri gh t.To bypass flap ❑ Coolant hose schematic diagram ⇒ page 101 4 .Upper coolant pipe ❑ Bolted to cylinder head cover 3 .Coolant pipe 19 .Coolant temperature send‐ er -G62❑ With coolant tempera‐ ture display sender -G27 . Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his do cu m en 13 .Connection 9 . Co py i 99 .

23 . 100 Rep.C op yi 25 . cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n Golf 2004 4-cylinder n AG. do cu m en . Gr.2009 ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his 26 .To auxiliary heater ❑ Coolant hose schematic diagram ⇒ page 101 . ❑ Note installation position.20 . ❑ Removing and installing ⇒ page 106 .Rear coolant pipe 24 . removing and installing thermostat. 21 . ht rig py Co t. 22 . ❑ Check: Heat thermostat in water ❑ Opening begins at approx. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or ➤ .Engine oil cooler ❑ Removing and installing ⇒ page 92 .Edition 01. 105 °C ❑ Opening lift at least 7 mm. 29 . in part or in wh ole.9 l sengine) .To heat exchanger ❑ Coolant hose schematic diagram ⇒ page 101 . ❑ Observe installation position ⇒ page 108 .Coolant pump ❑ Check for ease of movement.Connection ❑ For thermostat.19 .Coolant pipe 28 .Thermostat ❑ Removing and installing ⇒ page 108 . 85 °C ❑ Ends at approx. Golf Plus 2005 ➤uth or ac a s diesel engine (1. 27 .To exhaust gas recirculation cooler ❑ Coolant hose schematic diagram ⇒ page 101 . Prote cted by cop yri gh t .Cooling agen lksw Vo by AG.10 Nm urposes.

cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his 11 .2009 1.3 Coolant hose schematic diagram 1 .Coolant pump and ther‐ mostat 12 .Heat exchanger for heater unit 5 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. do cu m en Note Coolant hose schematic diagram for vehicles with optional equip‐ ment ⇒ Heating.Expansion tank 2 . 82 .Upper coolant hose 8 .Bypass flap 3 .Exhaust gas recirculation cooler 4 . Connection diagram for coolant hoses in vehicles with auxil‐ iary heater ht rig py Co t.Golf 2004 ➤ .Gearbox oil cooler ❑ For gear oil ❑ Only on vehicles with automatic gearbox 7 . Prote cted by cop yri gh t . Rep. in part or in wh ole.9 l engine) . ventilation. agen lksw Vo by AG.C op yi 1.Auxiliary heater ❑ Vehicles with optional equipment only.Cylinder head/cylinder block n AG.Lower coolant hose 10 . Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce 6 .Engine oil cooler urposes. Gr.Edition 01.Cooler 9 . Parts of cooling system 101 . air conditioning system.

Rep. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.4 Draining and filling with coolant Special tools and workshop equipment required ♦ Refractometer -T10007-wagen AG.G 1274/8- urposes. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng th ♦ Spring-type uclip pliers a sAs VAS 5024 s no t gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en 1.2009 1. exterior. Gr. Steam may be released when cap is removed from expansion tank.A. Co py i .G e1306db is or ks Vol ♦ Cooling system charge unit -VAS 6096♦ Adapter -V. in part or in wh ole. Cover cap with a cloth and open carefully.A.Edition 01.9 l engine) .19 .4. Gr.1 Draining WARNING – Open cap on coolant expansion tank. 50 .Cooling ht rig py Co t. Body . agen lksw Vo by AG.front. Prote cted by c op yri gh t. – Remove insulation tray. Assembly overview . Volkswagen AG doe y ♦ Drip tray -V. ⇒ General body repairs.Golf 2004 ➤ . 102 Rep.

open drain plug -arrow-. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n n AG.Edition 01. urposes. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his do cu m en ht rig py Co t. Prote cted by c o py rig ht. Note Observe environmental regulations for disposal. agen lksw Vo by AG. – To drain coolant from engine.9 l engine) . in part or in wh ole. Co py i 1.Golf 2004 ➤ . also remove coolant hose from engine oil cooler -arrow-.2009 – To drain coolant from radiator. Parts of cooling system 103 .

exterior.is recommended for determining b ♦ If radiator.9 l engine) . gine reliability under heavy loads.0 l Water 1) 4. Therefore.2 Note Filling ♦ In vehicles as of model year 2008. Gr.G 1274/8. Body . ♦ Coolant additives marked “according to TL VW 774 G” or “ac‐ ♦ Because of its higher boiling point.8 l 4. y ed cylinder head or cylinder head ris gasket is renewed.A. ♦ If for climatic reasons greater frost protection is required. – Connect coolant hoses to oil cooler.onto expansion tank.19 .front. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.n AG. the coolant improves en‐ ♦ Frost protection is required down to about -25 °C (in countries ♦ The coolant concentration must not be reduced by adding wa‐ ter even in warmer seasons and in warmer countries. – Install noise insulation tray. – Close radiator drain plug. – Fill coolant circuit using cooling system charge unit VAS 6096. cording to TL VW 774 F” prevent frost and corrosion damage.⇒ Operating instructions for cooling system charge unit VAS 6096 ht rig py Co t. the current anti-freeze concentration.Cooling agen lksw Vo by AG. only G 12 plus-plus ac‐ cording to TL VW 774 G may be used as coolant additive. ⇒ General body repairs.2009 1. do onot reuse old coolant. particularly in countries with tropical climates. . scaling and also raise boiling point of coolant. in part or in wh ole. The coolant additive concentration must be at least 40 %.Golf 2004 ➤ . Identification: Both are coloured purple. 50 . previous coolant additive G 12 plus. ♦ For vehicles up to and including model year 2007 coolant ad‐ ♦ The coolant additive G 12 plus-plus can be mixed with the ditive G 12 plus according to TL VW 774 F and G 12 plus-plus according to TL VW 774 G can be used. the cooling system must be filled all year round with coolant ad‐ ditive and corrosion protection additive. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n au ss Recommended mixture ratios: Frost protection to -25 °C -35 °C 1) Anti-freeze proportion 40 % 50 % G 12 plus1) G 12 plusplus1) 3. Otherwise frost protection and cooling effectiveness are reduced again. th urposes. – Screw adapter -V.C op yi do cu m en 104 Rep.2 l 4.Edition 01. Gr. Rep. with arctic climates: down to about -35 °C). the amount of coolant additive can be increased. Prote cted by cop yri gh t . but only up to 60 % (frost protection to about -40 °C). heat exchanger. Assembly overview . Volkswagen AG doe wage ks Vol s no t gu ara nte eo ra c ility ab y li an pt ce ♦ The refractometer -T10007.0 l rrectness of i t to the co nform spec at ion h re wit in t his The quantity of coolant can vary depending upon the vehicle equipment.4.

When installing.9 l engine) . – Separate connector for radiator fan. exterior. Volkswagen AG doe wag b ♦ Cooling systemycharge unit ed r -VAS 6096-is ho ks Vol urposes. Prote cted by 1. in part or in wh ole. 1.G 1331♦ Spring-type clip pliers VAS 5024 A♦ Adapter -V.5. note the following: – Fill with coolant. Parts of cooling system 105 . ⇒ page 102 AG. Body . Gr. ⇒ General body re‐ pairs.5.Edition 01. 50 . ⇒ page 102 – Pull coolant hoses off radiator. agen lksw Vo by c op yri gh t.5 Removing and installing radiator Special tools and workshop equipment required ♦ Refractometer -T10007♦ Drip tray -V.1 Removing ht rig py Co t. – Remove radiator downwards.front. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng t au ss s no t gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en – Bring lock carrier into service position. Lock carrier service position .A. Rep. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.G 1274/8-en AG.Golf 2004 ➤ .2009 1.G 1306♦ Torque wrench V. Co py i 1.A.A. – Remove radiator securing bolts.2 Installing Installation is carried out in the reverse order. – Drain coolant.

cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n Special tools and workshop equipment required ♦ Refractometer -T10007♦ Drip tray -V. – Remove toothed belt ⇒ page 50 .19 .Edition 01. in part or in wh ole.A.6 Removing and installing coolant pump urposes.A. – Remove poly V-belt ⇒ page 13 .G 1274/8♦ Cooling system charge unit -VAS 6096- n AG. agen lksw Vo by AG. – Drain coolant ⇒ page 102 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.G 1306♦ Torque wrench V.Cooling ht rig py Co t. Co py i . Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his do cu m en 1. Prote cted by c o py rig ht.2009 1.9 l engine) .A. 106 Rep.G 1331♦ Spring-type clip pliers VAS 5024 A♦ Adapter -V. Gr.6.1 Note Removing Always renew seals and gaskets.Golf 2004 ➤ .

– Insert coolant pump -2. When installing. in part or in wh ole.with coolant.2 Installing Installation is carried out in the reverse order.and carefully remove coolant pump. 1. agen lksw Vo by AG. Note The coolant pump plug faces downwards.9 l engine) . cial p is n mer ot com pe rm itte d un le n AG.6. – Fill cooling system with coolant ⇒ page 102 . Prote cted by c o py rig ht. urposes.for coolant pump -2. Co py i 107 .to 15 Nm. – Install poly V-belt ⇒ page 13 .in cylinder block and tighten securing bolts -1. Parts of cooling system ht rig py Co t.Golf 2004 ➤ . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.2009 – Remove securing bolts -1. – Install toothed belt ⇒ page 50 .Edition 01. note the following: – Moisten new O-ring -3. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his or ate riv p or gf n do cu m en 1.

7 Removing and installing thermostat Special tools and workshop equipment required ♦ Refractometer -T10007♦ Drip tray -V. do cu m en 108 Rep. 27 . Re‐ moving and installing alternator with poly V-belt . in part or in wh ole. Rep.G 1274/8♦ Cooling system charge unit -VAS 6096- urposes.7. Gr.A. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n n AG.2009 1. agen lksw Vo by AG. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his 1.9 l engine) . Gr.A. – Drain coolant. ⇒ Electrical system. ⇒ page 102 – Remove alternator.Edition 01.G 1331♦ Spring-type clip pliers VAS 5024 A♦ Adapter -V.1 Note Removing Always renew seals and gaskets. Prote cted by c o py rig ht.19 . Co py i . – Pull coolant hose off connection.Cooling ht rig py Co t.G 1306♦ Torque wrench V. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.A.Golf 2004 ➤ .

2009 – Remove securing bolts -1.with thermostat -4. Note The brace on the thermostat mustsbe almost vertical.Edition 01. ⇒ page 102 agen AG n AG. olk w – – urposes.into connection -2. Tightent ra au c s s ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his or ate riv p or gf n do cu m en ht rig py Co t. note the following: – Moisten new O-ring -3.of connection -2.to 15 Nm.and turn 1/4 turn (90 °) to right.with coolant. cial p is n mer ot com pe rm itte d un le – Replenish coolant. 1. V does wage not olks gu y V -2. agen lksw Vo by AG. – Turn thermostat -4.in cylinder block. Co py i 1. Prote cted by c o py rig ht.9 l engine) . – Insert thermostat -4.2 Installing Installation is carried out in the reverse order.7.Golf 2004 ➤ .with thermostat -4-. When installing. in part or in wh ole. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.and remove con‐ nection -2.1/4 turn (90°) to left and remove it from connection -2-. Insert connection b ara ed nte ris o eo hsecuring bolts -1. Parts of cooling system 109 .

9 l engine) .G 1274/9un le n AG. Test sequence: WARNING Hot steam may escape when expansion tank is opened. Prote cted by c op yri gh t.2009 1. agen lksw Vo by AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce es. is n mm ot p co erm or te itte va ri d p rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng Test prerequisite • Engine at operating temperature.19 . Gr. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.8 Checking cooling system for leaks Special tools and workshop equipment required ♦ Cooling system tester V. in part or in w l purpos hole ercia .Cooling ht rig py Co t.G 1274/8♦ Adapter for cooling system tester -V.G 1274♦ Adapter for cooling system tester -V. 110 Rep.Golf 2004 ➤ . Place rag over cap and open with caution.Edition 01.A. Co py i . – Open cap on coolant expansion tank.A.A.

9 l engine) . If pressure drops: – Find leaks and rectify. 1. Volkswagen AG do e n wage ot g olks tester -V. tee ris ho t or ac a Use handupump on cooling system tester to create a pressure ss of max.A. If the pressure relief valve does not open: – Renew sealing cap. Checking pressure relief valve in filler cap – – urposes.A.G 1274. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.G 1274.A.2009 – Attach cooling system tester -V. agen lksw Vo by AG. Co py i 1.Golf 2004 ➤ . The pressure relief valve must open.Edition 01.to cap.to expansion tank. in part or in wh ole. – Increase pressure to over 1. If the pressure relief valve opens prematurely: – Renew sealing cap. ility ab y li an pt ce The pressure relief valve must not open.G 1274/9.with cooling system tester adapter -V. – Use hand pump on tester to create a pressure of about 1.6 bar.0 bar.6 bar. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n n AG. rrectness of i t to the co nform spec at ion h re wit in t his do cu m en ht rig py Co t.A. Prote cted by c o py rig ht. Parts of cooling system 111 .withscooling system Attach cooling system yV ua db ran tester adaptere-V.G 1274/8.

Cooling ht rig py Co t.C op yi . in part or in wh ole.A.A.or -1J0 121 407 B♦ Plug -191 211 343- 112 Rep.2009 1.Edition 01.G 1331- Not illustrated: ♦ Expansion tank -1K0 121 407 A. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng Special tools and workshop equipment required G do es n ot g ua ran tee or ac ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en Special tools and workshop equipment required ♦ Torque wrench -V.9 Checking engine oil cooler for leaks ss agen ksw Vol y db ise or th au ♦ Refractometer -T10007♦ Hose clamps up to Ø 25 mm -3094♦ Cooling system tester V.9 .G 1274/8♦ Spring-type clip pliers -VAS 5024A♦ Drip tray -VAS 6208- urposes.l Volkswagen A AG engine) . Gr.G 1274♦ Adapter for cooling system tester -V. Prote cted by cop yri gh t .A. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.or -6Q0 121 407 A.Golf 2004 ➤ . agen lksw Vo by AG.19 .

A. – Secure sealing plug -2. – Loosen spring type clips -arrows. rrectness of i t to the co nform spec at ion h re wit in t his Assembly is carried out in the reverse order. Parts of cooling system 113 . Assembly overview . yV AG do es n ot g ua b ra ed ris Attach cooling systemotester -V. Gr.6 bar.front.to breather connection of expansion tank -1-. – Clamp supply line and return line off engine oil cooler using hose clips to ∅ 25 mm -3094. olkswagen olk – Fill expansion tank up to “Max”smarking. exteri‐ or. – Secure coolant hose -3. Prote cted by cop yri gh t . If pressure drops: – Renew oil cooler.G 1274...A. Note Collect escaping coolant with drip tray -VAS 6208.to expansion tank. A pressure drop within 10 minutes is not permitted.9 l engine) . cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n nA wage – ility ab y li an pt ce Use hand pump on tester to create a pressure of about 1.to rear connection of oil cooler -4-. 50 .G 1274/8. Body . if necessary replenish coolant.with cooling system ntee o th ra tester adapter -V. note the following: – Check coolant level. – Push sealing cap -5.2009 ♦ Cap -1J0 121 324♦ Coolant hose -251 265 056♦ Screw clamp Test prerequisite: • Engine cold Test procedure – Remove noise insulation tray ⇒ General body repairs. G.Edition 01.noise insulation . Watch pressure drop on pressure gauge.to oil cooler andVexpansion tank. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.. au c ss urposes. – Pull coolant hoses off oil cooler.Golf 2004 ➤ .C op yi 1. agen lksw Vo by AG. do cu m en ht rig py Co t.using spring type clip pliers -VAS 5024A. Rep. in part or in wh ole.

Then carefully loosen connection to release the pressure! rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en ♦ Before beginning work. coolant.g. When removing and installing fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel tank.C op yi ♦ Wear eye and hand protection when performing any type of repair work on the fuel system! . If no exhaust gas ex‐ traction system is available. for fuel. acti‐ vated charcoal filter system. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng n AG. observe the following: ht rig py Co t.Golf 2004 ➤ .Fuel supply system agen lksw Vo by AG. place cloths around the connections.20 . in part or in wh ole. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) . ♦ Ensure that there is sufficient clearance to all moving or hot components. ♦ Prevent skin contact with fuel! Wear fuel-resistant gloves! 114 Rep. a radial fan with a displacement greater than 15 m3/h can be used providing that motor is not in air flow. pay attention to the following due to the cramped condi‐ tions: ♦ Route all the various lines (e. Gr. refrigerant. place an extraction hose close to sender opening in fuel tank to extract escaping fuel fumes and switch on exhaust extraction system.2009 20 – 1 Fuel supply system Safety precautions when working on fuel supply system WARNING urposes.Edition 01. brake fluid and vacuum) and electrical wiring in their original po‐ sitions. hydraulics. Prote cted by cop yri gh t . Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce When doing any repair work. especially in the engine compart‐ ment. ♦ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! ♦ The fuel system is also under pressure! Before opening the system.

g. pe rm itte d s ♦ Carefully covers opened components or seal if repairs cannot be carried out immediately. in part or in wh ole. ♦ Also ensure that no diesel fuel runs on to the coolant hoses.2009 2 Rules for cleanliness When working on the fuel supply and injection systems. t au or ac ility ab y li an pt ce un le rrectness of i t to the co nform spec a tion h re wit in t his or ate riv p or gf n do cu m en ht rig py Co t. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Do notguse on ran is tee fluffy cloths! or h urposes. Do not move vehicle unless absolutely nec‐ essary. Prote cted by cop yri gh t . agen lksw Vo by AG.Golf 2004 ➤ .). Do not use parts that have not been stored in their packing (e.Edition 01. Damaged hoses must be renewed. e wage ks Vol s no t ua ♦ Place removed parts ed bya clean surface and cover. ♦ When system is open: do not work with compressed air if this can be avoided. Rules for cleanliness 115 . Volkswagen AG do connecting. the hoses must be cleaned immediately. in tool boxes etc. Do not remove replacement parts from packing until immediately before installing. Should this occur. cial p is n mer ot com ♦ Install clean components only. pay care‐ ful attention to the following “6 rules” for cleanliness: ♦ Thoroughly clean all unions and adjacent areas before dis‐ n AG.C op yi 2.9 l engine) .

Seal ❑ Renew if damaged.Edition 01.Clamping washer r fo ng . Removing and installing fuel tank ⇒ page 121 .25 Nm ❑ To secure the securing straps for the fuel tank. 9 . Prote cted by c op yri gh t. ❑ Removing and installing ⇒ page 121 . 10 .20 . vehicles with front-wheel drive Observe safety precautions ⇒ page 114 . agen lksw Vo by AG. ❑ Moisten with fuel when installing 116 Rep.Fuel supply system ht rig py Co t. Bolts ⇒ ET‐ KA (electronic parts catalogue) . Emptying fuel tank ⇒ page 117 . Removing and installing fuel gauge sender ⇒ page 124 .Heat shield ❑ For fuel tank.2009 3 Fuel tank. only bolts with loose washers must be used. Assembly overview .9 l engine) . ot g olks V 4 .fuel tank ⇒ page 116 .Earth connection ❑ Check for secure seat‐ n AG.fuel tank 1 . sup‐ port using engine and gearbox jack -V.Sealing cap 2 ..1.Fuel tank ❑ When removing. Gr.A. the securing straps could be twisted whilst tightening.5 Nm 3 . Checking fuel pump ⇒ page 125 .10 Nm un le 5 . ❑ Renew.Golf 2004 ➤ .Wiring duct es. Co py i 8 . 3. Observe rules for cleanliness ⇒ page 115 .1 Assembly overview . 7 . rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en 11 . If other bolts are used.G 1383/A. Removing and installing fuel delivery unit ⇒ page 123 . Volkswagen AG do es n wage ing.Securing strap ❑ Note installation posi‐ tion. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. is n mm ot p co erm or te itte va ri d p by ed ris ho ut sa s ua ran tee or ac ility ab y li an pt ce 6 . in part or in w l purpos hole ercia .

vehicles with front-wheel drive agen lksw Vo by AG. ht rig py Co t. ❑ Checking fuel pump ⇒ page 125 . Fuel tank.Fuel delivery unit ❑ With fuel gauge sender (G).2 Emptying fuel tank Special tools and workshop equipment required 3. Return line blue or with blue marking -1-. ❑ To pull off flange. Gr.Tank flap unit ❑ Removing and installing ⇒ General body repairs. press release button on connecting piece. ❑ Specified torque: 110 Nm. Note After installing fuel delivery unit flange. check that supply. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n 12 . ❑ Removing and installing fuel gauge sender ⇒ page 124 .Supply line ❑ To fuel filter ❑ Clipped onto fuel tank ❑ Check for secure seating.on the flange must align with marking on the fuel tank. ❑ Clipped onto fuel tank ❑ Check for secure seating. Tank flap unit .2009 an e is tee or th or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his 13 . ❑ Note installation position of flange on fuel tank ⇒ page 117 .9 l engine) . 14 . press release button on connecting piece. ❑ Removing and installing ⇒ page 123 . exterior. in part or in wh ole.. ❑ Clean strainer if soiled n AG. Volkswagen AG do Plus 2005 ➤ es wage Golf 2004 ➤ .urposes. 3.Return line ❑ From fuel cooler ❑ Blue or with blue marking.Locking ring ❑ Remove and install using fuel tank sender unit tool -T10202. Golf n ot g olks 4-cylinder d by V engine (1. ❑ Black ❑ To pull off flange. return and breather lines are still clipped onto fuel tank. 117 . Supply line (black) -2-. Prote cted by cop yri gh t .Edition ar diesel u 01. Installation position of fuel delivery unit Marking -3. 15 .C op yi do cu m en 16 . 55 . Rep.

Emptying fuel tank. in part or in wh ole.9 l engine) se ♦ Fuel extractor -VAS 5190- urposes.Fuel supply system ht rig py Co t. agen lksw Vo by AG. wrap a cloth around the connec‐ tion. Emptying fuel tank if more than 3/4 full ⇒ page 120 Emptying fuel tank if less than 3/4 full ⇒ page 120 3. bleeding fuel system when fuel pump is intact ⇒ page 118 .ag Golf 2004 ➤ .A.2. Prote cted by cop yri gh t . Then release pressure by carefully pulling hose off con‐ nection. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng ri tho au ss olkswagen AG en AG. 118 Rep. V does not gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit ♦ Fuel tank sender unit tool -T10202- thi sd oc um en ♦ Torque wrench (40…200 Nm) -V.C op yi .20 . Gr. bleeding fuel system when fuel pump is intact Special tools and workshop equipment required ♦ Diagnostic tester ♦ Fuel extractor -VAS 5190♦ Adapter for fuel extraction -VAS 5190 /3 WARNING Fuel supply line is pressurised.Edition 01. Before loosening hose connections.2009 d 4-cylinder diesel engine (1. Golf Plus 2005 ➤ ksw Vol by .G 1332– Note safety precautions before beginning work ⇒ page 114 . Note Press in securing ring to release fuel lines. Wear eye protection and pro‐ tective clothing to avoid possible injury and skin contact.1 Emptying fuel tank.

Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit – Connect fuel extractor -VAS 5190.with adapter for fuel ex‐ tractor -VAS 5190 /3 .. Bleeding fuel system 1) Low-pressure section • Fuel tank filled. “stop” the function to prevent the fuel pump from running “dry”. – Connect a diagnostic tester. Co py i 119 . Prote cted by The fuel pump is being activated when engine is not running. 3. in part or in wh ole. – Perform the function “Bleeding fuel system” in “guided func‐ tions”. agen lksw Vo by c op yri gh t. – Remove filler cap from fuel tank filler neck. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng n AG. – Perform the function “Emptying fuel system” in “guided func‐ tions”. urposes. Fuel tank. Note – Switch on ignition. If the fuel tank is emptied.Edition 01. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.2009 – Pull off supply line -arrow.and catch escaping fuel with a cloth.9 l engine) . – Operate shut-off tap on fuel extractor -VAS 5190.to fuel supply line. thi sd oc um en – Connect a diagnostic tester.Golf 2004 ➤ . ht rig py Co t. vehicles with front-wheel drive AG. until the fuel tank is emptied.

2.Fuel supply system agen lksw Vo by ♦ If the fuel tank has to be drained fully. Therefore push hose into filler neck only as far as marking -arrow-. Note do cu m en enough for the sender flange to be opened without danger. e wage – Push extraction hose into fuel tank until marking eonyhose db ris -arrow.2009 3. ho t urposes. – At distance -a.3 Emptying fuel tank if it is less than 3/4 full – Remove bench seat ⇒ General body repairs.is located at the bottom of the filler neck in the fuel tank -1-. – Remove cotter -2. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Removing and installing bench seat . Prote cted by c o py rig ht. the tank is emptied just . Gr. proceed as follows: ht rig py Co t. it must not be damaged by the extraction hose -3-. Rear seats. interior. Co py i ♦ When no more fuel is extracted.9 l engine) . 120 Rep. – Remove filler cap from fuel tank filler neck.Edition 01. 72 . in part or in wh ole. Volkswagen AG do filler neck.= 1180 mm from end.of fuel extractor -VAS 5190.coincides with shaft end. AG. Rep..20 .to a bare metal part of the body.of fuel extractor unit -VAS 5190. Gr. ⇒ page 120 3. mark extraction hose with insulating tape -arrow-.from shaft -1. – Screw shaft end -1.Golf 2004 ➤ .2 Emptying fuel tank if it is more than 3/4 full Caution Secure earth wire of fuel extractor -VAS 5190. – Empty fuel tank as far as possible. – Carefully pull out extraction hose.onto fuel n AG.2. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n au ss ks Vol s no t gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his Note A ball valve -2.

– Open locking ring using fuel tank sender wrench -T10202. WARNING Fuel supply line is pressurised. in part or in wh ole. reinstall sender flange. agen lksw Vo by AG. – Insert extraction hose of fuel extractor -VAS 5190. 3.G 1383/A- or ate riv p or gf n do cu m en 3.Edition 01.as deeply as possible into fuel tank and extract fuel.Golf 2004 ➤ . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Volkswagen AG a lksw does not gu ara nte eo ra c ility ab y li an pt ce urposes.2009 – Remove cover from fuel delivery unit. Prote cted by c op yri gh t. vehicles with front-wheel drive ht rig py Co t.3 Special tools and workshop equipment requiredby Vo ♦ Torque wrench -V. – Pull connector and fuel lines off flange.A. wrap a cloth around the connec‐ tion. If fuel tank needed only to be emptied. Co py i 121 . cial p is n mer ot com un le rrectness of i t to the co nform spec a tion h re wit in t his ♦ Engine and gearbox jack -V..G 1331pe rm itte d ed ris ho t au ss Removing and installing fuel tankgen AG. Before loosening hose connections.A. Note Press buttons on hose couplings to do this. – Lift sender flange. Then release pressure by carefully pulling hose off con‐ nection.9 l engine) . Wear eye protection and pro‐ tective clothing to avoid possible injury and skin contact. Fuel tank.

Fuel supply system AG. Rep. 66 .A. Rep. 3. Gr. – Fold rear seats forwards. ⇒ Supplementary heating. agen lksw Vo by – Remove cover from fuel delivery unit. – Slowly lower fuel tank. ⇒ General body repairs. c op yri gh t . disconnect battery earth strap. Check whether a coded radio is fitted. in part or in wh ole. In the process. 70 . ht rig py Co t. Gr. Rep. Prote cted by – Pull connector off flange. – Empty fuel tank ⇒ page 117 .3. Removing and installing luggage compartment floor do cu m en . Gr.20 . – Remove fuel flap unit.9 l engine) - 3. 55 . Removing and installing wheel housing liner . Load and luggage compartment trim. guide it carefully to prevent damage. – Remove bolts from filler neck -arrows-.G 1383/ A.2009 u ra a c ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his ♦ Before carrying out further work. – With the ignition switched off.2 Installing Installation is carried out in the reverse sequence of removal. – Disconnect fuel lines at front right of fuel tank. Obtain anti-theft coding first if necessary.for the fuel tank. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n AG. – If vehicle has supplementary heating. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. note the following: 122 Rep. Gr. ⇒ General body repairs.Golf 2004 ➤ . Note Press buttons on hose couplings to do this. ♦ When lowering fuel tank. exterior. exterior.. interior.3. Observe rules for cleanliness ⇒ page 115 . Removing and installing metering pump -V54 – Support fuel tank using engine and gearbox jack -V. ⇒ General body re‐ pairs.C op yi – Detach carpet under seats and fold it back. disconnect battery earth strap. Rep.1 Removing – Note safety precautions before beginning work ⇒ page 114 . 82 . – Tilt fuel tank to get it past rear axle. separate connector to metering pump and unclip wire. Note urposes. – Remove securing bolts -arrows. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th Edition 01. Gr. Fuel flap unit – Remove rear right wheel housing liner.

Load and luggage compartment trim. Prote cted by 3. Observe rules for cleanliness ⇒ page 115 .4. supply line black). agen lksw Vo by thi sd oc um en – Pull connector and fuel lines off flange. c op yri gh t .4 Removing and installing fuel delivery unit Special tools and workshop equipment required ♦ Fuel tank sender unit tool -T10202- ♦ Torque wrench -V. – Fold rear seats forwards. ⇒ General body repairs. – The fuel tank must not be more than 3/4 full when removing the suction-jet pump.G 1332- 3. Fuel tank. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce Removing rrectness of i t to the co nf orm spec atio h re n in wit – Note safety precautions before beginning work ⇒ page 114 . 70 .9 l engine) . 3. If so.1 urposes.C op yi 123 . Removing and installing luggage compartment floor – Remove cover from fuel delivery unit. vehicles with front-wheel drive ht rig py Co t. Rep. ♦ Clip fuel lines onto fuel tank. obtain antitheft coding. – With the ignition switched off. ♦ Do not interchange supply line and return line (return line blue or with blue marking. ♦ Ensure that fuel hose connections are tight. Drain fuel tank if necessary ⇒ page 117 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.2009 ♦ Install breather and fuel hoses free of kinks. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng AG. disconnect battery earth strap. interior.Edition 01. Gr.A. – First check whether a coded radio is fitted. – Detach carpet under seats and fold it back.Golf 2004 ➤ . in part or in wh ole. AG.

Golf Plus 2005 ➤ 4-cylinder diesel engine (1. in part or in wh ole. – Pull fuel delivery unit with seal out of opening in fuel tank. by Note does not gu ara nte eo ra c ility ab y li an pt ce ♦ Do not bend fuel gauge sender when installing. Note If delivery unit is to be renewed.C op yi – Remove fuel delivery unit. ♦ Insert seal for flange or fuel delivery unit dry into opening of fuel tank.Fuel supply system agen lksw Vo by AG.2 Installing . ⇒ page 123 . ♦ Note installation position of fuel delivery unit flange: mark on 3.Edition 01. Volkswagen AG ed ris tho au ss – Installing the fuel delivery unit is carried out in reverse kswagen AG order Vol of removal. ♦ Ensure that fuel hose connections are tight..20 . Then carefully loosen connection to release the pressure! ♦ Wear eye and hand protection when performing any type of repair work on the fuel system! – Remove union nut using fuel tank sender unit tool -T10202. place cloths around the connections. ♦ After installing fuel delivery unit. Prote cted by c op yri gh t .9 l engine) . drain old delivery unit before dis‐ posal.4. 3. do cu m en 124 Rep.2009 Note Press buttons on hose couplings to do this. Gr. check that the supply. flange must align with mark on fuel tank.5 Removing Removing and installing fuel gauge sender ht rig py Co t. return and breather lines are still clipped onto the fuel tank. urposes. WARNING ♦ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! ♦ The fuel system is also under pressure! Before opening the system.Golf 2004 ➤ . cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his ♦ Moisten seal with fuel only when installing flange or fuel de‐ livery unit.

A. – Fold rear seats forwards.⇒ page 126 c sa Checking fuel pump ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit ♦ Auxiliary measuring set -V. Installing – Insert fuel gauge sender into guides on fuel delivery unit and press upwards until it engages.or multimeter -V. thi sd oc um en All electrical consumers. Fuel pump must be heard to run.A.G 1594 C♦ Diode test lamp -V. ht rig py Co t.9 l engine) . Volkswagen AG d agen oes not lksw Vo gu by ara d voltage supply of fuel pumpe -G6. 70 . AG. ⇒ General body repairs.using a screwdriver and pull fuel sender off downwards -arrow-. e. in part or in wh ole. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Switch on ignition.and -4. – Raise retaining tabs -1.Golf 2004 ➤ .2009 – Release connector tabs of lines -3. Gr.1 Checking function and voltage supply Special tools and workshop equipment required ♦ Hand multimeter -V. Prote cted by The battery voltage must be at least 11. lights and rear window heating.C op yi Test prerequisites 3. Rep. must be switched off. interior. agen lksw Vo by c op yri gh t . Load and luggage compartment trim. If the fuel pump does not start: – Pull 4-pin connector off fuel delivery unit flange. Fuel tank. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng AG.A. – Switch off ignition.and -2.and pull them off.A.g. 3.G 1715- urposes. vehicles with front-wheel drive 125 .⇒ page 125 nte is or eo th u ra current consumption sof fuel pump -G6.G 1527 B• • • Fuses must be OK.5 V. – Detach carpet under seats and fold it back.G 1526 B.6 Checking Checking 3.6.Edition 01. Removing and installing luggage compartment floor – Remove cover from fuel delivery unit.

utho o n AG. – Start engine and run at idling speed. Prote cted by c o py rig ht. – If the measured value is not within specifications: – Renew fuel delivery unit.to outer contacts tof gu yV db connector using auxiliary cables from auxiliary measuring setaran e tee ris -V. Volkswagen AG do e wage – Check actuation of fuel pump relay and wiring for open circuit or short circuit.of con‐ nector and fuel pump.2 Checking current draw of fuel pump – Pull 4-pin connector off fuel delivery unit flange. in part or in w l purpos hole ercia . If no open circuit can be found: – Renew fuel delivery unit.5 Amperes.A.G 1594 C. – Connect contacts -4. The LED must light up for about 2 seconds.6.G 1594 C.A.of connector and fuel pump using auxil‐ iary cables from auxiliary measuring set -V. Co py i .G 1715. ⇒ page 123 es. Gr.Edition 01. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. sa ra c ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en 3. testing and information system VAS 5051 If LED lights up (voltage supply OK): – Remove fuel delivery unit.can also be attached to an auxiliary cable between contacts -1.G 1527 B. 7. – Set multimeter to measuring range 20 A and connect in series between contacts -1.G 1594 C. r fo ng agen lksw Vo by Note The current pick-up clamp of multimeter -V.20 .. ⇒ page 123 – Check that electrical wiring between flange and fuel pump is connected and has continuity..of connector and fuel pump using an auxiliary cable from auxiliary measuring set -V.Fuel supply system ht rig py Co t. AG.Golf 2004 ➤ . is n mm ot p co erm or te itte va ri d p If LED does not light up un le s – Switch on ignition. – Measure current draw of fuel pump: Specification: max.A.2009 s no olks – Connect diode test lamp -V. ⇒ Vehicle diagnosis.A..9 l engine) .A. ⇒ page 123 126 Rep.

wage olks yV e . ❑ When installing. Fuel tank. gen AG does not gu ara nte eo ra c ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en 5 . 6 . Removing and installing fuel gauge sender 2 -G169⇒ page 135 . Co py i 4. ❑ With fuel gauge sender -G❑ Removing and installing fuel gauge sender ⇒ page 124 . vehicles with four-wheel drive Observe safety precautions ⇒ page 114 .Golf 2004 ➤ . Tank flap unit.9 l engine) . 110 Nm ❑ Check for secure seat‐ ing. Removing and installing fuel tank flap unit . agen lksw Vo by AG. 3 ..Seal ❑ Renew if damaged. Rep. Gr. ht rig py Co t. Removing and installing fuel tank ⇒ page 132 . ❑ Remove and install us‐ ing wrench -T10202.Supply lined b ris ho ut ❑ Black sa s Assembly overview .Locking ring. Observe rules for cleanliness ⇒ page 115 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. r fo ng un le n AG.Tank flap unit ❑ With rubber cup ❑ Removing and installing ⇒ General body repairs. is n mm ot p co erm or te itte va ri d p 2 . in part or in w l purpos hole ercia . 4 .fuel tank Volkswa ❑ Check for secure seat‐ ing.Return line ❑ Blue ❑ Check for secure seat‐ ing. 55 . Emptying fuel tank ⇒ page 128 . exterior.Edition 01. ❑ Note installation posi‐ tion on fuel tank ⇒ page 128 . Assembly overview . vehicles with four-wheel drive 127 .1 1 es. Removing and installing suction jet pump ⇒ page 137 Checking fuel pump ⇒ page 125 .fuel tank ⇒ page 127 . ❑ Checking fuel pump ⇒ page 125 .Fuel delivery unit ❑ Removing and installing ⇒ page 123 . 4.2009 4 Fuel tank. Prote cted by c op yri gh t. fit dry in fuel tank opening ❑ Moisten with fuel only when installing flange.

Fuel supply system AG.Securing bolt ❑ Tighten to 1. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng 11 . 9 .5 Nm. The marking on the flange must align with the marking on the fuel tank -arrow-. support using engine and gearbox jack -V. 14 .9 l engine) .Securing strap ❑ Note installation position. ❑ Renew. c op yri gh t. 8 . 15 .20 . the securing straps could be twisted whilst tightening. Co py i .2 Emptying fuel tank Special tools and workshop equipment required ♦ Fuel extractor -VAS 5190- 128 Rep.Fuel gauge sender 2 -G169- urposes.Edition 01.Fuel tank ❑ When removing. ❑ Removing and installing ⇒ page 132 . agen lksw Vo by Prote cted by Installation position of flange for fuel delivery unit and fuel gauge sender 2 -G169- ht rig py Co t. in part or in wh ole. 10 . ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit 13 .25 Nm ❑ To secure the securing straps for the fuel tank.G 1383 A.Suction-jet pump ❑ Clipped onto fuel gauge sender 2 -G169❑ Removing and installing ⇒ page 137 . If other bolts are used.10 Nm n AG. 16 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Cap ❑ Renew if damaged.Heat shield ❑ Riveted to exhaust pipe mounting thi sd oc um en Note The marking on the fuel tank is not clearly visible. Bolts ⇒ ETKA (electronic parts cata‐ logue) . Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss 12 .Golf 2004 ➤ . 4.2009 7 .Earth connection ❑ Check for secure seating.. only bolts with loose washers must be used. Gr.A.

Fuel tank. Then release pressure by carefully pulling hose off con‐ nection.2. un le rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en Note Press in securing ring to release fuel lines. Emptying fuel tank when fuel pump is intact ⇒ page 129 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.1 Emptying fuel tank. Before loosening hose connections.Golf 2004 ➤ .Edition 01.9 l engine) . – Pull off supply line -arrow. in part or in w l purpos hole ercia . Emptying fuel tank if it is less than 3/4 full ⇒ page 131 . Co py i 129 . Volkswagen AG do es n wage ot g olks yV ua db ran se i tee r/3 5190 ho t or ac au ss Special tools and workshop equipment required ♦ Diagnostic tester ♦ Fuel extractor -VAS 5190♦ Adapter for fuel extraction -VAS es. vehicles with four-wheel drive ht rig py Co t. r fo ng 4. is n mm ot p co erm or te itte va ri d p ility ab y li an pt ce WARNING Fuel supply line is pressurised. Prote cted by c op yri gh t. Emptying fuel tank if it is more than 3/4 full ⇒ page 130 . agen lksw Vo by AG.and catch escaping fuel with a cloth. bleeding fuel system when fuel pump is intact n AG.G 1332– Note safety precautions before beginning work ⇒ page 114 . wrap a cloth around the connec‐ tion. 4. Wear eye protection and pro‐ tective clothing to avoid possible injury and skin contact.A.2009 ♦ Fuel tank sender unit tool -T10202- ♦ Torque wrench (40…200 Nm) -V.

20 . – Remove filler cap from fuel tank filler neck. 130 Rep.Golf 2004 ➤ . – Switch on ignition. Co py i do cu m en If the fuel tank is emptied. – Operate shut-off tap on fuel extractor -VAS 5190. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n ss ot g ua ran tee or ac ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his – Connect a diagnostic tester.2. Bleeding fuel system 2) Low-pressure section • Fuel tank filled. n lksw Vo by ed ris tho au urposes.to a bare metal part of the body. Volkswagen AG d agen oes tractor -VAS 5190 /3 .2 Emptying fuel tank if it is more than 3/4 full Caution Secure earth wire of fuel extractor -VAS 5190. Prote cted by c o py rig ht..2009 – Connect fuel extractor -VAS 5190. in part or in wh ole. Gr. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Note The fuel pump is being activated when engine is not running. – Perform the function “Emptying fuel system” in “guided func‐ tions”. – Perform the function “Bleeding fuel system” in “guided func‐ tions”. until the fuel tank is emptied.to fuel supply line. ht rig py Co t. 4. .with adapter for fuel ex‐ AG. – Connect a diagnostic tester.9 l engine) . “stop” the function to prevent the fuel pump from running “dry”.Edition 01.Fuel supply system agen lksw Vo by AG.

– Empty fuel tank as far as possible. tho au ss At distance -a. proceed as follows: 4.onto fuel filler neck. Note ♦ When no more fuel is extracted. in part or in wh ole. Wear eye protection and pro‐ tective clothing to avoid possible injury and skin contact. the tank is emptied just enough for the sender flange to be opened without danger..2009 no lksw o t gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit – Remove filler cap from fuel tank filler neck. Volkswagen AG d agen o 4-cylinder diesel engine (1.is located at the bottom of the filler neck in the fuel tank -1-. vehicles with four-wheel drive ht rig py Co t. 72 . interior.9els engine) . Therefore push hose into filler neck only as far as marking -arrow-. Rep.2. – Push extraction hose into fuel tank until marking on hose -arrow.from shaft -1. mark extraction hose with Golf 2004 ➤ . WARNING Fuel supply line is pressurised.Edition 01. 4.= 1180 mm from end. urposes.of fuel extractor -VAS 5190. ⇒ page 131 ♦ If the fuel tank has to be drained fully. thi sd oc um en Note A ball valve -2.3 Emptying fuel tank if it is less than 3/4 full – Remove bench seat ⇒ General body repairs. Removing and installing bench seat .– – insulating tape -arrow-. it must not be damaged by the extraction hose -3-. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng yV db ise r Remove cotter -2. wrap a cloth around the connec‐ tion. Before loosening hose connections. agen lksw Vo by AG. – Carefully pull out extraction hose. Gr. Golf Plus 2005 ➤ AG. Rear seats. Fuel tank. – Remove cover from fuel delivery unit.coincides with shaft end. Prote cted by c op yri gh t . – Screw shaft end -1.of fuel extractor unit -VAS 5190.C op yi 131 . Then release pressure by carefully pulling hose off con‐ nection.

Golf Plus 2005 ➤ 4-cylinder diesel engine (1. in part or in w l purpos hole ercia .G 1383 A- Remove fuel tank ⇒ page 132 .A.G 1331- r fo ng ♦ Engine and gearbox jack -V.A. is tee or th or ac au ss ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en 4.3.. es. – Open locking ring using – Lift sender flange.as deeply as possible into fuel tank and extract fuel. Note Press buttons on hose couplings to do this.9 l engine) . un le n AG.C op yi .Golf 2004 ➤ . agen lksw Vo by AG. reinstall sender flange.20 . Volkswagen AG do es n wage ot g olks V ua by ran ed fuel tank sender wrench -T10202. Prote cted by cop yri gh t .Fuel supply system ht rig py Co t. Gr. 132 Rep. 4.2009 – Pull connector and fuel lines off flange.1 Removing fuel tank – Note safety precautions before beginning work ⇒ page 114 .Edition 01.3 Removing and installing fuel tank Special tools and workshop equipment required ♦ Torque wrench (5…50 Nm) -V. is n mm ot p co erm or te itte va ri d p – Insert extraction hose of fuel extractor -VAS 5190. If fuel tank needed only to be emptied.

disconnect battery earth strap.G 1383 Aht rig py Co t. obtain antitheft coding. If so. in part or in wh ole. Special tools and workshop equipment required ♦ Torque wrench (5…50 Nm) -V.A. drain fuel tank using fuel extractor -VAS 5190. If necessary. Vehi‐ cles from 06/2007 are fitted with a single part propshaft. Co py i – First check whether a coded radio is fitted. Rep. Before disconnecting battery. 4. – Unscrew securing bolts and remove tank flap unit. Fuel flap unit agen lksw Vo by AG. ⇒ page 128 – Unbolt rear right wheel. For these vehicles the complete propshaft must be removed. Rep. cial p is n mer ot com pe rm itte d Vehicles up to 06/2007 are fitted with a two-part propshaft.G 1331- n AG. Disconnecting and con‐ necting batteries . – With the ignition switched off.2009 Note un le urposes.. Rear wheel housing liner . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. exterior. Gr.A. – Remove rear right wheel housing liner. Prote cted by c o py rig ht.Golf 2004 ➤ . Gr. exterior.Edition 01. 55 . ⇒ General body re‐ pairs. Removing and installing wheel housing liner. vehicles with four-wheel drive 133 . ⇒ General body repairs. 27 . Rep. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his or ate riv p or gf n do cu m en ♦ Engine and gearbox jack -V.9 l engine) . open fuel tank flap and if necessary remove wheel lock adapter from luggage compartment. Fuel tank. For these vehicles it is sufficient to remove the rear propshaft. 66 . Gr. ⇒ Electrical system.

interior.20 . Rep. Gr. Rear seat. wrap a cloth around the connec‐ tion. Final drive..9 l engine) . Gr. ht rig py Co t. Gr. differential.2009 – Unscrew filler neck from body -arrows. un le n AG.Edition 01. Rep. Continuation for all vehicles: WARNING do cu m en – Pull off adapter cable on four-wheel drive control unit -J492. 39 . 39 . Wear eye protection and pro‐ tective clothing to avoid possible injury and skin contact. – Remove rear propshaft ⇒ Manual gearbox.Fuel supply system agen lksw Vo by AG. 134 Rep. – Remove centre and rear silencers. cial p is n mer ot com pe rm itte d rrectness of i t to the co nform spec a tion h re wit in t his – Secure exhaust system to underbody using wire.Golf . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. or ate riv p or gf n – Remove complete propshaft ⇒ Propshaft and rear final drive. 72 . Gr. – Remove bench seat ⇒ General body repairs. Fuel supply line is pressurised. in part or in wh ole. Repairing propshaft . Prote cted by cop yri gh t .C op yi .and unclip electrical wire from filler neck. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce urposes. Then release pressure by carefully pulling hose off con‐ nection. Removing and installing seat bench . – Remove covers and separate electrical connectors -arrows-. differential lock Vehicles from 06/2007 (single part propshaft): – Remove complete exhaust system ⇒ page 186 . Before loosening hose connections.Golf 2004 ➤ . Rep.

♦ Ensure that line connections are firmly seated.. supply line black). Fuel tank.4 • Removing and installing fuel gauge sender 2 -G169- The fuel tank should be no more than half full agen lksw Vo by AG. take theisfuel nte r eo ho 1383 A.2009 – Support fuel tank using engine and gearbox jack -V. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng n AG. Volkswagen AG do es n wage olks tg The filler neck must be y V “guided out” between body andorear axle. guide the filler neck in between rear axle and body. u ra c sa s ility ab y li an pt ce Installing fuel tank rrectness of i t to the co nf orm spec atio h re n in wit – Clip in cable for four-wheel drive control unit -J492. ht rig py Co t. – Fit adapter cable on four-wheel drive control unit -J492.. Then place the fuel tank on the engine and gearbox jack -V.2 urposes. The remaining installation steps are carried out in the reverse se‐ quence. note the following: ♦ Install breather and fuel lines free of kinks. 4. ara d b tank off engine and gearbox jacku-V.and unscrew tensioning straps and securing bolts.3. in part or in wh ole.Golf 2004 ➤ . – With the aid of a 2nd mechanic. thi sd oc um en – Raise the fuel tank slowly up to the installation position and secure -arrows-.with the tassistance of a 2nd mechanic.A. – Slowly lower fuel tank. In the process.A. Co py i 4.Edition 01. vehicles with four-wheel drive 135 .G 1383 A.on fuel tank.G 1383 A. ♦ Do not interchange supply line and return line (return line blue or with blue marking. Note 4. Prote cted by c op yri gh t. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.A.G e To do this. ♦ Check earth connection on fuel tank and body to filler neck.9 l engine) .

ht rig py Co t.2009 Note ♦ Ensure that the fuel gauge sender is not bent. ar db un le ho – Remove bench seat ⇒ General body repairs.. Gr. Rep. Removing and installing seat bench .20 . s e ris an tee or ac ility ab y li an pt ce urposes. obtain antitheft coding. – Place fuel gauge sender 2 -G169. ♦ Observe rules for cleanliness ⇒ page 115 . Gr. cial p is n mer ot com – Disconnect electrical connectors. AG.Fuel supply system agen lksw Vo by Caution . 136 Rep. interior.in fuel tank. pe rm itte d – Remove left cover (as seen facing direction of normal travel) from fuel gauge sender 2 -G169. ⇒ page 128 ♦ Note safety precautions before starting work ⇒ page 114 . – Open locking ring using wrench -T10202.C op yi or ate riv p or gf n do cu m en Installing: When installing do not bend fuel gauge sender 2 -G169. Volkearthnstrap. Removing: – First check whether a coded radio is fitted. Disconnecting and con‐oes no t gu V y necting batteries .. battery swage A Gd ⇒ Electrical system.9 l engine) . ut sa Gr. disconnect n AG.Golf 2004 ➤ . 72 . – With the ignition switched off. drain fuel tank using fuel extractor -VAS 5190. rrectness of i t to the co nform spec a tion h re wit in t his – Pull fuel gauge sender 2 -G169. If so. Prote cted by cop yri gh t .Edition 01. Rear seat. Rep. ♦ If necessary. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.. in part or in wh ole.upwards slightly and unclip it from the suction-jet pump. 27 olkswage .float arm.

Golf 2004 ➤ .5 or ate riv p or gf n Removing and installing suction-jet pump Note ht rig py Co t.⇒ page 135 . 72 . – Remove fuel gauge sender 2 -G169. Removing and installing seat bench . 4. Specified torque: 110 Nm. pe rm itte d – Tighten locking ring using wrench -T10202. even though the fuel gauge shows that the tank is still 1/4 full. vehicles with four-wheel drive 137 . AG. in part or in wh ole. – Place a new flange seal dry into opening in fuel tank and mois‐ ten inside (contact to flange) only with fuel. Rear seat. Gr. un le rrectness of i t to the co nform spec a tion h re wit in t his – Install bench seat.to the fuel delivery unit by means of a suction jet pump due to the shape of the fuel tank.. Rep. of fuel. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce urposes. – Check that the fuel lines on suction-jet pump are fitted securely and are not damaged.2009 – Fit suction-jet pump on sender on inside of fuel tank. – Pull return hose of suction-jet pump out of fuel delivery unit -arrow-. – Now the suction-jet pump can be pulled out from side of fuel gauge sender 2 -G169.Edition 01. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. 4. – Install cover. Prote cted by ♦ Checking is only necessary when the engine stops due to lack do cu m en Procedure – Remove fuel delivery unit ⇒ page 123 . cial p is n mer ot com – Fit connectors. – Separate quick-release coupling of supply line from suctionjet pump on Y-piece of fuel delivery unit. – Additionally check suction-jet pump for possible soiling. Fuel tank.(left side of vehicle).9 l engine) . Locating lugs must engage. fuel has to be pumped from agen lksw Vo by c op yri gh t . – Note installation position of fuel gauge sender 2 -G169⇒ page 128 – Check for correct position of seal. AG. ♦ On vehicles with four-wheel drive.C op yi the area of fuel gauge sender 2 -G169. interior. ⇒ General body repairs.

6. is n mm ot p co erm or te itte va ri d p AG.2009 4. If the fuel pump does not start: – Pull 4-pin connector off fuel delivery unit flange. e. in part or in w l purpos hole ercia . ⇒ General body repairs. rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng 138 Rep.20 .Fuel supply system ht rig py Co t.9 l engine) .A. y Volksw b ed ris The battery voltage must be at least 11. Gr. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.⇒ page 138 Checking current consumption of fuel pump -G6. Rep. interior.⇒ page 139 4. Co py i .A. c ility ab y li an pt ce 4.6 Checking fuel pump Checking voltage supply of fuel pump -G6.2 Checking function and voltage supply – Fold rear seats forwards. un le t au not gu ara nte eo ra window heating. Prote cted by c op yri gh t. – Detach carpet under seats and fold it back.6. lights and rear s must be switched off. Volkswagen AG d agen oes All electricals consumers.A.Golf 2004 ➤ .g. ho es.G 1526C.G 1527 B• • • Fuses must be OK. Fuel pump must be heard to run. – Switch off ignition.5 V.1 Test prerequisites Special tools and workshop equipment required ♦ Hand multimeter -V.A.G 1715- ♦ Auxiliary measuring set -V. Gr.or multimeter -V. 70 .G 1594 C♦ Diode test lamp -V. Load and luggage compartment trim. Removing and installing luggage compartment floor – Remove cover from fuel delivery unit. – Switch on ignition. agen lksw Vo by AG.Edition 01.

testing and information system VAS 5051 If LED lights up (voltage supply OK): – Remove fuel delivery unit. ⇒ Vehicle diagnosis.of connector ris tho auxiliary cable from auxiliary umeasuring set -V. ⇒ page 123 – Check that electrical wiring between flange and fuel pump is connected and has continuity. in part or in w l purpos hole ercia .. – Set multimeter to measuring range 20 A and connect in series between contacts -1. Co py i 139 .A.Golf 2004 ➤ .G 1715.3 Checking current draw of fuel pump – Pull 4-pin connector off fuel delivery unit flange. If no open circuit can be found: – Renew fuel delivery unit.G 1594 C. The LED must light up for about 2 seconds. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.G 1527 B. is n mm ot p co erm or te itte va ri d p .A. ⇒ page 123 un le – Start engine and run at idling speed. agen lksw Vo by AG.to outer contacts of connector using auxiliary cables from auxiliary measuring set -V.of connector and fuel pump using auxil‐ iary cables from auxiliary measuring set -V.G 1594 C.of con‐ nector and fuel pump.. Fuel tank.Edition 01. ⇒ page 123 4. – Measure current draw of fuel pump: Specification: max.2009 – Connect diode test lamp -V. Prote cted by c op yri gh t. – If the measured value is not within specifications: – Renew fuel delivery unit. Note The current pick-up clamp of multimeter -V. If LED does not light up – Check actuation of fuel pump relay and wiring for open circuit or short circuit.6.A. Volkswagen AG d agen o – ksw Vol by dand fuel pump using an e Connect contacts -4.can also be attached to an auxiliary cable between contacts -1.A. AG.5 Amperes.9 l engine) . 7. es n ot g ua ran tee or ac ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng 4. – Switch on ignition. vehicles with four-wheel drive ht rig py Co t.A.G 1594 Ca ss es.

r fo ng agen lksw Vo by Prote cted by 5 . Gr.20 .Fuel temperature sender -G8110 .Filter insert ❑ Observe change intervals. c op yri gh t.Golf 2004 ➤ . 8 .Fuel filter upper part 9 . 7 . 100 cm3 of liquid using diesel extractor VAS 5226- ht rig py Co t. 11 .Seal ❑ Renew. ❑ Check for secure seat‐ ing. ❑ Blue or with blue mark‐ ing. ss w g Assembly overview .Edition 01. Co py i .fuel filter rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en 1 . 2 .8 Nm 3 . 12 .Supply line ❑ To tandem pump ❑ White or with white marking.Return line ❑ From tandem pump ❑ Blue marking ❑ Check for secure seat‐ ing.accelerator mechanism ⇒ page 142 . ❑ Check for secure seat‐ ing.Supply line ❑ From fuel tank. olks ility ab y li an pt ce Assembly overview .Seal ❑ Renew. 6 . in part or in w l purpos hole ercia .9 l engine) . Volkswagen AG do es n ot g yV ua d b fuel cooler ⇒ page 141 ran Removing and installing se tee ri ho t or ac au Assembly overview .Plug for water extraction ❑ Unscrew and drain ap‐ prox. ❑ White or with white marking.Seal ❑ Renew. 140 Rep.Return line ❑ To fuel cooler ❑ Check for secure seat‐ ing.Fuel supply system AG. is n mm ot p co erm or te itte va ri d p Checking tandem pump ⇒ page 143 un le n AG. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. 4 .fuel filtera⇒epage 140 .1 es.2009 5 Repairing fuel supply system Removing and installing tandem pump ⇒ page 147 5.

17 . cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his 18 . – Separate fuel lines at fuel cooler.A. – Remove securing nuts -arrows-. 5. agen lksw Vo by AG.9 l engine) .Fuel filter lower part 14 .G 1331- do cu m en Removing – Note safety precautions before beginning work ⇒ page 114 .Retaining clip ❑ Check for secure seating.Edition 01.Return line ❑ With connection for fuel temperature sender -G8119 .Seal ❑ Renew. Repairing fuel supply system ht rig py Co t. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Observe rules for cleanliness ⇒ page 115 .Golf 2004 ➤ . Co py i 141 . n AG. in part or in wh ole. It is located on the vehicle underbody.From tandem pump 5. – Remove underbody panel. Prote cted by c op yri gh t.2 Removing and installing fuel cooler Special tools and workshop equipment required ♦ Torque wrench -V. In the process.Bracket 16 . Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce urposes.8 Nm 15 .2009 13 . Installing Installation is carried out in the reverse sequence of removal. note the following: ♦ Tighten fuel cooler securing nuts to 15 Nm. Note The fuel cooler is located in the return line to fuel tank.

Fuel supply system ht rig py Co t.1 Removing Special tools and workshop equipment required ♦ Release tool -T10238- do cu m en 142 Rep.Connector ❑ Black..Edition 01.20 .C op yi . 3 .Accelerator position sender -G79❑ Not adjustable.Cap urposes. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n AG.3. Prote cted by c op yri gh t . -A. ❑ To remove. in part or in wh ole.accelerator mechanism 1 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. agen lksw Vo by AG.2009 5. ❑ The accelerator position sender passes the posi‐ tion of the accelerator on to the engine control unit.9 l engine) .openings for release tool T10238. release us‐ ing release tool T10238.or release tool -T10240.. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his 5. Gr.10 Nm 4 .Golf 2004 ➤ .3 Assembly overview . 6-pin. 2 .

Golf Plus 2005 ➤ 4-cylinder diesel engine (1. specified tor‐ que 10 Nm and fit cap -3-.) into openings provided to stop.onto accelerator pedal module. ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his 5. testing and information system -VAS 5051- AG.4 Checking tandem pump Checking delivery pressure ⇒ page 143 Checking for internal leaks ⇒ page 146 5. remove cover in footwell by removing plastic nuts -arrows-. – Insert centring pin -6. push release tool - T10238. note the following: – Push electrical connector -1.Edition 01.(for right-hand drive vehicles release tool -T10240. Volkswagen AG do es n wage ot g olks yV ua db ran e tee Releasing accelerator pedal moduleoris h t or ac au – To remove accelerator pedalss module. Prote cted by c o py rig ht. 5. When installing.2009 – Before removing accelerator pedal module.into hole in floor of vehicle.2 Installing Installation is carried out in the reverse order.Golf 2004 ➤ . pe rm itte d un le n AG. or ate riv p or gf n – Press accelerator pedal module onto securing pins -5-. urposes. – Remove bolt ⇒ Item 3 (page 142) . – Lever out cap ⇒ Item 4 (page 142) using a screwdriver. Repairing fuel supply system 143 . in part or in wh ole. Co py i 5.9 l engine) .3. – Secure accelerator pedal module with bolt -2-. agen lksw Vo by do cu m en – Install steering column trim. cial p is n mer ot com – Separate electrical connection and pull wire guide off accel‐ erator pedal module.1 Checking delivery pressure Special tools and workshop equipment required ♦ Vehicle diagnosis. ht rig py Co t.4.

Fuel supply system AG.wage Edition 01. ♦ Banjo bolt -5187/1A- ht rig py Co t. 5 m without voltage supply -VAS 5051/3tee ris ho or ut ac a ss Golf 2004 ➤ . in part or in wh ole.2009 .♦ urposes. 3 m with by V voltage supply -VAS 5051/1.or di‐ uar d an e agnosis cable. Gr. The non-return valve in the fuel supply hose must be OK. Intact fuel delivery unit 144 Rep. agen lksw Vo by Prote cted by c op yri gh t. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.20 .G 1331Test prerequisites • • • • • Coolant temperature must be at least 85 °C. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng n AG d n AG oes wage not olks g Diagnosis cable. Vol s ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit ♦ Tandem pump tester -VAS 5187- thi sd oc um en ♦ Torque wrench -V.A.9 l engine)k. Co py i . Unit injectors OK Fuel filter and fuel lines must not be blocked.

or h w olks – Increase engine speed to 4. – Connect tandem pump tester -VAS 5187. 7. – Renew unit injector O-rings.5 bar If specification is now obtained: Pressure loss at unit injectors. testing and information system VAS 5051. tighten plug to 25 Nm.Edition 01. AG. – Observe pressure indicated on pressure gauge. – Observe pressure indicated on pressure gauge.000 rpm. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.2009 Procedure – Remove plug -arrow-. in part or in wh ole. If the specification is not attained: – Renew tandem pump. Prote cted by c op yri gh t . ht rig py Co t.Read en AG. – Connect vehicle diagnosis. ⇒ page 147 agen lksw Vo by urposes. Specification: min. – Start engine and run at idling speed.Engine electronics” on display. 7. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng – Read engine idlingssspeed in display zone “1”. – Increase engine speed to 4.and select “vehicle self-diagnosis” operating mode.5 bar If the specification is not attained: – Using a hose clip.9 l engine) . – Press key “01 . Always renew seal.Golf 2004 ➤ . Specification: min. Repairing fuel supply system 145 .000 rpm. t au es n ot g ua ran tee or ac ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en Note After removing pressure tester. – Press diagnosis function “08 . agen A block”.C op yi 5. clamp off return line between fuel filter and tandem pump. VolkswvalueG do ag measured y – Enter display group “1” usingVnumber block (key pad) and db ise confirm entry with Q key.as shown.

the knob must be pulled upwards.2009 5. Prote cted by c op yri gh t .G 1687.to fuel supply union of tandem pump using a commercially available compressed air connec‐ tion and a section of fuel hose.20 .9 l engine) .A.2 Note Checking for internal leaks The tandem pump must be checked for internal leaks between fuel side and oil side after reinstalling a used tandem pump.as follows: – Unscrew pressure regulating valve -2. agen lksw Vo by AG.Edition 01. Note To turn the pressure regulating valve -2. c ss ility ab y li an pt ce – Seal fuel return union on tandem pump with a plug. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.A.C op yi .Golf 2004 ➤ .and close valves -3and -4-. When leaking it is possible for the fuel to mix with the oil which may cause the engine to fail. Secure sealing plug with a spring-type clamp. Gr.Fuel supply system ht rig py Co t. Volkswagen AG d agen oes not lksw Procedure Vo gu by ara d nte ise – Pull fuel supply hose (white marking) and fuel return hoseo or e th u ra a (blue marking) off tandem pump. rrectness of i t to the co nform spec at ion h re wit in t his – Connect test connection -5. in part or in wh ole. Prepare test unit -V. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n AG. Use a spring-type clamp to secure. Special tools and workshop equipment required ♦ Tester -V. do cu m en 146 Rep. for example after renewing or repairing a cylinder head and/or when installing a "short" engine.4.G 1687- urposes.

This would result in the failure of the brake servo. agen lksw Vo by AG. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.0 bar. V – Open The maximum test pressure is 1. – Open valve -4.0 bar with pressure regulating valve -2-.and wait until the test circuit is filled. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n – Adjust pressure to 1.(compressed air source) to charge air system tester -V. in part or in wh ole. ut sa s gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his 5. do cu m en The tandem pump may. ot Vol olkswagen AG en AG. – Close valve -3. If the pressure does not drop the tandem pump can be reused. Caution by ed ris ho valve -3-.Golf 2004 ➤ .Edition 01. if the pressure drops the tandem pump must be renewed.3 bar and this must not be exceeded. urposes.2009 – Connect compressed air hose -1. Repairing fuel supply system 147 ..G 1687.9 l engine) . glass.5 Removing and installing tandem pump DANGER! ht rig py Co t. Prote cted by c op yri gh t. under no circumstances. be disman‐ tled as the vacuum part could otherwise malfunction.to retain pressure and observe the pressure drop over a period of 1 minute. Co py i 5.A. Note does If there is water in the sightkswag drain at water drainnscrew -6-. If neces‐ sary readjust pressure to 1.

9 l engine) .Edition 01.2009 Special tools and workshop equipment required ♦ Torque wrench -V.G 1390/1♦ Spring-type clip pliers -VAS 5024 A- urposes.Fuel supply system .A.A.G 1390♦ Water drainage container V.5. in part or in wh ole. Be careful that no fuel is sucked into hand vacuum pump.A.G 1390and water drainage container -V. – Operate hand vacuum pump until no more fuel comes out of return hose. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng n AG. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit 5.1 Removing ht rig py Co t.Golf 2004 ➤ . Co py i thi sd oc um en – Pull supply hose (white marking) and return hose (blue mark‐ ing) off fuel filter.G 1331♦ Hand vacuum pump with accessories -V. Prote cted by c o py rig ht. – Remove air filter housing with air mass meter and connecting pipe. AG. 148 Rep. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.to return hose -2-.A. agen lksw Vo by – Connect hand vacuum pump with accessories -V. Gr.20 .A.G 1390/1.

2 Installing rrectness of i t to the co nf orm spec atio h re n in wit Installation is carried out in the reverse order.5. – Connect supply hose (white marking) to fuel filter. – Install tandem pump and tighten upper securing bolts to 20 Nm.. note the following: Note ♦ Ensure that tandem pump coupling seats properly in cam‐ shaft. Co py i 5. ht rig py Co t. Repairing fuel supply system 149 .Edition 01. thi sd oc um en agen lksw Vo by Prote cted by c op yri gh t. – Attach supply hose (white marking) to supply connection -2and vacuum hose from brake servo -1. When installing.(white marking) and return hose -3. -4.(blue marking) off tandem pump -4-. Volk wagen AG doe wag olks yV db e ris ho ut a ss s no t gu ara nte eo ra c ility ab y li an pt ce urposes. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Attach return hose (blue marking) to return connection -3. – Remove tandem pumpen AGfromscylinder head. – Tighten lower securing bolts to 10 Nm.2009 – Remove bolt -arrow A. – Remove securing bolts -arrows-.Golf 2004 ➤ . ♦ Always renew tandem pump seals.to tandem pump -4-. in part or in wh ole.off tandem pump -4-.and pull air filter housing upwards out of mounting.9 l engine) . – Pull vacuum line from brake servo -1.of tandem pump. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng 5. AG. – Pull supply hose -2.

20 .Fuel supply system ht rig py Co t.G 1390.A. agen lksw Vo by AG. urposes.C op yi .G 1390/1. – Connect return hose (blue marking) to fuel filter.A. Gr.until fuel comes out of return hose. Prote cted by c op yri gh t .2009 – Connect hand vacuum pump with accessories -V.A. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his do cu m en 150 Rep. Be careful that no fuel is sucked into hand vac‐ uum pump. in part or in wh ole.to return hose -2-.9 l engine) . – Operate hand vacuum pump -V.Golf 2004 ➤ .G 1390and water drainage container -V. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Edition 01. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n AG.

C op yi 151 .Edition 01. in tool boxes etc. do cu m en When working on the turbocharger. pay a ss attention to the following due to the cramped condi‐ tions: Observe following if test and measuring instruments are required during a road test: ♦ Test and measuring instruments must be secured to rear seat and operated by a second person from this location. Charge air system with turbocharger c op yri gh t .2 or ate riv p or gf n Rules for cleanliness ht rig py Co t. If test and measuring instruments are operated from front pas‐ senger seat and the vehicle is involved in an accident. Volkswagen AG d agen oes urposes. 1. Installing hose connections with connector couplings ⇒ page 161 Assembly overview .g. coolant. especially in the engine compart‐ eo When doingth any u ra c ment. for fuel. ♦ Existing transport and protective packaging and sealing caps must only be removed immediately prior to installation. in part or in wh ole.turbocharger ⇒ page 152 Removing and installing turbocharger ⇒ page 156 Assembly overview . ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his 1. pe rm itte d un le not gu y ara db nte ise or repair work. pay careful attention to the following rules for cleanliness: ♦ Thoroughly clean all unions and adjacent areas before dis‐ connecting. hydraulics. cial p is n mer ot com ♦ Route all the various lines (e.g.parts of charge air cooling ⇒ page 158 Checking charge air system for leaks ⇒ page 162 1. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Do not use parts that have not been stored in their packing (e. ♦ Ensure that there is sufficient clearance to all moving or hot components. acti‐ vated charcoal filter system.). Do not remove replacement parts from packing until immediately before installing.1 Safety precautions WARNINGlksw Vo AG. ♦ Install clean components only. brake fluid and vacuum) and electrical wiring in their original po‐ sitions. agen lksw Vo by AG.2009 21 – 1 Turbocharging/supercharging Charge air system with turbocharger Safety precautions ⇒ page 151 Rules for cleanliness ⇒ page 151 . refrigerant. there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered.Golf 2004 ➤ . ♦ When making repairs. Do not use fluffy cloths! ♦ Carefully cover opened components or seal if repairs cannot be carried out immediately. Prote cted by ♦ Place removed parts on a clean surface and cover.9 l engine) . remove oil from connection and hose ends.

Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce urposes. fill turbocharger at connec‐ tion with engine oil. ♦ Charge air system must be free of leaks.3 Note Assembly overview . ♦ Renew self-locking nuts. run engine for about 1 minute at idling speed to ensure that oil is supplied to turbocharger. Do not move vehicle unless absolutely nec‐ essary. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Golf 2004 ➤ . agen lksw Vo by AG. ♦ Before screwing on oil supply line.turbocharger ♦ All hose connections are secured. Prote cted by c o py rig ht.Edition 01.9 l engine) . Gr. n AG.21 . Observe rules for cleanliness ⇒ page 151 . in part or in wh ole. 1. Co py i .2009 ♦ When system is open: do not work with compressed air if this can be avoided. ♦ After installing turbocharger. Observe safety precautions ⇒ page 151 . cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his do cu m en 152 Rep.Turbocharging/supercharging ht rig py Co t.

Vacuum hose ❑ To solenoid valve block n AG. ❑ Before installing. ensure that it is not blocked. axles.17 Nm 17 . 8 . 40 Nm 15 .Connecting pipe ❑ Air filter/turbocharger 11 . 9 .10 Nm Engine codes BJB.Washer 7 . BRU. BRU. 14 .3.Oil return line ❑ To cylinder block.Golf 2004 ➤ .9 l engine) .25 Nm ❑ Renew.1 1 .Union nut. Gr. 13 . Charge air system with turbocharger ht rig py Co t.Connection. 40 . agen lksw Vo by AG. BKC. is n mm ot p co erm or te itte va ri d p un le rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng 18 .Support ❑ Between turbocharger and cylinder block.Seal ❑ Renew.Edition 01. remove right drive shaft ⇒ Running gear. Prote cted by c o py rig ht. 22 Nm 3 . in part or in w l purpos hole ercia . BXE and BXF 2 . Rep. steering.Connecting piece 12 .Gasket ❑ Renew. 16 . ❑ To remove turbocharger. 4 . BXE and BXF ⇒ page 153 Engine codes BLS and BXJ ⇒ page 155 1. 22 Nm 5 . 1. 6 . ❑ Note installation posi‐ tion. ❑ Tighten union nut to 30 Nm.40 Nm ❑ First hand tighten all bolts 10 .2009 Engine codes BJB. Re‐ moving and installing drive shafts .Gasket ❑ Renew. fill tur‐ bocharger with engine oil through oil supply line connection ❑ Removing and installing ⇒ page 95 . Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce es.Oil supply line ❑ Before installing oil sup‐ ply line. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. BKC. Co py i 153 .Union nut.Turbocharger ❑ Can only be renewed with exhaust manifold.

Turbocharging/supercharging ht rig py Co t.Heat shield 22 . ot g olks yV ua db ran ❑ Before installing. Volkswagen AG do es n wage ❑ For oil supply line ⇒ Item 3 (page 153) .21 . 21 . Prote cted by c op yri gh t. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his 28 .Gasket ❑ Renew.Connecting pipe ❑ To bypass flap urposes. secure oil supply line.9 l engine) .Golf 2004 ➤ . agen lksw Vo by AG.22 Nm ss ❑ Renew. 30 Nm ❑ Renew. Co py i .2009 19 . ❑ Note installation position. rise tee ho t or ac au 26 . 27 . ❑ Coat threads and bolt head seating surface with “G 052 112 A3”.Edition 01.Front exhaust pipe 25 .Clamp.Connection.Bracket n AG. Gr. 7 Nm 24 . do cu m en 154 Rep.20 Nm ❑ Renew. in part or in wh ole. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.20 Nm ❑ First hand tighten all bolts 20 . 23 .

Vacuum hose 7 . ❑ Assembly overview . Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th Golf 2004 ➤ . Prote cted by c op yri gh t . agen lksw Vo by AG.Support ❑ For turbocharger do cu m en 1. 8 . cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n AG.10 Nm 2 .Edition 01.Heat shield 4 . Charge air system with turbocharger ht rig py Co t.Turbocharger ❑ Can only be renewed with exhaust manifold. ❑ Removing and installing ⇒ page 156 . in part or in wh ole.3. fill tur‐ bocharger via oil supply hose with engine oil 5 . 6 .25 Nm ❑ Renew 16 .Gasket ❑ Renew 14 .9 l engine) .C op yi 155 .25 Nm ❑ Renew.To particulate filter 9 . 12 .parts of exhaust gas recirculation ⇒ page 196 15 .2 1 .Gasket ❑ Renew. 7 Nm ❑ For turbocharger/partic‐ ulate filter 10 . Golf Plus 2005 ➤ u ra a c ss 4-cylinder diesel engine (1.Connecting pipe ❑ For exhaust gas recirculation.15 Nm 17 .Exhaust manifold ❑ Can only be renewed to‐ gether with turbocharg‐ er 11 . ❑ Note installation posi‐ tion.Clamp.25 Nm 13 .Bracket urposes. ❑ Before installing. 60 Nm ❑ Renew 19 .O-ring ❑ Renew 18 .Oil supply hose ❑ To oil supply line con‐ nection on turbocharger ❑ Before installing oil sup‐ ply line.1.Banjo bolt. ensure that it is not blocked.2009 ility ab y li an pt ce Engine codes BLS and BXJ rrectness of i t to the co nform spec at ion h re wit in t his 3 .

21 . cial p is n mer ot com Special tools and workshop equipment required ♦ Torque wrench -V. in part or in wh ole. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his or ate riv p or gf n do cu m en 156 Rep.2009 ❑ With oil return line 20 .9 l engine) .Heat shield 22 . Prote cted by c op yri gh t .Connection ❑ For intake hose for air filter/turbocharger ❑ Assembly overview .G 1331♦ Lambda probe open ring spanner set -3337- pe rm itte d un le AG. 45 Nm ❑ Lubricate thread of sender using high-temperature paste -G 052 112 A3❑ Use tool set -T10395.Turbocharging/supercharging ht rig py Co t.4 Removing and installing turbocharger urposes.9 Nm 24 .to remove and install. agen lksw Vo by AG.Exhaust gas temperature sender bank 1 -G235.Edition 01.air filter ⇒ page 177 .C op yi ♦ Tool set -T10395- .. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.10 Nm 1.A. 21 . 23 . Gr.Golf 2004 ➤ .

the charg‐ ed air routing must be cleaned and the charge air cooler must be renewed. axles. olks s no t t au or a ility ab y li an pt ce urposes. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n If foreign objects are found in the charge air system. perform the followingwrepairs: Volkswagen AG doe agen gu ♦ Check aired by V housing. – Remove subframe and the right drive shaft ⇒ Running gear. ht rig py Co t. if part of original equipment. it is not only sufficient to renew the turbocharger. Charge air system with turbocharger 157 . – Remove particulate filter. o e h c ♦ Check complete charged air routing and charge air cooler ss for foreign objects. Noise insulation . do cu m en Continuation for all vehicles: agen lksw Vo by Prote cted by cop yri gh t .C op yi – Disconnect fasteners -arrows.g. AG. rrectness of i t to the co nform spec at ion h re wit in t his Removing – Remove noise insulation tray ⇒ General body repairs. e. exteri‐ or.2009 Caution When a mechanical fault is found on the turbocharger.front. Rep.9 l engine) .⇒ Item 2 (page 188) in engine compartment and un‐ screw securing bolts. in part or in wh ole. To prevent this from causing further damage. Gr. 40 .Golf 2004 ➤ . 50 . steering. a destroyed compressor impeller. 1. Rep.Edition 01. if necessary. Body .of coolant pipes for auxiliary heater. – Separate electrical connectors to particulate filter. AG. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Engine codes BLS and BXJ – Pull electrical connector off exhaust gas pressure sensor 1 G450. Gr. air filter element and intake hoses filter ara nte ris for soiling.

21 . is n mm ot p co erm or te itte va ri d p un le Golf 2004 ➤ . Installing – Installation is carried out in the reverse sequence of removal. in part or in w l purpos hole ercia . – Remove connecting pipe to exhaust gas recirculation cooler.– Unbolt pendulum support -arrows-.2009 Edition ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en – Unscrew securing bolts for exhaust manifold. – Pull vacuum hose off turbocharger. Note Note ♦ Charge air system must be free of leaks. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.parts of charge air cooling ht rig py Co t. ♦ Checking charge air system for leaks ⇒ page 162 158 Rep. agen lksw Vo by c op yri gh t . – Tilt the engine forwards in lower mounting and remove turbo‐ charger with exhaust manifold downwards.9 l engine) - AG. ♦ All hose connections of charge air system are secured by spring-type clips or by connector couplings. – Separate charge pressure line from turbocharger. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss 01. – Separate oil supply line from turbocharger. – Remove turbocharger support and oil return line. remove oil from connection and hose ends.Turbocharging/supercharging AG. ♦ When making repairs.5 Assembly overview . es. Gr.C op yi Torque setting of pendulum support ⇒ page 10 . r fo ng . Prote cted by 1.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Engine codes BJB, BKC, BRU, BXE and BXF ⇒ page 159 Engine codes BLS and BXJ ⇒ page 160 Installing hose connections with connector couplings ⇒ page 161

1.5.1

Engine codes BJB, BKC, BRU, BXE and BXF

1 - 8 Nm ❑ Fitting location ⇒ page 160 2 - Bracket ❑ Note installation posi‐ tion. 3 - Charge air cooler 4 - Connecting hose 5 - 8 Nm 786 - To turbocharger.
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1.5.2
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Rep. Gr.21 - Turbocharging/supercharging

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Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.6

Hose connections

Installing hose connections with connector couplings ⇒ page 161 Hose connections with spring band ring ⇒ page 162

1.6.1

Installing hose connections with con‐ nector couplings
Caution

The seal in the plug-in connector can be damaged if the se‐ curing clip is in the locked position when fitting the connector. This can cause leakage. Observe installation instructions.
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1.6.2
Note

Hose connections with spring band ring

There is a danger of a “hose detaching” whilst driving after re‐ moving and reinstalling charge pressure lines with spring-type clamps. For this reason, spring band rings are used which can be opened if a defect item requires the charge pressure line has to be disconnected. In cases of repair, destroy the spring band ring using a suitable tool and renew it with a replacement part from ⇒ ETKA (electronic parts catalogue) .
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♦ Charge air system tester -V.A.G 1687♦ Adapter -V.A.G 1687/10– Remove intake hose -1- from air filter. – Insert adapter -V.A.G 1687/10- in intake hose -1- and secure with clip. Prepare charge air system tester -V.A.G 1687- as follows:

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1.7

Checking charge air system for leaks

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162

Rep. Gr.21 - Turbocharging/supercharging

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touching. cial p is n mer ot com pe rm itte d – Connect charge air system tester -V.G 1842.G 1687.Edition 01.A. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho 4-cylinder or diesel t ac au ss Golf 2004 ➤ .A.. un le n AG. Caution The pressure must not exceed 0. – Check the charge air system for leaks by hearing.A.as shown. If neces‐ sary readjust pressure to 0.(compressed air source) to charge air system tester -V. – Adjust pressure to 0.G 1842.before removing adapter. Note ♦ How to use the ultrasonic tester -V. drain at water drain screw -6-. ♦ Depressurise test circuit by detaching coupling from adapter - V. agen lksw Vo by AG. Co py i 1. Note ht rig py Co t.G 1687/10. in part or in wh ole.2009 ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his or ate riv p or gf n – Connect compressed air hose -1.9 l engine) . Golf Plus 2005 ➤ engine (1. – Open valve -4.A.5 bar with pressure regulating valve -2-. do cu m en If there is water in the sight glass. with leak detector spray or using ultrasonic tester -V.G 1687.5 bar! If the pressure is too high this can cause damage to the engine. Prote cted by c o py rig ht. when doing any repair work observe notes for charge air system ⇒ page 158 .G 1687/10.to adapter V.urposes.and wait until the test circuit is filled.A. – Open valve -3-.A. Charge air system with turbocharger 163 .5 bar.⇒ operating instructions ♦ If leaks occur..

Charge pressure control solenoid valve -N75or ate riv p or gf n 6 .Cylinder head/cylinder block c op yri gh t.Connecting pipe air filter/ turbocharger 3 . 14 .Cooler ❑ For exhaust gas recircu‐ lation. Volkswagen AG d agen oes 4-cylinder diesel engine (1.Turbocharger 2 .Non-return valve ❑ Note installation posi‐ tion. in part or in wh ole.Non-return valve ❑ Note installation posi‐ tion.2009o n olk 1. 7 .Bypass flap ❑ For exhaust gas recircu‐ lation cooler.Turbocharging/supercharging agen lksw Vo by AG.Edition 01. Golf Plus 2005 ➤ AG. Co py i .Air filter do cu m en 8 .Vacuum unit ❑ Turbocharger 164 Rep. 11 . Gr.1 Vehicles with particulate filter un le Vehicles with particulate filter ⇒ page 164 V by ed ris ho ut sa s t gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec a tion h re wit in t his 1 . ht rig py Co t. Prote cted by 9 .21 .To brake servo 5 .Golf 2004 ➤ . 4 .Exhaust gas recirculation valve -N1812 .Intake manifold 10 . cial p is n mer ot com 1.Exhaust gas recirculation cooler change-over valve N34513 .9 slwengine) .8.8 Vacuum hose schematic diagram pe rm itte d Vehicles without particulate filter ⇒ page 165 urposes.

Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Air filter 6 . Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce urposes.C op yi 165 . Charge air system with turbocharger ht rig py Co t.Intake manifold 7 .2009 1.Cylinder head/cylinder block 8 .Exhaust gas recirculation valve -N1812 .Cooler ❑ For exhaust gas recircu‐ lation.Non-return valve ❑ Note installation posi‐ tion. in part or in wh ole.Bypass flap ❑ For exhaust gas recircu‐ lation cooler.To brake servo 4 .Edition 01.Solenoid valve block 2 .Connecting pipe air filter/ turbocharger 5 . Prote cted by cop yri gh t .8.2 Vehicles without particulate filter 1 . 10 .Non-return valve ❑ Note installation posi‐ tion. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his do cu m en 1. 3 .Golf 2004 ➤ .9 l engine) . agen lksw Vo by AG.Turbocharger 13 . 11 .Vacuum reservoir 9 . n AG.

hydraulics.unit injector ⇒ page 167 Removing and installing unit injector ⇒ page 169 Adjusting non-contact gap of unit injectors ⇒ page 171 Removing and installing O-rings for unit injector ⇒ page 172 Repairing intake manifold flap ⇒ page 174 Assembly overview .1 Safety precautions WARNING When doing any repair work. brake fluid and vacuum) and electrical wiring in their original po‐ sitions. especially in the engine compart‐ ment.Edition 01. is n mm ot p co erm or te itte va ri d p ♦ Test and measuring instruments must be secured to rear seat and operated by a second person from this location.2009 23 – 1 Mixture preparation .g. obtain radio code for radios with anti-theft coding. as otherwise the control unit for diesel direction injection system could become damaged. ♦ If the engine is to be turned at starter speed.23 . Read fault memory before and after making repairs or adjustments.g. 166 ht rig py Co t. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.injection Diesel direct injection system The diesel direct injection system control unit is equipped with a fault memory. the following must be noted: ♦ The ignition must be switched off before connecting or dis‐ connecting injection or glow plug system wiring or tester ca‐ bles. coolant and refrigerant. without starting. To prevent injuries to persons and/or destruction of the injection and glow plug system. Prote cted by . disconnect unit injector connector on cylinder head. in part or in w l purpos hole ercia . acti‐ vated charcoal filter system. Assembly overview .Golf 2004 ➤ . olkswagen AG en AG. ♦ Before disconnecting battery. for fuel.air filter ⇒ page 177 . e. V does not gu ara nte instruments are required eo ra c ility ab y li an pt ce ♦ If test and measuring instruments are operated from front pas‐ senger seat and the vehicle is involved in an accident.Mixture preparation . ♦ Disconnecting and connecting the battery must only be done with the ignition switched off.9 l engine) . 1. pay attention to the following due to the cramped condi‐ tions: ♦ Route all the various lines (e. Safety precautions ⇒ page 166 Rules for cleanliness ⇒ page 167 . wag olks yV db se o Observe followinghifritest and measuring t au during a road test: ss ♦ Ensure that there is sufficient clearance to all moving or hot components. Co py i es. there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered.injection AG. Gr. un le rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en Rep. when checking compressions. r fo ng agen lksw Vo by c op yri gh t.

Volkswagen AG do e n wage Golf 2004 ➤ . ♦ Place removed parts on a clean surface and cover.2009 yV ara db nte se ri eo ho ut ra c sa s ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en 1. Damaged hoses must be renewed.unit injector 1. c op yri gh t. ht rig py Co t. in part or in wh ole.9 l engine) . GolfsPlus 2005 ➤ ot g olks 4-cylinder diesel engine (1.1.). Should this occur. ♦ Always renew seals and O-rings agen lksw Vo by Prote cted by ♦ Observe rules for cleanliness ⇒ page 167 . ♦ When system is open: do not work with compressed air if this can be avoided. ♦ Install clean components only. 167 . Do not use fluffy cloths! ♦ Carefully cover opened components or seal if repairs cannot be carried out immediately. Co py i urposes. Do not move vehicle unless absolutely nec‐ essary. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng n AG.2 Rules for cleanliness When working on fuel supply and injection system. ♦ Also ensure that no diesel fuel runs on to the coolant hoses. Do not use parts that have not been stored in their packing (e. Diesel direct injection system AG. pay careful attention to the following rules for cleanliness: ♦ Thoroughly clean all unions and adjacent areas before dis‐ connecting.Editionu01. the hoses must be cleaned immediately. Do not remove replacement parts from packing until immediately before installing.g. in tool boxes etc.3 Assembly overview .

ht rig py Co t.Heat shield seal ❑ Renew 11 . 3 .Mixture preparation .1 .O-ring ❑ Renewing ⇒ page 172 8 . 168 Rep.oGolf tee ris h t or 4-cylinder diesel engine (1. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n n AG.Circlip 12 .Tensioning block 14 .O-ring ❑ Renew ⇒ page 172 .Edition 01.23 . in part or in wh ole. .Cylinder head 13 . 30 Nm 4 .Adjuster screw ❑ Renew 5 .Rocker arm shaft ❑ With rocker arms ❑ Removing and installing ⇒ page 169 . 10 . Volkswagen AG do es n wage ot g olks yV ua db ran e Plus 2005 ➤ Golf 2004 ➤ .Unit injector ❑ Removing and installing ⇒ page 169 .12 Nm + 3/4 turn (270°) further ❑ Renew.Ball stud ❑ Renew urposes.injection agen lksw Vo by AG. Gr.Lock nut. Co py i do cu m en 7 .2009 ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his 6 .20 Nm + 1/4 turn (90°) fur‐ ther ❑ Renew 2 . Prote cted by c o py rig ht.9 l engine) .O-ring ❑ Renewing ⇒ page 172 9 .

Observe unit injector cylinder allocation.G 1331n AG. long reach -T10054. agen lksw Vo by AG. – Loosen lock nuts of adjustment screws -1. support opposite side of connector with light finger pressure. Diesel direct injection system ht rig py Co t.Golf 2004 ➤ .A.with special wrench. Prote cted by cop yri gh t .1 Removing – Remove toothed belt guard upper part. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce urposes.and remove the block. – Remove tensioning block securing bolt -3. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Lever connector off unit injector with a screwdriver. – Remove cylinder head cover.(from outwards to in‐ wards) with socket XZN 10 -3410.4 Removing and installing unit injector Special tools and workshop equipment required ♦ Universal dial gauge brack‐ et -VW 387♦ Special wrench.Edition 01. in part or in wh ole.2009 1. To avoid canting.and remove rocker arm shaft. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en 1.4.9 l engine) . – Remove rocker arm securing bolts -2. long reach -T10054♦ Puller -T10055♦ Torque wrench V.and remove ad‐ justment screws. 1. long reach -3410♦ Special wrench.C op yi 169 . ⇒ page 48 – Turn crankshaft until the cam pair point evenly upwards for the unit injector which is to be removed.

Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Prote cted by cop yri gh t . Volkgentle AG doe w ge s no olks taps. in part or in wh ole. unit injector. ht rig py Co t. – Therefore align the unit injector as follows. Note If the unit injector is not at right angles to the tensioning block the securing bolt may loosen and this can damage the unit injector or the cylinder head. – Screw the new securing bolt into the tensioning block until the unit injector can still be turned easily. ⇒ page 172 AG. – Push the unit injector evenly into the cylinder head onto its limit stop. n A with swagen upward – Pull unit injector out of cylinder headaseatG.Mixture preparation . – Oil the seals and fit the unit injector into the seat in cylinder head with great care. – Insert tensioning block in slot on side of unit injector. t gu yV ss db ise or th au ara nte e or ac ility ab y li an pt ce urposes.Edition 01.23 . – Now align unit injector at right angles to camshaft bearing seat. the adjustment screw in the rocker arm and also the unit injector ball stud must be renewed. 170 Rep. Gr.Golf 2004 ➤ . . Note The seals must not be twisted.in place of the clamping block in the slot on the side of the unit injector.4.injection agen lksw Vo by seal.2009 – Insert puller -T10055.9 l engine) .C op yi – Check that the three O-rings and the heat shield seal along with securing clip are seated correctly before installing unit in‐ jector.2 Note Installing thi sd oc um en ♦ Each time work is performed which requires adjustment of the ♦ New unit injectors are supplied with O-rings and heat shield – Heat shield seal and O-rings must be renewed if old unit in‐ jector is reused. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng rrectness of i t to the co nf orm spec atio h re n in wit 1.

in part or in wh ole.8 mm 65. – Fit rocker arm shaft and tighten new securing bolts as follows: – First evenly tighten inner bolts -2.and then outer bolts -1hand-tight. dial gauge -arrow Bpositioned at lowest point. urposes. Cylinder 1 2 3 4 Dimension “a” 333.positioned at highest point. – Hold adjuster screw in this position and tighten lock nut to 30 Nm.2009 – Check dimension “a” from outer edge of cylinder head to roun‐ ded surface of unit injector with a vernier gauge (measuring range min. 1.0 ± 153.6 ± 0. AG.8 amm u ra c ss ility ab y li an pt ce – If necessary. – Adjust non-contact gap of unit injectors ⇒ page 171 .8 mmised nte or eo th 0.5 – Turn crankshaft in direction of engine rotation until roller of rocker arm is located at tip of drive cam. – Now turn the adjuster screw into rocker arm until significant resistance can be felt (unit injector is at limit stop). adjust the unit injector and tighten the securing bolt as follows: – Tighten securing bolt to 12 Nm and turn 270° (3/4 turn) further (turning further can be done in several stages).Edition 01.C op yi 171 . – Fit dial gauge onto adjustment screw of unit injector as shown. Roller side -arrow A.0 ± 245.6 ± 0. Volkswagen AG d agen oes not lksw Vo gu by ara 0. Then using same sequence. – Remove dial gauge. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his do cu m en 1.9 l engine) .Golf 2004 ➤ . – Connect unit injector connector. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Turn adjustment screw 180° back off stop. c op yri gh t . tighten to 20 Nm and 90° (1/4 turn) further evenly. Diesel direct injection system agen lksw Vo by Prote cted by Adjusting non-contact gap of unit injec‐ tors ht rig py Co t.8 mm AG. – Install cylinder head cover ⇒ page 48 . 400 mm).

urposes. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss – Lever old O-rings very carefully out of unit injector. – Ensure above all that no burrs are formed on O-ring seat.2 Note Installing ility ab y li an pt ce ♦ Always use the assembly sleeves to fit the O-rings. do cu m en 172 Rep. Prote cted by c o py rig ht. agen lksw Vo by AG. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his ♦ Gradual introduction of O-rings without different coloured ♦ Prevent O-rings from rolling when sliding them on. – Place assembly sleeve -T10056/1. markings.1 Removing n AG. The O-rings – Pull heat shield seal off together with securing clip.injection ht rig py Co t. Note the correct allocation of O-rings to grooves: the thickness of the rings reduces towards injector nozzle.6.6 Removing and installing O-rings for unit injector Special tools and workshop equipment required ♦ Assembly sleeves -T10056- 1. Gr.Mixture preparation . must not be twisted in their seats in unit injector. There is a danger of damaging the O-rings if the sleeves are not used. – Clean seating surfaces for O-rings on unit injector very care‐ fully. – Remove assembly sleeve. in part or in wh ole.onto stop on unit injector. thicker O-ring carefully onto assembly sleeve and into seat on unit injector.9 l engine) .2009 1. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Push the upper.Edition 01.23 .6.Golf 2004 ➤ . Co py i . 1.

onto stop on unit injector. – Fit new heat shield seal together with securing clip. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his do cu m en 1. – Place assembly sleeve -T10056/3. in part or in wh ole.onto stop on unit injector. – Remove assembly sleeve.Golf 2004 ➤ . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Prote cted by c op yri gh t .C op yi 173 . thinner O-ring carefully onto assembly sleeve and into seat on unit injector.Edition 01. – Slide the middle.2009 – Place assembly sleeve -T10056/2. Diesel direct injection system ht rig py Co t. – Remove assembly sleeve. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n AG. agen lksw Vo by AG.9 l engine) . – Push the lower O-ring carefully onto the assembly sleeve and into the seat of the unit injector. urposes.

O-ring ❑ Renew.Intake manifold ❑ Tighten securing bolts to 22 Nm. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Mixture preparation .7. Prote cted by cop yri gh t .Intake manifold flap motor V157❑ The intake manifold flap is closed for approx. 8 .Golf 2004 ➤ . 2 .9 l engine) .2009 1. 3 . in part or in w l purpos hole ercia .7 Assembly overview . BXE and BXF es.intake manifold un le Engine codes BKC. Gr.1 Engine codes BKC. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or BXF ⇒ th page 174 or ac au ss ility ab y li an pt ce 1.10 Nm 6 . This reduces the stop jolt.Gasket ❑ Renew.10 Nm 7 . r fo ng .22 Nm 9 .Edition 01. BRU. 174 Rep.injection ht rig py Co t. BRU.Intake connecting pipe ❑ With exhaust gas recir‐ culation valve 4 . 3 seconds when stopping engine and then opens again. is n mm ot p co erm or te itte va ri d p Engine codes BLS and BXJ ⇒ page 176 rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en 1 . BXE and Engine code BJB ⇒ page 175 n AG.23 . agen lksw Vo by AG.Connecting pipe ❑ To exhaust gas recircu‐ lation cooler.C op yi 5 .

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Connecting pipe ❑ For exhaust gas recircu‐ lation cooler.injection agen lksw Vo by 6 . e. Co py i . Golf Plus 2005 ➤ ran Golf 2004 e tee ris ho 4-cylinder diesel engine (1. This reduces the stop jolt.22 Nm 12 .Gasket ❑ Renew.10 Nm 8 . AG. Gr. the support will have to be cleaned..3 un le n AG. If these are found.Intake manifold flap motor V157❑ The intake manifold flap is closed for approx.From charge air cooler ht rig py Co t.or the intake manifold flap motor -V157.Exhaust gas recirculation valve -N18. 176 Rep. 3 seconds when stopping engine and then opens again.Connection 5 .23 .g.2009 t or ac au ss ility ab y li an pt ce Engine codes BLS and BXJ rrectness of i t to the co nform spec a tion h re wit in t his do cu m en 7 .22 Nm 1.Seal ❑ Renew 4 .urposes.with exhaust gas recirculation potentiometer G212❑ Assembly overview .7.9 l engine) . Volkswagen AG do es n wage ot g olks V ua by d➤ . 2 . cial p is n mer ot com 1 .Edition 01. ❑ Assembly overview parts of exhaust gas re‐ circulation ⇒ page 193 11 .Intake manifold ❑ Tighten securing bolts to 22 Nm 3 . or ate riv p or gf n pe rm itte d 1. in part or in wh ole. Prote cted by c o py rig ht.. Engine code BLS and BXJ Note Carbon deposits can occur in the throttle valve support through the combination of unfavourable factors.ex‐ haust gas recirculation ⇒ page 196 9 .Mixture preparation . when disassembling the exhaust gas recirculation valve -N18.Bracket 13 .8 Cleaning the intake manifold flap sup‐ port.Gasket ❑ Renew 10 .

10 .Filter element ht rig py Co t. Prote cted by 8 . – Allow the acetone to evaporate fully. 2 . especially tho au around exhaust gas return valve.Golf 2004 ➤ .air filter 1 . Volkswagen ran tee or ac ility ab y li an pt ce – Wipe off intake manifold flap support using a lint-free cloth. e ris rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en 1. Diesel direct injection system 177 .10 Nm AG.Air filter lower part 11 .Intake hose ❑ To turbocharger. Wear eye protection and protective clothing to avoid possible injury and skin contact.Vacuum hose ❑ To solenoid valve block r fo ng 1. is n mm ot p co erm or te itte va ri d p un le – Thoroughly clean intake manifold flap support. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. using commercially available ss acetone according to DIN 53247 and cleaning brush. replace the seals and insert it back in position. Please observe the accidental regulations and safety notes when handling with highly inflam‐ mable fluids. 4 .Air duct ❑ To lock carrier.Air filter upper part 9 .O-ring ❑ Renew if damaged. agen lksw Vo by c op yri gh t .and the in‐ s n e ks ot g Vol take manifold flap motor -V157-by .Air mass meter -G703 .9 l engine) .8 Nm 5 .9 Assembly overview . es.2009 WARNING Acetone is highly inflammable.Edition 01. – Remove intake manifold flap connection.C op yi 7 . assemble the cleaned intake manifold flap support. in part or in w l purpos hole ercia . ua d G. A AG do agen – Remove the exhaust gas recirculationwvalve -N18.8 Nm 6 .

injection AG. Golf ss urposes. in part or in wh ole. – Connect vehicle diagnostic. Removing and installing Removing and installing ⇒ page 180 . Golf ⇒ page 180 .2009 2 Engine control unit n AG. rrectness of i t to the co nform spec at ion h re wit in t his 2.Mixture preparation .1 Reading and erasing engine control unit fault memory Special tools and workshop equipment required ♦ Vehicle diagnostic. testing and information system VAS 5051. Golf Plus ⇒ page 183 .Edition 01. Volkswagen AG do es n wage ot g olks V ua by ran ed engine control unit. ris tee o th or ac au anti-theft engine control unit.C op yi .Golf 2004 ➤ . agen lksw Vo by Prote cted by cop yri gh t . testing and information system -VAS 5051- do cu m en 178 Rep. Gr. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. ility ab y li an pt ce Removing and installing engine control unit.as follows: ht rig py Co t.9 l engine) . cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n Reading and clearing engine control unit fault memory ⇒ page 178 Adapting functions and components ⇒ page 179 . Removing and installing anti-theft engine control unit Golf Plus ⇒ page 183 .23 .

179 . – Select “Function/component selection”. Prote cted by cop yri gh t . Engine control unit ht rig py Co t.Read fault memory” on display. – Select “Functions”. – Select “Engine management”. Select diagnostic function – Press button “02 . Only when engine does not start: – Switch on ignition. When all control units have been read: – Press “GoTo” button.C op yi – Select “01-Systems capable of self-diagnosis”. these are shown one below the other on the display. – Start engine and run at idling speed. Volkswagen AG do es n wage ot g olks V Vehicle diagnostic. Select operating mode – Press button on display for “Vehicle self-diagnosis”. – Press function “06-End output”. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Edition 01. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n n AG. 2. – Select “Engine code”. – Select “Function or component”.9 l engine) .2 ♦ Adapting functions and components Special tools and workshop equipment required urposes.2009 – Push diagnosis cable connector onto diagnosis connector. agen lksw Vo by AG. – Press ← button. – If faults are stored in the engine control unit. in part or in wh ole.Golf 2004 ➤ . testing and in‐ formation system -VAS 5051. – If no fault is stored in engine control unit “0 fault detected” is displayed. Select vehicle system – Press button “01 .Clear fault memory” on display. – Select “Drive train”. testing and information system -VAS 5051ua by ran ed is tee or th or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his Select “guided fault finding” in vehicle diagnostic.Engine electronics” on display. – Press button “05 . do cu m en 2.. The control unit identification and coding are indicated on display.

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2.3

– Before removing engine control unit, read the control unit iden‐ tification and thus the coding of the current control unit. ⇒ page 179 Removing – Switch off ignition.

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2.4

Removing and installing anti-theft en‐ gine control unit, Golf

Removing and installing anti-theft engine control unit Golf Plus ⇒ page 183 . Special tools and workshop equipment required ♦ Electric cutter -V.A.G 1561 A♦ Saw set -V.A.G 1561/14-

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Removing – Switch off ignition.
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2.5

Removing and installing engine control unit, Golf Plus
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Removing: – Switch off ignition. – Remove plenum chamber bulkhead ⇒ General body repairs; Rep. Gr. 50 ; Body - front; Plenum chamber bulkhead . – Loosen securing nuts -arrows-. – Release connectors on engine control unit and pull off con‐ nector.
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2.6

Removing and installing anti-theft en‐ gine control unit, Golf Plus

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183

front. Then pull engine control unit off control unit bracket in direction of arrow. pound. Plenum chamber bulkhead AG. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n a – Then remove securing nuts for control unit bracket -arrows-.outwards. agen lksw Vo by Prote cted by c o py rig ht. – Fit connectors to engine control unit and lock in position. ensure that no adjacent cables. connect vehicle ♦ The shear-head bolt threads are coated with locking com‐ diagnostic. in part or in wh ole. Volkswagen AG . 184 Rep. testing and information system -VAS 5051B. the shear-head bolts can be heated using hot air blower -VAS 1978/14.and -2. connectors or components are damaged! Removing – Switch off ignition.out using gripopliers and re‐ by move cover from protective housing. ss does not gu ara nte eo ra c ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his – Release connectors on engine control unit and pull off con‐ nector.Mixture preparation .injection AG. – Remove plenum chamber bulkhead ⇒ General body repairs. en V – Twist shear-head bolts -arrows.Golf 2004 ➤ . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.and perform “Renewing engine control unit” in guided functions. When doing this. Rep. do cu m en Installing – Push engine control unit onto control unit bracket until it en‐ gages in catches. Body .Edition 01. ht rig py Co t. To simplify removing.9 l engine) . 50 . Co py i .2009 Note ♦ If the engine control unit is to be renewed. Gr.23 . rised ho ut ag lksw urposes.. Gr. – Press catches -1.

– Tighten urposes. Engine control unit 185 .evenly until heads shear-head off.to 10 Nm. – Install plenum chamber bulkhead ⇒ General body repairs. 50 .C op yi 2. AG.front. thi sd oc um en ht rig py Co t. Golf Plus 2005 ➤ agen oes not lksw Vo g 4-cylinder diesel uengine (1. Plenum chamber bulkhead . Prote cted by c op yri gh t .9 l engine) . Rep.Edition 01. c ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit – Tighten new shear-head bolts -arrows. Gr. in part or in wh ole. Body . cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng – Install cover of protective housing. agen lksw Vo by AG. Volkswagen AG d Golf 2004 ➤ .2009 by ara ed nte ris eo tho ra securingau bolts -arrows.

Gr. agen lksw Vo by AG. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng rrectness of i t to the co nf orm spec atio h re n in wit 4 . 10 .Exhaust system ht rig py Co t.2009 26 – 1 Exhaust system Exhaust system Assembly overview .front exhaust pipe with catalytic converter ility ab y li an pt ce 1 .front exhaust pipe with catalytic converter ⇒ page 186 .Front exhaust pipe with cat‐ alytic converter 2 . Co py i . Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Prote cted by c op yri gh t.Clip thi sd oc um en 186 Rep.front exhaust pipe with particulate filter ⇒ page 187 Assembly overview .7 Nm 9 . 8 .Mounting ❑ Renew if damaged. in part or in wh ole.silencer with mountings AG. Assembly overview .To front silencer 6 .Edition 01. no olks V by ed ris ho ut sa s t gu ara nte eo ra c 1. ❑ Installation position of clamp ⇒ page 187 .Golf 2004 ➤ .Gasket ❑ Note installation posi‐ tion.25 Nm 7 .Marking ❑ For clamp.1 Assembly overview .silencer with mountings (vehicles with front wheel drive) ⇒ page 189 .26 . Volkswawith G n (vehicles gen Afourdoes wage wheel drive) ⇒ page 191 .Support urposes.9 l engine) .40 Nm 3 . 5 . Assembly overview .

in part or in wh ole..= 5 mm from marking on front ex‐ haust pipe. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.2009 Installation position of clamp Position clamp at distance -a. agen lksw Vo by AG. 1. Co py i ♦ Tool set -T10395- ht rig py Co t.9 l engine) . Prote cted by c o py rig ht.front exhaust pipe with particulate filter urposes. adapting exhaust pressure sensor 1 -G450. the exhaust gas pressure sensor 1 -G450must always be adapted using diagnostic tester : Guided functions.is changed.Golf 2004 ➤ . 1.Edition 01. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his Special tools and workshop equipment required ♦ Lambda probe open ring spanner set -3337- do cu m en Note If the particulate filter or the exhaust gas pressure sensor 1 G450. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n n AG.2 Assembly overview . Exhaust system 187 .

Prote cted by c op yri gh t .Front exhaust pipe 10 .Golf 2004 ➤ .Temperature sender after particulate filter -G527❑ 45 Nm ❑ Lubricate thread of sender using high-temperature paste -G 052 112 A315 .Exhaust gas temperature sender bank 2 -G448.Gasket ❑ Renew ❑ Note installation position. 45 Nm ❑ Lubricate thread of sender using high-tem‐ perature paste -G 052 112 A38 .Mounting ❑ Renew if damaged. 50 Nm ❑ Grease only the threads with high-temperature paste -G 052 112 A3.8 Nm 2 . 9 .Edition 01. 40 . Volkswagen AG d agen oes not lksw o 4-cylinder diesel engine (1. 45 Nm 6 .Lambda probe -G39.26 . Gr. steering.Bracket ❑ For control lines 4 . ❑ To remove use lambda probe open ring span‐ ner set -33377 . cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en 188 Rep.To front silencer 12 . ❑ Installation position of clamp ⇒ page 189 . Golf Plus 2005 ➤ AG.must not get into the slots of probe body.2009 g yV 1 .Marking ❑ For clamp. agen lksw Vo by AG.9 l engine) . axles. 7 Nm 17 . db ise or th au ss ua ran tee or ac ility ab y li an pt ce urposes. in part or in wh ole. Rep.C op yi .10 Nm 5 . remove subframe and steering ⇒ Running gear..From turbocharger 16 . high-temperature paste -G 052 112 A3.Clamp.Particulate filter ❑ is removed downwards with exhaust gas pres‐ sure sensor 1 -G450❑ To remove.25 Nm 13 .Exhaust gas pressure sen‐ sor 1 -G4503 . Gr..Control line. 11 . 14 .Exhaust system ht rig py Co t..

cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng rrectness of i t to the co nf orm spec atio h re n in wit 1.Edition 01. front and rear silencers are supplied separately. front and rear silencers are installed as a single component. in part or in wh ole. agen lksw Vo by AG. M10 = 40 Nm. ht rig py Co t.9 l engine) .Separating point ❑ Marked by indentation on exhaust pipe ❑ During production. For repairs.Mounting ❑ Renew if damaged. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Bracket ❑ Bolted to cylinder head n AG.Golf 2004 ➤ .25 Nm ❑ Renew 2 . thi sd oc um en 4 . ❑ The connection is made with a clamp. ❑ Cutting exhaust pipe ⇒ page 190 ❑ Installation position of rear clamp (repair dou‐ ble clamp) ⇒ page 190 . ❑ Before tightening.40 Nm 19 . 3 .Rear silencer 5 . ss ex‐ ility ab y li an pt ce urposes.silencer with mountings (vehicles with front wheel drive) 1 .2009 18 . ❑ Evenly tighten threaded connections of clamp (repair double clamp). align cold exhaust system free of tension ⇒ page 192 Prote cted by cop yri gh t . ❑ Specified torques for clamp (repair double clamp): M8 = 25 Nm. Exhaust system 189 . Volkswagen AG do es n wage ot g olks V ua Installation position of clamp by ran ed is tee or th or – Position double clamp -a.Retaining ring ❑ Renew if damaged.3 Assembly overview .= 5 mm from marking on front ac au haust pipe of particulate filter.C op yi 1.

G 1523 An AG. .2009 6 .and -arrow 3-.Edition 01. Installation position of rear clamp (repair double clamp) – Install clamp so that ends of bolts do not protrude beyond bot‐ tom of clamp.A. • Bolt connection faces to left.26 . in part or in w l purpos hole ercia . Gr. Prote cted by cop yri gh t .3.at side mark‐ ings -arrow 1.1 Separating front and rear silencers Special tools and workshop equipment required ♦ Pneumatic sabre saw -V.Mounting ❑ Renew if damaged.Exhaust system agen lksw Vo by AG.Tunnel bridge 8 . is n mm ot p co erm or te itte va ri d p un le rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en ♦ Eye protection Procedure WARNING Wear eye protection. ht rig py Co t.25 Nm 7 . position repair double clamp -4.9 l engine) .C op yi 190 Rep.Front silencer 9 . Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss ility ab y li an pt ce es.Golf 2004 ➤ . 1. – Cut exhaust pipe at right angles at separating point -arrow 2-. r fo ng – When installing. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.

Mounting ❑ Renew if damaged. M8: 25 Nm Specified torque. in part or in wh ole. 3 .9 l engine) .Rear silencer 7 .silencer with mountings (vehicles with four-wheel drive) 1 . n AG.Clamp ❑ Align exhaust system free of stress before tightening clamp ⇒ page 192 . agen lksw Vo by AG. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Align cold exhaust system free of stress ⇒ page 192 .25 Nm 5 . ❑ Installation position ⇒ page 192 ❑ Tighten threaded con‐ nections evenly. M10: 40 Nm 1.2009 – Install repair double clamp so that end of bolt does not extend beyond lower edge of clamp.Bracket ❑ For retaining ring 4 . – Tighten bolts on repair double clamp.Edition 01. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n rrectness of i t to the co nform spec at ion h re wit in t his do cu m en ht rig py Co t. • Bolted connection faces rear. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce urposes.From particulate filter 2 . Exhaust system 191 . Co py i 1.4 Assembly overview . 6 . Specified torque. Prote cted by c o py rig ht.Golf 2004 ➤ .Retaining ring ❑ Renew if damaged.

M10: 40 Nm – Once clamp has been tightened. 192 Rep.17 mm is attained between mounting attach‐ ment points for body and rear silencer. do cu m en – Align rear silencer horizontally.Golf 2004 ➤ . ht rig py Co t. – With parts in this position. – Push exhaust pipe with silencer forwards into clamp until di‐ mension -a. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his – Loosen bolted connection of clamp between front exhaust pipe and silencer. in part or in wh ole. tighten bolted connections of clamp. check distance -a. Prote cted by c o py rig ht.Exhaust system agen lksw Vo by AG.Edition 01. Gr.9 l engine) . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.5 Aligning exhaust system free of stress n AG.and cor‐ rect if necessary.2009 Installation position of clamp – Install clamp so that ends of bolts do not protrude beyond bot‐ tom of clamp. Specified torque.= 5 mm from marking on front exhaust pipe and lightly tighten front bolted connection..26 . Prerequisite • Engine must be cold Procedure urposes.points in direction of travel. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n 1.. – Position clamp at distance -a. M8: 25 Nm Specified torque.15. -Arrow. Co py i .

BRU.(electric-pneumatic) to the exhaust gas recirculation valve (mechanical).2009 2 2. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n ility ab y li an pt ce ♦ The exhaust gas recirculation system is activated by the diesel rrectness of i t to the co nform spec at ion h re wit in t his direct injection system control unit -J248. do cu m en ht rig py Co t. agen lksw Vo by AG. Co py i 2.Edition 01. BXE and BXF urposes. BXE and BXF ⇒ page 193 Engine code BJB ⇒ page 195 Engine codes BLS and 2. ♦ The electro-pneumatic exhaust gas recirculation valve -N18♦ The cone-shaped plunger in the mechanical exhaust gas re‐ ♦ Pulsed control enables every conceivable valve position. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. BRU. circulation valve ensures that various cross sectional openings are possible at different plunger lifts. Exhaust gas recirculation system 193 . ♦ Renew self-locking nuts.1. is located in the solenoid valve block.Golf 2004 ➤ .parts of exhaust gas recirculation n AG. Volkswagen AG do es n wage ot g olks yV ua d b 196 BXJ ⇒ page ran e tee ris ho t or ac au ss Engine codes BKC.1 Note Engine codes BKC. in part or in wh ole.1 Exhaust gas recirculation system Assembly overview .9 l engine) .via exhaust gas re‐ circulation valve -N18. Prote cted by c o py rig ht.

C op yi Connector assignment on solenoid valve block. Attach to manifold 3. Attach to bypass flap 2. directs exhaust gas to exhaust gas recirculation cooler via the electro-pneu‐ matic exhaust gas recir‐ culation valve -N18.Bracket ❑ For bypass flap ht rig py Co t. ❑ Tighten securing bolts to 22 Nm. 3 . Tighten to bypass flap 4.Exhaust manifold 8 .Exhaust system AG.5 Nm agen lksw Vo by 10 . c op yri gh t .Edition 01. AG. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en Tightening sequence: 1. is n mm ot p co erm or te itte va ri d p 5 . Gr. in part or in w l purpos hole ercia . BXE and BXF 123456Vacuum connection (on non-return valve for brake servo) Exhaust gas recirculation valve Bypass flap Air filter Vacuum reservoir Vacuum unit on turbocharger 194 Rep. Tighten to manifold r fo ng 9 . .22 Nm 2 .Golf 2004 ➤ .Connecting pipe ❑ ❑ ❑ ❑ es. Prote cted by 11 .Connecting pipe un le 6 .26 .Intake manifold ❑ With exhaust gas recir‐ culation valve and in‐ take manifold flap motor -V157.Cooler ❑ For exhaust gas recircu‐ lation. BRU. engine codes BKC.Bypass flap ❑ When activated.2009 1 .9 l engine) .10 Nm 7 ...Gasket ❑ Renew 4 .

1. is n mm ot p co erm or te itte va ri d p un le n AG. agen lksw Vo by AG. Prote cted by c op yri gh t.Exhaust manifold 6 . es.9 l engine) . ♦ The electro-pneumatic exhaust gas recirculation valve -N18♦ The cone-shaped plunger in the mechanical exhaust gas re‐ ♦ Pulsed control enables every conceivable valve position. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng 2.Edition 01.Golf 2004 ➤ .via exhaust gas re‐ circulation valve -N18. in part or in w l purpos hole ercia .22 Nm 5 .Connecting pipe circulation valve ensures that various cross sectional openings are possible at different plunger lifts.Intake manifold ❑ With exhaust gas recir‐ culation valve and in‐ take manifold flap ❑ Tighten securing bolts to 22 Nm. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. 1 . is located in the solenoid valve block.2009 2. 2 . ♦ Renew self-locking nuts. Exhaust gas recirculation system ht rig py Co t.Gasket ❑ Renew 4 . Co py i 195 .From charge air cooler 3 .(electric-pneumatic) to the exhaust gas recirculation valve (mechanical).2 Note Engine code BJB ♦ The exhaust gas recirculation system is activated by the diesel direct injection system control unit -J248.

in‐ take manifold ⇒ page 176 8 .Exhaust system ht rig py Co t.3 Note Engine codes BLS and BXJ ♦ The exhaust gas recirculation system is activated by the diesel direct injection system control unit -J248. 1 . is n mm ot p co erm or te itte va ri d p 6 .9 l engine) .Exhaust gas recirculation cooler 9 . agen lksw Vo by AG.26 .22 Nm 4 . Gr.via the exhaust gas recirculation potentiometer -G212.Vacuum unit ❑ For bypass flap un le AG.To connection for exhaust gas recirculation valve -N18with exhaust gas recirculation potentiometer -G212❑ Assembly overview . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.Golf 2004 ➤ . in part or in w l purpos hole ercia .Gasket ❑ Renew 3 . ♦ Renew self-locking nuts. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss ility ab y li an pt ce rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng 196 Rep.Connecting pipe 14 .25 Nm ❑ Renew 7 .Coolant hose ❑ From rear coolant pipe 11 .Coolant hose ❑ To connection 2 .C op yi . Prote cted by c op yri gh t .Connecting pipe 5 ..10 Nm 10 .2009 Pin assignment on solenoid valve block for engine code BJB 123456Vacuum connection (on non-return valve for brake servo) Exhaust gas recirculation valve Intake manifold flap Air filter Vacuum reservoir Vacuum unit on turbocharger 2.Exhaust gas recirculation cooler change-over valve N34513 .From exhaust manifold es.1.Edition 01.Connecting hose 12 .

Prote cted by c op yri gh t.Golf 2004 ➤ . Co py i 2. cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nform spec at ion h re wit in t his do cu m en ht rig py Co t.Edition 01. Exhaust gas recirculation system 197 . Golf Plus 2005 ➤ 4-cylinder diesel engine (1.2009 ❑ Renew only together with exhaust gas recirculation cooler urposes.9 l engine) . in part or in wh ole. agen lksw Vo by AG.

installing and checking glow plugs ⇒ page 198 Characteristics of ceramic glow plugs ⇒ page 199 Removing.A. agen lksw Vo by Prote cted by Test procedure ht rig py Co t.9 l engine) .Golf 2004 ➤ .Edition 01.Glow plug system AG. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. – Pull glow plug connectors off glow plugs.A. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit thi sd oc um en Test requirements • • Ignition switched off 198 Rep.G 1594 C- ♦ Diode test lamp -V. Gr. Co py i Battery voltage at least 11. c op yri gh t.28 .5 V .1 Removing. installing and checking ceramic glow plugs ⇒ page 200 1. in part or in wh ole.2009 28 – 1 Glow plug system Checking glow plug system Removing.G 1527 B♦ Jointed spanner -3220- urposes. installing and checking glow plugs Special tools and workshop equipment required ♦ Auxiliary measuring set -V.

Visual features of ceramic glow plugs Vehicles with 2 valves per cylinder head n AG. Checking glow plug system agen lksw Vo by AG.cable to battery posi‐ tive. -D.= Metal glow plug. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au to jolts and ss ility ab y li an pt ce rrectness of i t to the co nf orm spec atio h re n in wit -A.A. using clamps from adapter set -V.on each glow plug one after the other. Vehicles with 4 valves per cylinder head -C. replace glow plug. – Place probe of diode test lamp -V. even if there is no obvious damage.A.2009 – Connect voltage tester -V. Co py i 199 . 1. Remove and install or check ceramic glow plugs ⇒ page 200 .= Metal glow plug. -B.G 1527 B.. otherwise the heater pin of the glow plug can break and cause engine damage. in part or in wh ole. glow plug is OK.. Prote cted by c op yri gh t. thi sd oc um en 1.= Ceramic glow plug with support tube -arrow-. colour-coded -arrow-. colour-coded -arrow-.= Ceramic glow plug with support tube -arrow-.2 Characteristics of ceramic glow plugs WARNING urposes. cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng The ceramic glow plugs ⇒ page 199 are sensitive bending.A. not colourcoded.G 1527 B. – Remove and install glow plugs using jointed spanner -3220. For this reason a glow plug which has dropped from a small height (approx. ht rig py Co t.Golf 2004 ➤ . If diode does not light up. It is absolutely necessary to follow the installation instructions.G 1594 C. Specified torque: 15 Nm.Edition 01. If diode lights up. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) . not colourcoded. 2 cm) must not be used.

28 . Co py i .A.kswagen AG Vol V.Glow plug system ht rig py Co t. – Pull connectors off ceramic glow plugs. – Remove ceramic glow plugs using U/J extension and socket. Installation is carried out in the reverse order. When installing.G 1331♦ Hand-held multimeter . in part or in w l purpos hole ercia . Prote cted by c o py rig ht.A. is n mm ot p co erm or te itte va ri d p . installing and checking ceramic glow plugs Special tools and workshop equipment required ♦ Jointed spanner -3220♦ Torque wrench (5…50 Nm) -V..2009 1.A. note the following: – Before installing the drilling in cylinder head and the threads must completely cleaned of all deposits. Remove any components hindering assembly. 10 mm -3220.9 l engine) . 200 Rep. Volkswagen AG d ise does not gu ara nte eo ra c ility ab y li an pt ce un le rrectne ss of in t to the co form spec atio h re n wit in t his do cu m en r fo ng Test prerequisites • • Engine is cold Ignition switched off Procedure Note Do not cant ceramic glow plugs when removing and installing.Edition 01.G 1526 Aby r ♦ Auxiliary measuring set tho au V.3 Removing. agen lksw Vo by AG.Golf 2004 ➤ .G 1594 sCs es. Golf Plus 2005 ➤ 4-cylinder diesel engine (1. Gr.

Edition 01. otherwise these can cause damage to the engine. in part or in wh ole. thi sd oc um en 1. 10 mm -3220. Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) . Checking glow plug system ht rig py Co t. ♦ Specification: max. salways db ran e tee ri perform a resistance test on all ceramic glowtho plugs when or ac au engine is cold.2009 Note Never oil or grease thread of cylinder head bore or of ceramic glow plugs. Prote cted by c op yri gh t. Volkswagen AG do es n wage ot g olks yV ua After installing and before the engine is started. renew the defective ceramic glow plug.Golf 2004 ➤ . Co py i 201 . cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng WARNING ♦ ility ab y li an pt ce ♦ If the defective ceramic glow plug is broken. – Then tighten the ceramic glow plugs. ss urposes. n AG. 1 Ω rrectness of i t to the co nf orm spec atio h re n in wit – If the specification is exceeded. agen lksw Vo by AG. Specified torque: 15 Nm. – Screw ceramic glow plugs into cylinder head by hand using U/ J extension and socket. remove all fragments from the engine..