4-Cylinder Diesel Engine With Unit Injector

Service
Workshop Manual
Jetta 2005
Bora 2006
Golf Variant 2007
4-cylinder diesel engine with unit injector
Engine ID BKC BLS BRM BXE
Edition 05.2007
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright 2010 Volkswagen AG, Wolfsburg MEX5R006420

Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine ewith unit injector - Edition 05.2007
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Checking and adjusting assembly mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1.5 Assembly mounting - Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1.2 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1.3 Assembly overview - poly-V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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1.4 Assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1.5 Removing and installing poly-V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Assembly overview - sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.3 Identification of upper crankshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.4 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4 Pistons and connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.4 Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 54
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.3 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.2 Checking axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.3 Seal bearing caps 1 and 5 contact surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.6 Renewing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.7 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Contents i
4-cylinder diesel engine with unit injector - Edition 05.2007
2.8 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.1 Engine oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.2 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.3 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Oil pump, oil sump - assembly overview, engine codes BKC, BLS, BXE . . . . . . . . . . . . . . 98
2.2 Oil pump, oil sump - assembly overview, engine codes BRM . . . . . . . . . . . . . . . . . . . . . . 100
2.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Oil filter bracket, oil pressure, oil cooler and oil supply line . . . . . . . . . . . . . . . . . . . . . . . . 106
3.1 Assembly overview - oil filter bracket and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2 Removing and installing oil filter bracket with oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.4 Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.5 Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1 Parts of the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.1 Parts of cooling system - body side, engine agencodes BLS, BRM
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1.2 Parts of cooling system - body side, by V engine codes BKC, BXE . . o. t .gu. . . . . . . . . . . . . . . . . .
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1.3 Parts of cooling system - engineoris side, engine codes BLS, BRM . . . . . n.te.e . . . . . . . . . . . . .
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1.4 Parts of cooling system - sengine
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1.5 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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1.6 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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1.7 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 130
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1.8 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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1.9 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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1.10 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h re 136

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1.11 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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1.12 Checking oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

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1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 142

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2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

3 Fuel tank, models with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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3.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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3.2 Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

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3.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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3.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

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3.5 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

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3.6 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

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4 Repairing fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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4.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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4.2 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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4.3 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.4 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.2 Assembly overview - accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.3 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
ii Contents
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2 Charge air system with turbocharger, engine codes BKC, BXE . . . . . . . . . . . . . . . . . . . . 175
2.1 Turbocharger - Assembly overview, engine codes BKC, BXE . . . . . . . . . . . . . . . . . . . . . . 175
2.2 Removing and installing turbocharger, engine codes BKC, BXE . . . . . . . . . . . . . . . . . . . . 177
2.3 Parts of charge air cooling - Assembly overview, engine codes BKC, BXE . . . . . . . . . . . . 183
3 Charge air system with turbocharger, engine codes BLS, BRM . . . . . . . . . . . . . . . . . . . . 185
3.1 Turbocharger - Assembly overview, engine codes BLS (without diesel particulate filter), BRM
...................................................................... 185
3.2 Removing and installing turbocharger, engine codes BLS (without diesel particulate filter),
BRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.3 Turbocharger - Assembly overview, engine code BLS (with diesel particulate filter) . . . . 195
3.4 Removing and installing turbocharger, engine code BLS (with diesel particulate filter) . . . . 196
3.5 Parts of charge air cooling - Assembly overview, engine codes BLS, BRM . . . . . . . . . . . . 198
4 Hose connections
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4.1 Hoseby V connections . . . . . . . . . . . . .t g. u.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5 thorisRemoving and installing charge air coolerntee .o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.1 au Removing and installing charge air cooler . r.ac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
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6 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

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7 Vacuum hoses for connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

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7.1 Vehicles with engine codes BKC, BXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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7.2 Vehicles with engine codes BLS, BRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

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1 Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

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1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
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1.3 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

1.4 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
ss
1.5 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

o
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1.6 Removing and installing unit injector O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

inform
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1.7 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

atio
1.8 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

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1.9 Removing and installing intake pipe with exhaust gas recirculation potentiometer G212 and
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exhaust gas recirculation valve N18 , engine codes BLS, BRM . . . . . . . . . . . . . . . . . . . . 233
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1.10 Dismantling and assembling intake pipe with with exhaust gas recirculation potentiometer
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G212 and exhaust gas recirculation valve N18 , engine codes BLS, BRM . . . . . . . . . . . . 234
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1.11 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 235
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1.12 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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1.13 Connection diagram for charge pressure control, engine codes BKC, BXE . . . . . . . . . . . . 238
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Connection diagram for solenoid valve block, engine codes BKC, BXE . . . . . . . . . . . . . . 238
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1.15 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

1.16 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
1.17 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 240
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.1 Reading and clearing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
2.3 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

1 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.1 Parts of exhaust system - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.3 Connecting and disconnecting front and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Contents iii
1.4 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2.1 Parts of exhaust gas recirculation - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2.2 Parts of the exhaust gas recirculation cooler - Assembly overview, engine codes BLS,
BRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
2.3 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 266
2.4 Check mechanical exhaust gas recirculation valve, engine codes BKC, BXE . . . . . . . . . . 272
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.1 Checking, removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
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iv Contents
00 Technical data
1 Technical data
Engine number page 1
Engine data page 1
1.1 Engine number

The engine number (Engine code and Serial number) can be
found on the join between engine and gearbox -arrow-.
The engine number consists of up to nine characters (alphanu
meric). The first part (up to 3 code letters) represents the engine
code letters, the second part (6 digits) the serial number. If more
than 999,999 engines were produced with the same code letters,
the first of the 6 digits is replaced by a letter.
Additionally there is a sticker on the toothed belt guard with en
gine code and serial number.
The engine code is also located on the vehicle data sticker. The
vehicle data sticker is located in the Servicing schedule and in
rear of vehicle in the spare wheel recess or the luggage compart
ment floor.
1.2 Engine data olksw

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Engine code orise BKC BLS nte
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BRM BXE
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Emissions fulfil EU4 standard EU4 standard Tier 2 EU4 standard

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Capacity l 1.9 1.9 1.9 1.9

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Power output kW at rpm 77/4000 77/4000 74/4000 77/4000

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Torque Nm at rpm 250/1900 250/1900 250/1900 250/1900

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Bore in mm 79.5 79.5 79.5 79.5

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Stroke mm 95.5 95.5 95.5 95.5

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Valves per cylinder 2 2 2 2

Compression ratio 19.0 19.0 19.0 19.0
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CN at least 51 51 51 51
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
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Catalytic converter yes yes yes yes

Exhaust gas recirculation yes yes yes yes
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Diesel particulate filter no depending on no no

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Lambda control no yes no no

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Turbocharging/supercharging yes yes yes yes

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Charge air cooler yes yes yes yes

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Electronic power control yes yes yes yes
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1. Technical data 1
10 Removing and installing engine

1 Removing and installing engine
Removing engine page 2
Securing engine to assembly stand page 15
Installing engine page 16
Checking and adjusting assembly mounting page 19
Assembly mounting - Torque settings page 23
1.1 Removing engine
Special tools and workshop

equipment required
Lifting tackle -2024 A-
Engine support -T10012-
Support clamp -VW 313-
Engine and gearbox sup
port -VW 540- agen
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Workshop crane -VAS ed by ara
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Workshop crane -V.A.G ss c
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Drip tray -V.A.G 1306- or
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2 Rep. Gr.10 - Removing and installing engine

Torque wrench -V.A.G

1331-
Torque wrench -V.A.G agen
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Engine and gearbox jack - horis nte
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Spring-type clip pliers -VAS
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Stepladder -VAS 5085-
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Guide rods -T10093-
Cable ties
1. Removing and installing engine 3

Note
Before carrying out further work, disconnect battery earth

strap. First check whether a coded radio is fitted. Obtain anti-
theft code first if necessary.
The engine is removed downwards together with theAGgearbox.
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All wirings (e.g. for fuel, hydraulic system, coolant and re
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t to the co
ings must be installed in the original way.
Ensure that there is sufficient clearance to all moving or
rrectness of i
hot components.
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Procedure
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With ignition switched off, disconnect earth strap from battery.

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Remove engine cover. To do this, pull engine cover upwards
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abruptly at front -arrows A- and then pull forwards out of rear

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fastening -arrow B-.

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Remove bulkhead in plenum chamber General Body Re

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pairs, Exterior; Rep. Gr. 50 ; Plenum chamber bulkhead .

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Remove air filter housing with air mass meter and connecting
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Disconnect connector -2- on air mass meter -G70- .

Pull breather hose -1- and air duct hoses -3- and -5- off.
Unscrew bolt -4- and take off air filter housing.
Vehicles with engine codes BLS, BRM
Remove air cleaner housing with air mass meter.

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Pull breather hose -1- off and unhook from bracket -arrow-.
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Release spring-type clip -3- with spring-type clip pliers -VAS
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5024A- and pull intake hose off air mass meter -G70- .
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Pull intake manifold -5- off the air duct.
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Vehicles with diesel particulate filter
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Separate the following connectors -arrows- (on bulkhead):
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Connector for charge pressure regulation solenoid valve -
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Connector for bank 1 exhaust gas temperature sender 2 -
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Connector for bank 1 exhaust gas temperature sender 1 -
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Connector for Lambda probe -G39- yri
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Removing battery Electrical system; Rep. Gr. 27 ; Remov

ing and installing battery; Vehicles with diesel engine .
Remove battery tray -arrows-.

Vehicles with direct shift gearbox
If the metal components are touched it is possible to trigger an
electrostatic discharge. This is due to the electrostatic charge of
the human body. This charge can disturb the function of electrical
components of the gearbox and of the shift mechanism.

Before working on Mechatronic, touch an earthed object,

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Turn bayonet connection -1- of connector to left and pull con

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Release retaining clip -A- off and remove upwards.

Pull retaining clip -B- off upwards.
Remove selector lever cable from selector shaft lever and
place on the top.
Vehicles with manual gearbox
Unclip circlips -1- and -2- from both selector cables.

Pull off selector cable end-pieces from gearbox selector lever
and relay lever.

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Remove cable support bracket from gearbox -arrows- and lay
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Clamp off pressure line going to slave cylinder with hose
clamps for diameters up to 25 mm -3094- .
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Remove pressure line -1- out of hose coupling. To do this pull
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retaining clip upwards -arrow-.

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Do not press clutch pedal after removing slave cylinder.
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Loosen bolts -arrows- of assembly mounting on engine just a

bit (less than 1 turn).
Loosen bolts -arrows- of assembly mounting on gearbox just

a bit (less than 1 turn).

Pull connector -arrow 1- off.

Pull vacuum hoses -arrow 2- off.
Pull vacuum hose -arrow 3- off non-return valve for brake ser
vo.
Pull vacuum hose -arrow- to brake servo off tandem pump.
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Remove coolant hoses -arrows- to heater heat exchanger on

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Unscrew earth cable -1-.

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Remove wiring -2- and -3- on starter.

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Move wiring clear.

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Remove connector -arrow- on coolant temperature sender -

G62- .
Pull the release pin -arrow 1- and unscrew knurled nut

-arrow 2-.
Pull central switch for unit injectors off and free wiring harness.
Disconnect connector -arrow- on fuel temperature sender -

G81- and free wiring.
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Remove coolant hose between engine and radiator -arrows-.
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WARNING
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The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
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The fuel system is also under pressure! Before opening

the system, place cloths around the connections. Then
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carefully loosen connection to release the pressure!

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Wear eye and hand protection when performing any type

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Mark and pull hoses -2- off and free.

Remove air pipe. To do this lift retaining clips -1- slightly and
remove the bolt -3- from the transport bracket.
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Pull coolant hose -arrow- off.
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Separate fuel supply pipe -3- and fuel return pipe -2-. To do
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Pull coolant hose -1- off expansion tank.

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Disconnect connector -arrow- on intake manifold flap motor -

V157- .

Take connector -arrow- for Hall sender -G40- out of retainer

and separate.
Disconnect connector -arrow- on oil pressure switch -F1- .

Unscrew oil pressure switch.
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Disconnect connector -arrow- on engine speed sender -G28-

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using assembly tool -T10118- .

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Note
To unlock connector without assembly tool -T10118- , press con

rrectness of i
nector to engine speed sender with a screwdriver and raise

release button with a thin wire hook at the same time.
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Move wire clear.

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Pull connector strip off glow plugs -arrows-.

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Free wiring to body.

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Remove noise insulation General body repairs, exterior;

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Bring lock carrier into service position General body repairs,
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Vehicles with air conditioner
Note
To prevent damage to condenser or to refrigerant pipes and ho

ses, ensure that pipes and hoses are not stretched, kinked or
bent.
WARNING
The air conditioner refrigerant circuit must not be opened.

Remove bolts -2- and -3- on refrigerant lines brackets.

To facilitate removing and installing engine without opening re
frigerant circuit:
Remove poly-V-belt page 29 .
Separate air conditioner compressor Heating, Air condi
tioning system; Rep. Gr. 87 ; Repair work on refrigerant circuit;
Removing and installing air conditioner compressor .
Secure air conditioner compressor to lock carrier so that re
frigerant lines are free of stress.
Remove alternator Electrical system; Rep. Gr. 27 ; Alter
nator 1.9 l TDI engine .
Remove radiator page 132 .
Remove left air duct hose, to do this lift retaining clips

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Unscrew nut -arrow- and take retainer for wiring harness off
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Remove right air duct hose, to do this lift retaining clips

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Remove bolts -1- and -2-.
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Remove air hose fromthoturbocharger.
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Remove right air duct pipe. To do this lift retaining clips
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Remove connector -2- on radiator outlet coolant temperature
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Remove locking screw -arrow- for front air duct pipe.
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Prote AG.
Remove right-hand and left-hand drive shafts on gearbox

Running gear, axles, steering; Rep. Gr. 40 ; Servicing drive
shafts; Removing and installing drive shafts .
Remove front exhaust pipe page 251 .
Disengage and pull off connector on engine control unit
page 245 .

4-cylinder diesel engine with
wage
unit
n AG. Volinjector
kswagen A- GEdition 05.2007
doe
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Open all cable guide risefasteners -arrows-.
d
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Remove wiringss harness from cable guide on longitudinal mem r ac
a
ber and lay to side on engine.
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Pull off or disconnect all other electrical connections from en
d
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gine and gearbox as necessary and lay to side.
erm
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Separate all connection, coolant, vacuum and intake hoses
wit
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from engine.
h re
ole,
spec
t to the co
rrectne
Unscrew bolt -1 - first.
Unscrew bolts -2- and -3- and take pendulum support off.
ss o
cial p
f inform
mer
atio
om
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or
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Cop py
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Insert engine support -T10012- in engine and gearbox jack -
by c lksw
cted agen
V.A.G 1383 A- .
Prote AG.
Note
Support pins must be secured to engine bracket -T10012- as

shown.
Fit engine bracket -T10012- to cylinder block with bolt -

M1025/8.8- and tighten to approx. 40 Nm.
Raise engine and gearbox slightly using engine and gearbox
jack -V.A.G 1383 A- .
Note
To remove securing bolts use step ladder -VAS 5085- .
Unbolt assembly mounting on engine side from engine bracket

-arrows-.

Unbolt assembly mounting on gearbox side from gearbox

bracket -arrows-.
Note
Check whether all hoses and wiring connections between en

gine, gearbox and body are disconnected.
Engine with gearbox must be guided carefully when lowered
to prevent damage.
Carefully lower engine with gearbox.

AG. Volkswagen AG d
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1.2 Securing engine to assembly stand ol not
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Special tools and workshop ss c
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Support clamp -VW 313-
y li
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ab
ility
Engine and gearbox sup
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port -VW 540-
is n
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ole,
Lifting tackle -2024 A-
spec
Engine and gearbox jack -
t to the co
V.A.G 1383 A-
Workshop crane -
rrectne
VAS 6100-
ss o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
sd
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fo
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t.
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Cop py
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pyri by
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by c lksw
cted agen
Prote AG.
When working on the engine, secure it to support clamp -VW 313-

of the assembly stand using engine and gearbox support -VW
540- .

Procedure
Move engine/gearbox jack -V.A.G 1383 A- to a workbench.
Lower engine/gearbox assembly so that the gearbox is on the
workbench.
Remove engine/gearbox connecting bolts.
Press gearbox off engine.
Attach lifting tackle - 2024 A- as shown and raise engine out

of engine and gearbox jack -V.A.G 1383 A- using workshop
hoist -VAS 6100- or workshop hoist -V.A.G 1202 A- .
Belt pulley end: 1st hole of hook rail in position 2
Flywheel end: 4th hole in hook at position 8.
WARNING agen
AG. Volkswagen AG d
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The hooks and locating pins must be secured with locking pins.
d ara
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The positions marked 1...4 on the bar must be towards the
wit
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pulley end.
h re
ole,
The holes in the hooks are counted up from the hook. spec
t to the co
Secure engine on support clamp -VW 313- using engine and

gearbox jack -VW 540- .
rrectne
1.3 Installing engine

ss
Install in reverse order. In the process, note the following:

o
cial p
f inform
mer
Caution
atio
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thi
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tions:
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frigerant liquid, brake liquid, vacuum) and electrical wir C py
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ings must be installed in the original way. rig ht
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Ensure that there is sufficient clearance to all moving or cted agen
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hot components.

Note
Reinstall all cable ties in the same locations when assembling.

Hoses must be locked with clamps Electronic parts cata
logue ETKA .
Renew self-locking nuts and bolts when performing assembly
work.
Renew bolts which are tightened to a specified angle as well
as oil seals and gaskets.
Insert new dowel sleeves in cylinder block for centring engine

and gearbox.
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
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Cop py
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Prote AG.

Ensure that the intermediate plate is attached to the sealing

flange and is slid onto the dowel sleeves -arrows-.
Align engine mountings tension free by shaking. If necessary,
loosen engine mounting on body.
Note
Checking and adjusting assembly mounting page 19 .

Torque settings for assembly mounting page 23 .
Engine/gearbox connecting bolts Direct manual gearbox;
Rep. Gr. 34 ; Removing and installing gearbox .
Electrical connections and routing Electrical system; Rep.
Gr. 97 .
Procedure
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gen AG does
Install pendulum support
Vol
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Install drive shafts
oris Running gear, axles, steering; Rep.ntGr.
e
ee
40 ; Servicing
au drive shafts; Removing and installing drive or a
th
shafts . ss c ce
e
nl
pt
du
an
itte
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Vehicles with manual gearbox

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ility
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Install hydraulic clutch hydraulic lines 6-speed manual gear

wit
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box 02Q; Rep. Gr. 30 ; Repairing clutch control; Assembly

h re
hole
overview - Hydraulics .
spec
es, in part or in w
Install selector mechanism, adjust selector mechanism if nec

t to the co
essary 5-speed manual gearbox 0A4; Rep. Gr. 34 ; Serv

icing selector mechanism .
rrectness of i
Vehicles with direct shift gearbox

l purpos
Fit selector lever cable to gearbox Direct manual gearbox;

Rep. Gr. 34 ; Removing and installing selector lever cable .
nform
ercia

m
at
Install alternator Electrical system; Rep. Gr. 27 ; Alternator

om
io
1.9 l TDI engine .

n
c
in t
or
his
e
Install air conditioner compressor Heating, Air conditioning

at
do
riv
system; Rep. Gr. 87 ; Repair work on refrigerant circuit; Re

p
cum
or
moving and installing air conditioner compressor .

f
en
ng
t.
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Install poly-V-belt page 29 . C py
t. rig
gh ht
yri
Install noise insulation General body repairs, exterior; Rep.
p by
co Vo
by lksw
Gr. 50 ; Noise insulation . Prote
cted AG.
agen
Install engine control unit page 245 .

Install battery carrier first and tighten bolts -arrows-.

Route wiring -2- as shown in the figure and fit to electronics
box -1-.
Install bulkhead in plenum chamber General Body Repairs,
Exterior; Rep. Gr. 50 ; Plenum chamber bulkhead .
Fill coolant system with coolant page 127 .
Installing battery Electrical system; Rep. Gr. 27 ; Removing
and installing battery; Vehicles with diesel engine .
Adapt engine control unit Vehicle diagnosis, testing andVolkswa
information system -VAS 5051B - Guided fault finding.
swa
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. gen AG
does
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Perform vehicle system test using Vehicle by diagnosis sys ara
ed nte
tem, testing and information system -VAS oris 5051B - Guided eo
th
fault finding. ss
au ra
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Then end Guided fault finding.

nl
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Observe applicable safety precautions during road test.
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Carry out a road test.
wit
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After this, perform vehicle system test again and if necessary,
hole
rectify faults.
spec
es, in part or in w
t to the co
1.4 Checking and adjusting assembly
mounting
rrectness of i
Checking settings page 19
l purpos
Adjusting assembly mounting page 20
nform
ercia
1.4.1 Checking
m
at
om
ion
c
in t
or
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e

at
do
priv
cum
for
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Unlock locking devices and remove fuel filter with connected

hoses from retainer upwards -arrow- and place to side.
The following specifications must be obtained:

There must be a distance of -a- at least 10 mm between engine

support and longitudinal member (right-side).
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.
1.4.2 Adjusting assembly mounting

Special tools and workshop equipment required
Support bracket -10 - 222 A-
AG. Volkswagen AG d
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ab
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Torque wrench -V.A.G 1332- wit

, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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If dimension is too small or to large proceed as follows:

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pipe. Cop py
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Disconnect connector -2- on air mass meter -G70- . p by
o Vo
by c lksw
cted agen
Pull breather hose -1- and air duct hoses -3- and -5- off. Prote AG.



Pull breather hose -1- off and unhook from bracket -arrow-. . Volkswagen AG
gen AG does
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Release spring-type clip -3- with spring-type clip pliers y V -VAS
olk not
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5024A- and pull intake hose off air mass meter r-G70-
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Pull intake manifold -5- off the air duct. s au ra
c
s
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nl
pt
du
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erm
ab
ility
ot p
wit
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
atio
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n in
or c
thi
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sd
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Fit support bracket -10 - 222 A- before the gas pressure damp
er for the front flap using adapter -10 - 222 A/8- , adapter - 10
- 222 A/3- and adapter -10 - 222 A/16- .
Attach trigger snap of spindles to lifting eyes. On the right side
use additionally the adapter -10 - 222 A/20-
Take up weight of engine evenly with both spindles (but do not
raise engine).

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Jetta 2005 , Bora 2006 , Golf Variantks2007
wage
n AG does
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4-cylinder diesel engine with unit injector
db
y - Edition 05.2007
V gu
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Remove bolts -arrows- of engine assembly
au
t
mounting. ra
c
ss
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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Remove bolts -arrows- of gearbox assembly mounting.

Renew all bolts one after the other (if they had not been re
nform
ercia
moved when the engine was removed) and screw in loosely.

m
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Slide the engine with a lever between engine console -1- and
arm -2- until the following dimensions are set:
Between the engine support and the right longitudinal member
there must be a distance of -a- = 10 mm.
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
Dimension -a- can be checked e.g. with suitable round bars.
Tighten bolts for engine side assembly mounting

page 23 .
Ensure that the edges of the support arm on the gearbox as

sembly mounting -2- and gearbox support -1- are parallel.
Dimension -x- must be identical at top and bottom.
Tighten bolts for gearbox side assembly mounting
page 23 .
Installation is carried out in the reverse order.

1.5 Assembly mounting - Torque settings

olkswagen AG
en AG. V
Engine assembly mounting
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A = 20 Nm + 90ise 1
or ( /4 turn) further nte
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Renew sbolts.
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pt
B = 40 Nm + 90 (1/4 turn) further
du
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erm
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Renew bolts.
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wit
C = 60 Nm + 90 (1/4 turn) further
, is n
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hole
spec
Renew bolts.
es, in part or in w
t to the co
Gearbox assembly mounting
A = 40 Nm + 90 (1/4 turn) further
rrectness of i
Renew bolts.
l purpos
nform
ercia
Renew bolts.
m
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or
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ate
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for
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Pendulum support t. Cop py
rig
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A = 40 Nm + 90 (1/4 turn) further pyri by
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cted agen
Prote
Renew bolts.
AG.

Renew bolts.
Removing: First remove bolt -B- then bolts -A-.
Installing: First tighten bolts -A- then bolt -B-.

13 Crankshaft group
1 Dismantling and assembling engine
Assembly overview page 25
wage es n
Assembly overview - toothedyV
olks belt drive page 26 ot g
ua
d b ran
e
Assembly overviewhor-ispoly-V-belt drive page 27 tee
ut or
a ac
Assembly overview
ss - cylinder block page 28
ce
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nl
pt
Removing and installing poly-V-belt page 29
du
an
itte
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erm
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ility
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Note
wit
, is n
h re
hole
If large quantities of metal particles or other deposits (caused, for
spec
example, by partial seizure of the crankshaft or conrod bearings)
es, in part or in w
t to the co
are found in the engine oil when performing repairs, clean the oil
passages of the oil cooler, the oil spray jets and the oil filter thor
oughly and renew the oil cooler in order to prevent further damage
from occurring later.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
24 Rep. Gr.13 - Crankshaft group

AG. Volkswagen AG d
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Jetta 2005 , Bora 2006 , Golf ara Variant 2007
nte
ut 4-cylinder diesel engine with unit injector - Edition
ho eo
ra 05.2007
s a c
s
ce
le
1.1 Assembly overview
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
r
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thi
s
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
1. Dismantling and assembling engine 25

I = Toothed belt drive - Assembly overview page 26

II = Poly-V-belt drive - Assembly overview page 27
III = Cylinder block - Assembly overview page 28
1.2 Assembly overview - toothed belt drive
1 - Toothed belt guard upper

part
2 - 100 Nm
3 - 25 Nm
4 - Camshaft pulley
5 - Hub
With sender wheel. AG. Volkswagen AG d
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Use counter-hold - byV
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T10051 - to loosen and rised
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tighten ut
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To remove, use puller - ss
ce
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T10052- .
un
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Removing and installing
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page 92 .
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6 - 10 Nm
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Renew.
hole
spec
es, in part or in w
7 - Rear toothed belt guard
t to the co
8 - 25 Nm
9 - Sealing grommet
rrectness of i
Renew if damaged.
l purpos
10 - 20 Nm +45 (1/8 turn) fur

ther
nform
ercia
11 - Tensioning roller
m
a
com
tion in
12 - 20 Nm
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13 - Idler roller
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14 - Coolant pump
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page 134 .
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15 - Crankshaft toothed belt pulley
co Vo
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Prote AG.
16 - 120 Nm + 90 (1/4 turn) further
Renew.
Use counter-hold tool -3099- to loosen and tighten.
Do not additionally oil or grease thread and shoulder.
Turning further can be done in several stages.
17 - 15 Nm
18 - Toothed belt guard lower part
19 - Belt pulley and vibration damper
Can only be installed in one position. Holes are offset.

AG. Volkswagen AG d
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ara , Golf Variant 2007
ise nte
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ho 4-cylinder diesel engine with unit injector e o - Edition 05.2007
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20 - 10 Nm + 90 (1/4 turn) further
le
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21 - Cover
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ab
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22 - Toothed belt
ot
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Mark direction of rotation before removing.
h re
hole
spec
Check for wear.
es, in part or in w
Do not kink.
t to the co
Removing, installing and tensioning page 62 .
23 - 40 Nm + 180 (1/2 turn) further
rrectness of i
Renew.
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24 - Centre toothed belt guard
nform
ercia
25 - Engine support
m
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com
tion in
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1.3 Assembly overview - poly-V-belt drive
s
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1 - Belt pulley and vibration

t.
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damper
C py
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Can only be installed in p by
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by c lksw
one position. Holes are Prote
cted agen
offset.
AG.
2 - 25 Nm
3 - Alternator
4 - Retainer
For alternator and air
conditioner compressor.
5 - Poly-V-belt tensioner
Swing with ring spanner
to slacken poly-V-belt.
6 - 25 Nm
7 - Air conditioner compressor
8 - 25 Nm
9 - Dowel sleeves
10 - Poly-V-belt
Mark direction of rota
tion before removing.
Check for wear.
Do not kink.
page 29 .

1.4 Assembly overview - cylinder block
1 - Cylinder block
sealing flange and fly
wheel page 32 .
crankshaft
page 48 .
Dismantling and assem
bling pistons and con
rods page 48 .
2 - Retainer
For wiring harness and
charge air pipe
3 - 15 Nm
4 - Seal
Renew.
5 - Oil filter bracket
Removing and installing AG. Volkswagen AG d
page 107 . lksw
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Dismantling and eassem yV gu
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6 - 15 Nm + 90 s(1/4 turn) fur
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Renew.
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First fit upper left and

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lower right bolts and

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then tighten all four bolts

h re
ole,
diagonally.
spec
7 - Retainer
t to the co
8 - 20 Nm
rrectne
9 - Connection
For thermostat.
ss
10 - 15 Nm
o
cial p
f inform
11 - O-ring
mer
atio
Renew.
om
n
c
12 - Thermostat
or
n thi
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sd
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Removing and installing page 136 .

iv
o
pr
cum
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Note installation position page 136 .

fo
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t.
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Checking: heat thermostat in water.
Co
Cop py
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Opening begins at approx. 85C. opyri
gh by
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Ends at approx. 105C by c lksw

cted agen
Prote AG.
Opening lift min. 7 mm.
13 - Hexagon head bolt
Tightening sequence and tightening torque: Heating, air conditioning; Rep. Gr. 87 ; Removing and
installing compressor bracket .
14 - Retainer
For alternator and, if fitted, air conditioner compressor.

15 - Poly-V-belt tensioner
16 - 25 Nm
17 - Sump
Clean sealing surface before installing
Install with silicone sealant -D 176 404 A2- .
18 - 15 Nm
G. Volkswage
1.5 Removing
olks
wagand
en A installing poly-V-belt
n AG d
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Special tools and
ris workshop equipment required
ed nte
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ut
Mandrel
ss -T10060A-
a ra
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un
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ility
ot
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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Removing page 29
nform
ercia
Installing page 30
m
1.5.1 Removing
com
tion in
r
te o

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Rep. Gr. 50 ; Noise insulation .

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cum
fo

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t.
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fastening -arrow B-. t. C rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Pull fuel filter out in -direction of arrow- and lay it with hoses to
side.
Mark direction of rotation of poly-V-belt.

Swing tensioning element in -direction of arrow- to remove

tension from poly-V-belt.
AG. Volkswagen AG d
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an
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wit
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Lock tensioning element with retaining pin -T10060 A- . ole,
spec
Remove poly-V-belt.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
1.5.2 Installing
t
sd
iva
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cum
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fo
en
ng
t.
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Cop py
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Note p by
co Vo
by lksw
cted agen
Prote AG.
Ensure, before installing poly-V-belt, that all ancillaries (alter
nator, air conditioner compressor) are secured tightly.
When fitting poly-V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
Lastly, place poly-V-belt over alternator.
After completing repairs always:

Start engine and check how belt runs.
Belt drive without air conditioner compressor
1- Crankshaft pulley
2- Poly-V-belt
3- Tensioning roller
4- Alternator pulley

Belt drive with air conditioner compressor

1- Crankshaft pulley
2- Poly-V-belt
3- Tensioning roller
4- Alternator pulley
5- Air conditioner compressor pulley
AG. Volkswagen AG d
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2 Removing and installing sealing

flange and flywheel
Assembly overview - sealing flange and flywheel page 32
Renewing crankshaft oil seal - belt pulley end page 33
Removing and installing sealing flange - belt pulley end
page 33
Renewing crankshaft sealing flange - flywheel end page 38
Removing and installing dual-mass flywheel page 45
2.1 Assembly overview - sealing flange and

flywheel
AG. Volkswagen AG d
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Servicing of couplingthor
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5-speed manual gearbox 0A4; Rep. Gr.
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30 ; Service coupling
s au or Direct shift gearbox 02E; Rep. Gr. 30 ; r ac
Removing and installing coupling .
s
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1 - Oil seal ab
pe
ility
ot
Do not additionally oil or wit

, is n
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grease sealing lip of oil
hole
seal
spec
es, in part or in w
Before installing, re
t to the co
move oil residue from

crankshaft journal using
a clean cloth
rrectness of i
Renewing crankshaft oil

l purpos
seal - belt pulley end-

page 33
nform
ercia
2 - Sealing flange - pulley end

m
Must seat on dowel

a
com
tio
sleeves.
n in
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thi
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iva
page 35
do
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Install with silicone seal

fo
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ing compound -D
t.
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176 404 A2 - C py
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page 35 rig ht
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3 - Cylinder block cted agen
Prote AG.
crankshaft page 48
bling pistons and con
rods page 52
4 - 60 Nm + 90 (1/4 turn) fur
ther
Renew.
5 - Flywheel
When removing and in
stalling flywheel, lock
with counter-hold tool
-3067- .

6 - Intermediate plate
Must seat on dowel sleeves.
Do not damage or bend when assembling.
7 - 15 Nm
Renew.
8 - Sealing flange with oil seal.
Renew complete with oil seal and sender wheel only.
9 - Engine speed sender -G28-
Loosen and tighten using commercially available ball-ended hex key socket.
Tightening torque: 5 Nm
2.2 Renewing crankshaft oil seal (pulley end)

equipment required
Counter-hold tool -3099-
Oil seal extractor -3203-
Assembly device -T10053-
Torque wrench -
V.A.G 1331-
Torque wrench -
V.A.G 1332-
AG. Volkswagen AG d
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Prote AG.
2. Removing and installing sealing flange and flywheel 33

Removing page 34
Installing page 34
2.2.1 Removing
Remove toothed belt page 62 .
Remove crankshaft toothed belt pulley. To do this, lock tooth
ed belt pulley using counter-hold tool -3099- .
Note
When bolting on counter-hold tool, place two washers between

toothed belt pulley and counter-hold tool.
To guide oil seal extractor -3203- , screw central bolt by hand

fully into crankshaft.
Unscrew inner part of oil seal extractor nine turns (approx. 17
mm) out of outer part and lock with knurled screw.
Oil threaded head of oil seal extractor -3203- .
Forcefully screw oil seal extractor as far as possible into seal.

Loosen knurled screw and turn inner part against crankshaft
until oil seal is pulled out.
AG. Volkswagen AG d
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2.2.2 Installing
s
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Note
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The oil seal sealing lip must not be additionally oiled or greased.
h re
hole
spec
es, in part or in w
Remove oil residue from crankshaft journal using a clean

t to the co
cloth.
Fit guide sleeve -T10053/1 - onto crankshaft journal.
rrectness of i
Slide oil seal over guide sleeve onto crankshaft journal.

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Press seal with press sleeve -T10053- and central bolt to limit
stop.
Install crankshaft toothed belt pulley with new centre bolt.
Install and tension toothed belt page 62 .
2.3 Removing and installing sealing flange - pulley end

equipment required
Torque wrench -
V.A.G 1331-
Torque wrench -
V.A.G 1332-
olkswagen AG
en AG. V
Hand drill with plastic brush olkswag does
not
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Flat scraper ho eo
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Eye protection
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pt
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an
Silicone sealant -D 176 404

itte
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Removing page 35 by c lksw
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Prote AG.
Installing page 36
2.3.1 Removing

Remove crankshaft toothed belt pulley. To do this, lock tooth

ed belt pulley using counter-hold tool -3099- .
Note
olkswagen AG
en AG. V
When bolting on counter-hold tool, place Vol
ktwo
swa washers between
g does
not
toothed belt pulley and counter-hold
ed tool.
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Drain engine oil. ss
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nl
Remove sump page 101 .
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Remove sealing flange -belt pulley end-.
erm
ab
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Remove sealing flange -belt pulley end-, release using light
wit
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blows with a rubber headed hammer if necessary.
h re
hole
spec
Drive out oil seal with sealing flange removed.
es, in part or in w
t to the co
Remove sealant residue on cylinder block with a flat scraper.
Remove residual sealant from sealing flange using a plastic
rrectness of i
rotary brush (wear eye protection).
l purpos
Clean the sealing surfaces. The sealing surfaces must be free

of oil and grease.
nf
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2.3.2 Installing
p by
co Vo
by lksw
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Prote AG.
Note
Observe the use-by date of the sealing compound.

Sealing flange must be installed within 5 minutes of applying
silicone sealant.
Remove oil residue from crankshaft journal using a clean

cloth.
Cut off tube nozzle at forward marking (approx. 3 mm nozzle
).
Note
The sealing compound bead must not be thicker than 2...3

mm, otherwise excessive sealing compound will enter the
sump and may block the suction pipe strainer of the oil pump,
and can also drop on the sealing surface of the crankshaft
sealing ring.
Before applying sealant bead, cover sealing surface of oil seal
with a clean cloth.

Apply silicone sealant bead -arrow-, as shown to the clean

sealing surface of the sealing flange.
Install sealing flange immediately and tighten all bolts lightly.
Note
When fitting sealing flange with oil seal installed, use guide sleeve
-T10053/1- .
Tighten securing bolts for sealing flange to 15 Nm using alter

nate and diagonal sequence.
Install new oil seal page 33 .
Install sump page 101 .
Note
Sealing compound must dry for approx. 30 minutes after instal

lation. Then (and only then) fill the engine with engine oil.
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37
co Vo
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2. Removing and installing sealing flange and flywheel
cted agen
Prote AG.
AG. Volkswagen AG d
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Jetta 2005 , Bora d by2006
V , Golf Variant 2007 t guar
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4-cylinder dieselho engine with unit injector - Edition 05.2007 e o
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2.4 Renewing crankshaft sealing flange - flywheel end
ce
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un
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ab
ility
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equipment required
wit
is n
h re
Torque wrench -
ole,
spec
V.A.G 1331-
t to the co
Tool insert 24 mm -V.A.G
1332/11-
rrectne
Vernier gauge
ss
Three hexagon bolts -M6 x
o
cial p
f i
35 mm-
nform
mer
Two hexagon bolts -M7 x
atio
m
35 mm-
o
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Prote AG.
Pressing out sealing flange with sender wheel page 39

Pressing in sealing flange with sender wheel page 40
A - Fit assembling seal with sender wheel on assembly appliance
- T10134- page 40
B - Attaching assembling tool -T10134- with sealing flange to
crankshaft flange page 42
C - Bolting assembly tool -T10134- onto crankshaft flange
page 43
D - Pressing sender wheel onto crankshaft flange using assembly
tool -T10134- page 44
E - Checking sender wheel installation position on crankshaft
page 44
F - Re-pressing sender wheel page 45

2.4.1 Pressing out sealing flange with sender

wheel
Note
For the sake of clarity, the work is performed with the engine
removed.
The procedure is identical whether the engine is installed or
removed.
Remove dual-mass flywheel page 45

Remove intermediate plate.
Set the engine to TDC No. 1 cylinder page 62
Remove sump page 101 agen
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Remove engine speed sender -G28- -arrow-edusing by
a commer ara
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is
cially available ball-ended hex key socket.
thor eo
au ra
Undo sealing flange securing bolts. s s c
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Note
rm
ab
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Sealing flange and sender wheel are pressed off the crankshaft
, is n
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with hexagon bolts -M6 x 35 mm- .
hole
spec
es, in part or in w
t to the co
rrectness of i
Screw three hexagon bolts -M6 x 35 mm- into the threaded
holes arrows -arrows- of the sealing flange.
l purpos
Screw the bolts alternately (max. 1/2 turn (180) per bolt) into
the sealing flange and press the sealing flange and the sender
nform
ercia
wheel off the crankshaft.

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2.4.2 Pressing in sealing flange with sender r nte
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wheel ss c
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Note
ab
ility
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The sealing flange with a PTFE seal is equipped with a sealing
h re
lip support ring. This support ring serves as a fitting sleeve and
hole
spec
must not be removed prior to installation.
es, in part or in w
t to the co
Sealing flange and sender wheel must not be separated or
turned after removal from packaging.
The sender wheel is held in its installation position on the as
rrectness of i
sembly device -T10134- by a locating pin. l purpos
Sealing flange and seal are one unit and must be replaced
together with the sender wheel only.
nf
ercia
o
The assembly device -T10134- is held in its position relative
rm
m
atio
to the crankshaft by a guide pin inserted into a hole in the
om
crankshaft.
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A - Clamping surface
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B - Hexagon nut
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C - Assembly housing
cop Vo
by lksw
cted agen
Prote AG.
D - Locating pin
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
G - Guide pin for petrol engines (red knob)
2.4.3 A - Fit assembling seal with sender

wheel on assembly appliance -T10134-
Screw in hexagon nut -B- to just before clamping surface -A-
of threaded spindle.

Clamp assembly device -T10134- in a vice on clamping sur

face -A- of threaded spindle.
Press assembly hub -C- downwards so that it lies on hexagon
nut -B- -arrow-.
Note
Inner part of assembly tool and assembly housing must be at

same height.
Remove securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
turned.
Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
Place sealing flange with front side downwards on a clean flat
surface.
AG. Volkswagen AG d
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Push sealing lip support ring -A- downwards in

d
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-direction of arrow- until it lies on flat surface.

erm
ab
ility
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Cop py
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co Vo
by lksw
cted agen
41
Prote AG.
2. Removing and installing sealing flange and flywheel
Upper edge of sender wheel and front edge of sealing flange

must align -arrows-.
Place sealing flange with front side on assembly device -

T10134- so that locating pin -B- can be inserted in sender
wheel hole -A-.
Note
Ensure sealing flange lies flat on assembly

swa
gen AG tool.
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Push sealing flange and support ring for sealing lip -B- against
erm
ab
surface of assembly device - T10134- whilst tightening the
ility
ot p
three knurled screws -A- so that locating pin cannot slide out
wit
, is n
of sender wheel hole.

h re
hole
spec
es, in part or in w
t to the co
Note
When installing sealing flange, ensure that sender wheel remains

rrectness of i
fixed in assembly device.

l purpos
nf
ercia
orm
m
2.4.4 B - Attaching assembling tool -T10134-

atio
om
n in
with sealing flange to crankshaft flange

or c
thi
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sd
a
Crankshaft flange must be free of oil and grease.

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Engine positioned at TDC No. 1 cylinder

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Screw hexagon nut -B- to end of threaded spindle.
C py
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rig ht
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Press threaded spindle of assembly tool -T10134- in co Vo
by lksw
cted
-direction of arrow-, until hexagon nut -B- lies against assem
agen
Prote AG.
bly bell housing -A-.
Align flat side of assembly housing on sump side of crankcase
sealing surface.

AG. Volks4-cylinder
wagen AG diesel engine with unit injector - Edition 05.2007
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Secure assembly stoold b -T10134 - to crankshaft flange using ara
i e nte
hexagon socketthohead bolts -A-.
r eo
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un
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Note
an
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ab
Screw hexagon socket head bolts -A- into crankshaft flange (ap
ility
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prox. 5 full turns).
wit
is n
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ole,
spec
t to the co
rrectne
To guide sealing flange, screw two hexagon bolts -M7 x 35
mm- -A- into the cylinder block.
ss o
cial p
f inform
mer
atio
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Cop py
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2.4.5 C - Bolting assembly tool -T10134- onto
by lksw
cted agen
Prote AG.
crankshaft flange
Push assembly bell housing -C- by hand in
-direction of arrow- until sealing lip support ring -B- contacts
crankshaft -A-.
Push guide pin for diesel engines (black knob) -D- into hole in
crankshaft. This ensures that the sender wheel reaches its fi
nal installation position.
Note
The guide pin for petrol engines (red knob) -F- must not be inser
ted in threaded hole of crankshaft.
Hand tighten both hexagon socket head bolts of assembly

tool.
Screw hexagon nut -E- onto threaded spindle by hand until it
lies against assembly bell housing -C-.

2.4.6 D - Pressing sender wheel onto crank

shaft flange using assembly tool -
T10134-
Tighten hexagon nut of assembly tool -T10134- to 35 Nm us
ing torque wrench -V.A.G 1331- and insert -V.A.G 1332/11- .
Note
After hexagon nut is tightened to 35 Nm torque, a small air gap

must be present between cylinder block and sealing flange.
2.4.7 E - Checking sender wheel installation

position on crankshaft
Screw hexagon nut -E- to end of threaded spindle.
Remove the two bolts -A- from cylinder block.
Screw the three knurled screws -B- out of sealing flange.
Remove assembly tool -T10134- .
AG. Volkswagen AG d
Remove sealing lip support ring. agen oes
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The sender wheel is in the correct installation position on the ab

ility
ot p
crankshaft if a gap -a- = 0.5 mm exists between crankshaft wit

, is n
flange -A- and sender wheel -B-.

h re
hole
spec
Set vernier gauge on crankshaft flange.

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
Measure distance -a- between crankshaft flange and sender

o
n in
c
wheel.
or
thi
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sd
a
If dimension -a- is too small:

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Re-press sender wheel page 45 .

f
en
ng
t.
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op
If dimension -a- is achieved:
C py
t. rig
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Tighten new securing bolts for sealing flange to 15 Nm using cop Vo
by lksw
alternate and diagonal sequence.
cted agen
Prote AG.

Install engine speed sender -G28- -arrow- and tighten secur

ing bolt to 5 Nm.
Install sump page 101 .
Install intermediate plate. AG. Volkswagen AG d
agen oes
ksw
Install flywheel using new bolts. Tighten by Vsecuring bolt to 60
ol not
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ara
Nm + 90 (1/4 turn). orise
d
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au ra
ss c
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nl
pt
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erm
ab
ility
ot p
wit
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2.4.8 F - Re-pressing sender wheel
h re
hole
spec
Secure assembly tool -T10134 - to crankshaft flange using
es, in part or in w
hexagon socket head bolts -A-.
t to the co
Hand tighten both hexagon socket head bolts.
rrectness of i
Push assembly tool -T10134- by hand to sealing flange.
l purpos
nf
ercia
orm
m
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n in
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Screw hexagon nut -E- onto threaded spindle by hand until it
o
m
f
en
lies against assembly bell housing -C-.
ng
t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Tighten hexagon nut of assembly tool -T10134- to 40 Nm us

ing torque wrench -V.A.G 1331 - and insert -V.A.G 1332/11- .
Check installation position of sender wheel on crankshaft
again page 44 .
If dimension a is too small again:
Tighten hexagon nut for assembly tool -T10134- to 45 Nm.
Check installation position of sender wheel on crankshaft
again page 44 .
2.5 Removing and installing dual-mass fly

wheel

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ab
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ot p
wit
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h re
hole
Torque wrench -V.A.G 1332-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
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Removing page 46
um
for
en
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Installing page 47
Co
Cop py
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2.5.1 Removing
ht
pyri by
Vo
co lksw
by
cted agen
Fit counter-hold -3067- into the hole of the cylinder head.
Prote AG.
Position of counter-hold tool:

A - To tighten
B - To loosen
Mark installation position of dual-mass flywheel on engine.

Note
To avoid damaging the dual-mass flywheel during removal, the

bolts -B- must not be removed using a pneumatic or impact driver.
The bolts may only be removed by hand using conventional tools.
Rotate the dual-mass flywheel -A- so that the bolts align with
the holes -arrows-.
When unscrewing the bolts, make sure that the bolt heads do
not come into contact with the dual-mass flywheel; the fly
wheel will otherwise be damaged as the bolts are screwed out.
2.5.2 Installing
Use new bolts for securing.
olkswagen AG
en AG. V
Tighten bolts to 60 Nm ks+w 90 (1/4 turn).
ag does
not
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spec
es, in part or in w
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Cop py
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Prote AG.

3 Crankshaft
Assembly overview - crankshaft page 48
Crankshaft dimensions page 49
AG. Volkswagen AG d
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Marking of upper crankshaft bearing shells page 49 olksw not
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Pulling needle bearing out of and driving into crankshaft horis nte
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page 49 aut ra
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ss
3.1 Assembly overview - crankshaft
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1 - Bearing shells 1, 2, 4 and 5
ility
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For bearing cap without
h re
oil groove
hole
spec
For cylinder block with
es, in part or in w
t to the co
oil groove
Do not interchange
used bearing shells
rrectness of i
(mark)
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2 - 65 Nm + 90 (1/4 turn) fur

ther
nf
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Renew.
orm
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To measure radial clear
atio
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ance, tighten to 65 Nm
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but not further.
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3 - Bearing cap
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Bearing cap 1: Pulley
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Co
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Bearing cap 3 with re
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Bearing shell retaining
lugs in cylinder block
and bearing caps must
be above one another.
4 - Bearing shell 3
For bearing cap without
oil groove
For cylinder block with
oil groove
5 - Thrust washer
For bearing cap 3
Note fixing arrangement
6 - Crankshaft
Axial clearance new: 0.07...00.17 mm, wear limit: 0.37 mm
Check radial clearance with Plastigage new: 0.03...00.08 mm, wear limit: 0.17 mm.
Do not rotate crankshaft when checking radial clearance
Crankshaft dimensions page 49 .
7 - Thrust washer
For cylinder block, bearing 3

3.2 Crankshaft dimensions

(Dimensions in mm)
Honing dimen Crankshaft Conrod
sion main journal journal
Basic dimension 54.00 -0.022 47.80 -0.022
-0.042 -0.042
3.3 Identification of upper crankshaft bear

ing
Upper bearing shells with the correct thickness are allocated to
the cylinder block in the factory. Coloured spots serve to identify
the thickness of the bearing shells.
Letter codes on the lower sealing surface of the cylinder block
indicate the thickness of the bearing shell to be fitted at each lo
cation.
G = Yellow
B = Blue
W = White
Note
Arrow points in direction of travel. . Volkswagen AG

gen AG does
swa
If the coloured marks are no longer legible, use blue bearingy Volk not
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shells. risedb ara
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Crankshaft lower bearing shells with yellow colour mark are ra
s c
always supplied as spare parts. s
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3.4 Pulling needle bearing out of and driving
pe
ility
ot
into crankshaft
wit
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hole
Vehicles with direct shift gearbox only
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
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Cop py
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Prote AG.
3. Crankshaft 49

equipment required
Drift -VW 207 C-
or centring mandrel -3176-
Puller -T10055- with adapt
er -T10055/3-
1 Internal puller -Kukko
21/2- AG. Volkswagen AG d
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or eo
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
In vehicles with direct shift gearbox the needle bearing must be

mounted on the rear of the crankshaft.
Removing
Remove needle bearing with internal puller -Kukko 21/2-
-arrow-, adapter -T10055/3- and puller -T10055- .
Installing
Note
The lettering on the needle bearing must be visible when installed.

Drive in using drift -VW 207 C- or centring mandrel -3176- .
AG. Volkswagen AG d
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olksw not
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Installation depth: dimension -a- = 2 mm.
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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ion
c
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or
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ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
3. Crankshaft 51
4 Pistons and connecting rods

Assembly overview - pistons and conrods page 52
Checking piston projection at TDC page 53
Piston and cylinder dimensions page 54
Piston rings, cylinder bore and piston installation position
page 54
4.1 Assembly overview - pistons and conrods
1 - Piston rings
Offset gaps by 120
AG. Volkswagen AG d
Remove and install us lksw
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TOP faces towards horis
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piston crown. aut ra
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Checking ring gap
ce
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un
pt
page 54
an
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Checking ring-to-groove
erm
ab
clearance page 55
ility
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2 - Piston
h re
ole,
With combustion cham
spec
ber.
t to the co
Mark installation posi
tion and cylinder num
ber.
rrectne
Installation position and
allocation of piston to
ss
cylinder page 56
o
cial p
f i
Arrow on piston crown
nform
points to pulley end.
mer
atio
m
Install using piston ring

o
n
c
clamp.
i
or
n thi
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If piston skirt is cracked,

t
sd
iva
renew piston.
pr
cum
r
fo
Checking piston projec

en
ng
t.
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tion at TDC Cop py
page 53
t. rig
gh ht
pyri by
Vo
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3 - Piston pin
by c lksw
cted agen
Prote AG.
If difficult to remove,
heat piston to 60C.
Remove and install with
drift -VW 222 A-
4 - Circlip
5 - Conrod
Mark cylinder number -arrows A- with coloured pen
Installation position: Marking -arrows B- faces towards pulley end.
With industrially cracked conrod bearing cap
6 - Ball socket
Note installation position.
Note type: upper bearing shell (closest to piston) is constructed from more wear-resistant material. Iden
tification: Black line on bearing surface in area of joint
Do not interchange used bearing shells

Insert bearing shells centrally.
Check for secure seating.
Axial clearance: wear limit: 0.37 mm
Check radial clearance with Plastigage: Wear limit: 0.08 mm, do not rotate crankshaft when checking
radial clearance.
7 - Cylinder block
Checking cylinder bores page 55
Piston and cylinder dimensions page 54 .
8 - Conrod bearing cap
Due to the cracking method used to separate the bearing cap from the conrod in manufacture, the caps
only fit in one position and only on the appropriate conrod.
9 - Oil spray jet
For piston cooling
Note
10 - 25 Nm
AG. Volkswagen AG d
Insert without sealant. agen oes
olksw not
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11 - Conrod bolt, 30 Nm + 90 (1/4 turn)orfurther
ise nte
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th
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Renew. ss a c
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Oil threads and contact surface.

nl
pt
du
an
Use old bolt for measuring radial clearance
itte
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erm
ab
ility
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4.2 Checking piston projection at TDC
h re
hole
spec
es, in part or in w
t to the co
Measuring bridge -VW 382/7-
rrectness of i
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nf
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End dimension plate -VW 385/17- t. C rig
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Prote AG.
Dial gauge
4. Pistons and connecting rods 53

Test procedure
Note
If different values are determined during the projection meas

urement, use the largest dimension for selecting the gasket.
Turn engine clockwise to measure piston projection at TDC.
Piston projection at TDC must be measured when installing new

pistons or a short engine. Install the appropriate cylinder head
gasket depending upon piston projection, according to following
table:
Piston projection Identification
Holes/notches
0.91 mm ... 1.00 mm 1
1.01 mm ... 1.10 mm 2
1.11 mm ... 1.20 mm 3
Cylinder head gasket identification

Part No = -arrow 1-
Production control code = -arrow 2- (disregard)
Holes = -arrow 3- AG. Volkswagen AG d
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ility
4.3 Piston and cylinder dimensions

ot
wit
, is n
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hole
Honing dimension Piston Cylinder bore

spec
es, in part or in w
Basic dimen mm 79.47 79.51

t to the co
sion
1st oversize mm 79.72 79.76
rrectness of i
Stage ll mm 79.97 80.01

l purpos
4.4 Piston rings, cylinder bore and piston in

stallation position
nform
mercia
Checking piston ring gap

com
tion in
r
te o
thi
s
iva
do
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cum
fo
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t.
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Cop py
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Prote AG.

Feeler gauges

Push piston ring squarely from above down to approx. 15 mm

from bottom end of cylinder.
Piston ring New Wear limit
wage
e
dimensions in mm Vol
ks s no
t gu
d by ara
e
1st compression ring 0.20...0.40 horis 1.0 nte
eo
ut ra
2nd compression ring 0.20...0.40ss a 1.0 c
ce
le
Oil scraper ring 0.25...0.50 1.0
un
pt
an
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itte
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Checking ring-to-groove clearance
erm
ab
ility
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ole,
spec
t to the co
Feeler gauges
Clean groove in piston before checking clearance.
rrectne
Piston ring New Wear limit
dimensions in mm
ss o
1st compression ring 0.06...0.09 0.25
cial p
f inform
2nd compression ring 0.05...0.08 0.25
mer
atio
Oil scraper ring 0.03...0.06 0.15
om
n
c
i
or
n
Checking cylinder bores
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Cylinder gauge 50...100 mm
Take measurements at 3 positions in both transverse -A- and
longitudinal -B- directions, as illustrated. Difference between
actual and nominal diameter: not more than 0.10 mm.
4. Pistons and connecting rods 55

Note
Measuring the cylinder bores must not be done when the cylinder
block is mounted on a repair stand with adapter bracket -VW 540
- , as incorrect measurements would then be possible.
Piston installation position and allocation of piston to cylinder

Piston in cylinders 1 and 2:
olkswagen AG
en AG. V
Larger inlet valve recess -arrows- towards flywheel.
olks
wag does
not
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Piston in cylinders 3 and 4: rise nte
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ut
Larger inlet valve recess -arrows-
ss atowards belt pulley end. ra
c
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nl
pt
du
an
itte
Note
y li
erm
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ility
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New piston allocation to cylinders is shown by a coloured mark
wit
, is n
stamped on piston crown.
h re
hole
spec
Piston for cylinders 1 and 2: marked 1/2
es, in part or in w
t to the co
Piston for cylinders 3 and 4: marked 3/4
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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co lksw
by
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Prote AG.

AG. Volkswagen AG d
agen oes
15 Cylinder head, valve gear olksw not
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aut ra
1 Cylinder head ss c
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
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wit
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When installing an exchange cylinder head with fitted cam
h re
shaft, the contact surfaces between the bucket tappets and hole
spec
the cam must be oiled before installing the cylinder head cov
es, in part or in w
er.
t to the co
The plastic protectors fitted to protect the open valves must
not be removed until immediately before fitting the cylinder
rrectness of i
head.
l purpos
If the cylinder head is renewed, all the coolant in the system

must also be renewed.
nform
ercia
Cylinder heads with cracks between the valve seats may be

used without reducing engine life, provided the cracks are
m
at
om
small and not more than 0.5 mm wide.
ion
c
in t
or
Do not rework valve seats. Only lapping in of valves is permit
his
ate
ted.
do
priv
cum
or
Wait about 30 minutes after installing the camshafts before

f
en
ng
t.
starting the engine. Hydraulic compensation elements must
yi Co
op py
settle (otherwise valves will strike pistons). t. C rig
gh ht
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After working on the valve gear, turn the engine carefully at
o Vo
by c lksw
cted
least 2 rotations to ensure that none of the valves make con
agen
Prote AG.
tact when the starter is operated.
Always renew gaskets and seals.
1. Cylinder head 57
Cylinder head cover - Assembly overview page 58

Removing and installing cylinder head cover page 61
Removing, installing and tensioning toothed belts page 62
Removing and installing cylinder head page 79
Checking compression page 83
1.1 Assembly overview - cylinder head
1 - Toothed belt guard upper

part
2 - Toothed belt n AG. Volkswagen AG do
swage es n
Mark direction by Vof rota
olk ot g
ua
tion before ir se removing.
d ran
tee
ho
Check au for wear.
t or
ac
ss
Do not kink.
ce
e
nl
pt
du
Removing, installing
an
itte
y li
and tensioning
erm
ab
page 62 .
ility
ot p
wit
, is n
3 - 10 Nm
h re
hole
Renew. spec
es, in part or in w
4 - 25 Nm
t to the co
5 - 100 Nm
rrectness of i
6 - Camshaft pulley
l purpos
7 - Hub
With sender wheel.
nf
ercia
Use counter-hold -
or
T10051 - to loosen and

m
m
atio
tighten
om
n in
c
To remove, use puller -

or
thi
e
T10052- .
t
sd
iva
o
r

rp
cu
o
page 92 .
f
en
ng
t.
yi Co
op
8 - Rear toothed belt guard
C py
t. rig
gh ht
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9 - Sealing grommet cop Vo
by lksw
cted agen
Renew if damaged. Prote AG.
10 - Hall sender -G40-

For camshaft position
To remove sealing
grommet
Item 9 (page 58) , un
button from toothed belt
guard.
11 - Cylinder head bolt
Note sequence for loos
ening and tightening
page 79
Before installing, place
washers in cylinder
head Item 4 (page 87) .
12 - Cylinder head cover
Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth.
58 Rep. Gr.15 - Cylinder head, valve gear

13 - Pressure regulating valve

For crankcase breather.
14 - To turbocharger
15 - Cap
Renew seal if damaged.
16 - Seal
Renew if damaged.
17 - 10 Nm
Observe tightening sequence page 61
18 - Cylinder head cover gasket
Renew together with cylinder head cover only.
Seal with sealant, black -AMV 174 004 01- for gearbox housing before fitting page 61
19 - 20 Nm
swage es n
20 - Lifting eye yV
olk ot g
ua
d b ran
21 - Unit injector ir se tee
tho
u or
Removing and
ss installing page 219 .
a ac
ce
le
un
22 - 10 Nm
pt
an
d
itte
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23 - Central connector
rm
ab
pe
ility
For unit injector.
ot
wit
, is n
h re
24 - From brake servo
hole
spec
25 - Tandem pump
es, in part or in w
t to the co
For fuel and vacuum supply.
Checking page 160 . rrectness of i
Must not be dismantled
l purpos
26 - Supply hose
nform
ercia
From fuel filter page 158 .

White or with white marking.
m
a
com
tio

n in
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Secure with spring-type clips

s
iva
do
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27 - Return hose
um
fo
en
g
To fuel filter page 158 .

n
t.
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op py
Blue or with blue marking t. C rig
gh ht
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Check for secure seating. cop Vo
by lksw
cted agen
Secure with spring-type clips Prote AG.
28 - Seal
Renew.
29 - Bolt/screw
30 - Cylinder head
If renewed, change coolant in entire system.
31 - Cylinder head gasket
Renew.
Note marking page 60
If renewed, change coolant in entire system.
1. Cylinder head 59
32 - Glow plug/ceramic glow plug

15 Nm
Installation instructions and notes should be strictly adhered to page 274
Checking page 274 .
33 - Tensioning roller
34 - 20 Nm +45 (1/8 turn) further
Checking cylinder head for distortion
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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au ra
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un
pt
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ab
pe
ility
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wit
, is n
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hole
spec
Straight edge
es, in part or in w
t to the co
Feeler gauges
Max. permissible distortion: 0.05 mm.
rrectness of i
l purpos
Note
Reworking diesel cylinder heads is not permissible.

nform
mercia
Cylinder head gasket identification

com
tion in
r
te o
Part No = -arrow 1-
thi
s
iva
do
Production control code = -arrow 2- (disregard)

r
rp
cum
fo
en
g
Holes = -arrow 3-
n
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note
cop Vo
by lksw
cted agen
Prote AG.
Different thicknesses of cylinder head gasket are fitted de

pending on the piston projection. When fitting a new cylinder
head gasket, install a new gasket with same identification.
Piston projection at TDC must be determined when installing
new pistons or overhauled engine page 53 .

1.2 Removingageand
n AG. Vinstalling
olkswagen AG cylinder head
does
cover
db
y Volksw not
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ar
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ris tee
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au ac
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nl
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du
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itte
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
Sealant, black -AMV 174 004 01-
l purpos
Removing
nf
ercia
or
m
m
atio
om
n in
or c
Remove upper toothed belt guard.
thi
te
sd
iva
Pull crankcase breather hoses off cylinder head cover. o

r
rp
cu
o
m
f
en
Unbolt bracket from exhaust gas recirculation valve.

ng
t.
yi Co
op py
Remove cylinder head cover. t. C rig
gh ht
pyri by
Vo
Installing
o
by c lksw
cted agen
Prote AG.
Note
Renew seal for bolts if damaged.
Apply a drop of sealant, black -AMV 174 004 01- ( approx.

5 mm) to both forward edges of bearing cap/cylinder head
sealing surface -arrows-.
1. Cylinder head 61
Apply a drop of sealant, black -AMV 174 004 01- ( approx.

5 mm) to both rear edges of bearing cap/cylinder head sealing
surface -arrows-.
Engine codes BRM, BLS
AG. Volkswagen AG d
agen oes
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rise nte
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au ra
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un
pt
an
d
Tighten bolts of the cylinder head cover hand tight in the se

itte
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quence -113-.
rm
ab
pe
ility
Tighten the bolts in the sequence -1...13- to 10 Nm.
ot
wit
, is n
h re
Engine codes BKC, BXE
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Tighten bolts of the cylinder head cover hand tight in the se

m
quence -113-.
a
com
tion in
Tighten the bolts in the sequence -1...13- to 10 Nm.
r
te o
thi
s
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do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.3 Removing, installing and tensioning

toothed belt
Note
From 05.05 a modified engine support has been introduced, it is

no longer necessary to remove the engine support and supporting
the engine for the procedure removing, installing and tensioning
toothed belt.
Determine which type of engine support is installed in the ve

hicle.
-1-: Engine support 05.05 (Removal necessary) page 63

-2-: Engine support 06.05 (Removal not necessary)

page 72
1.3.1 Removing and installing toothed belt (on vehicles 05.05)

equipment required
Locking pin -3359-
Pin wrench -T10020-
Locking pin -T10115- n AG. Volkswagen AG do
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Crankshaft stop -T10050- sed b ua
ran
ir
for round crankshaft tooth
tho tee
or
ed belt sprocket ss
au ac
ce
le
Torque wrench -
un
pt
an
V.A.G 1331-
d
itte
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rm
ab
Torque wrench -
pe
ility
V.A.G 1332-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 63
Support bracket -10 - 222

A-
Adapter -10 - 222 A/3-
Frames -10 - 222 A/8-
5024A-
Crankshaft stop -T10100-
for oval crankshaft toothed
belt sprocket
Counter-hold -T10172- with
Pins -T10172/4-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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ss c
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nl
pt
du
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itte
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erm
ab
ility
Removing
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Adjustment work on toothed belts must always be performed only

on cold engines, as the indicator position on the tensioning ele
ment varies depending on the engine temperature.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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f
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.


Remove connecting pipe between charge air cooler and intake
connecting pipe.
Unscrew coolant expansion tank. Do not disconnect hoses.
Remove locking pin from poly-V-belt tensioning element.
Remove front right wheel housing liner General body re
pairs, exterior; Rep. Gr. 66 ; Wheel housing liner .
Remove charge air pipe between charge air cooler and turbo
charger page 183 . agen
AG. Volkswagen AG d
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olks ot g
Remove flexible charge air pipe between
db
y V turbocharger and air ua
ran
filter. rise tee
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au ac
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Note
nl
pt
du
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Carefully seal openings of charge air duct, e.g. with a clean cloth
ab
ility
to prevent particles of dirt from entering.
ot p
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hole
Remove belt pulley with vibration damper.
spec
es, in part or in w
t to the co
Unbolt toothed belt covers (bottom and centre) -arrows-.
rrectness of i
l purpos
nf
ercia
orm
m
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om
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or c
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Cop py
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Prote AG.
1. Cylinder head 65
Fit support bracket -10 - 222 A- before the gas pressure damp AG. Volkswagen AG d
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or
Attach trigger snap of spindles to lifting eyes. On the rightauside
th or
ac
use additionally the adapter -10 - 222 A/20- ss
ce
le
un
pt
Take up weight of engine evenly with both spindles (but do not
an
d
itte
raise engine).
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ab
pe
ility
ot
wit
, is n
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spec
es, in part or in w
t to the co
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nform
ercia
Remove securing bolts -arrows- from the assembly mounting

m
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engine and take engine mounting out completely.
on in
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Note
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The assembly mounting may only be removed if the engine is
Co
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supported with support bracket -10 - 222 A- !
t. C rig
gh ht
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The engine bracket must be loosened only when the assembly by c lksw
cted agen
mounting has been removed. Prote AG.
Lift the engine slightly using the support device - 10 - 222 A-

to loosen both engine bracket upper bolts -arrows-.
Lower the engine slightly using the support device - 10 - 222
A- to loosen engine bracket lower bolt -arrow-.
Remove engine bracket downwards.
Turn crankshaft to TDC No. 1 cylinder.
Note
Gradual introduction of oval crankshaft belt pulleys. When instal

ling this toothed belt pulley, the crankshaft stop -T10100- must be
installed to determine the TDC position.

Characteristics of crankshaft belt pulley

A = Round belt pulley, lock using crankshaft stop -T10050- , TDC
marking at 12 o'clock
B = Oval belt pulley, lock using crankshaft stop -T10100- , TDC
AG. Volkswagen AG d
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ab
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spec
es, in part or in w
t to the co
rrectness of i
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Note
nf
ercia
Turn crankshaft until marking on crankshaft pulley and tooth seg
orm
ment of camshaft pulley is on top. The marking on the rear toothed
m
atio
m
belt guard must align with the marking on the camshaft sender
o
n in
c
wheel -arrow-.
or
thi
te
sd
iva
o
r
Lock hub using locking pin - 3359- . To do this slide locking

rp
cu
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pin through the free elongated hole on left into hole in cylinder
f
en
ng
t.
yi
head.
Co
Cop py
t. rig
Lock crankshaft toothed belt pulley with crankshaft stop -
gh ht
pyri by
T10050 or T10100- . To do this, push crankshaft stop into teeth
o Vo
by c lksw
cted
of belt pulley from face side.
agen
Prote AG.
Note
The marks on the crankshaft toothed belt pulley and the crank
shaft stop must align. When doing this, the pin of the crankshaft
stop must insert in the drilling of the sealing flange.
Mark direction of rotation of toothed belt.
Loosen securing bolts -1- of camshaft toothed belt pulley until

camshaft pulley can be moved within the elongated holes.
Loosen tensioning roller securing nut.
1. Cylinder head 67
Note
Gradual introduction of a new toothed belt tensioning roller. The

tensioner has an additional hexagon hole -arrow-. Use a hexagon
key to tension/loosen toothed belt instead of the two-hole pin
wrench -T10020- . This does not alter the procedure.
AG. Volkswagen AG d
agen oes
olksw not
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nl
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du
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Turn two-hole pin wrench -T10020 - anti-clockwise until the
y li
erm
ab
toothed belt tensioner can be locked in position using locking
ility
ot p
pin -T10115- .
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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o
Now turn two-hole pin wrench -T10020 - clockwise onto top
rm
m
and tighten securing nut -1- hand tight.

atio
om
n in
c
Remove toothed belt first from coolant pump and then from
or
thi
e
remaining pulleys.
t
sd
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Installing
o
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f
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Lock camshaft with pin -3359- .
Co
Cop py
ht. rig
Lock crankshaft with crankshaft stop -T10050 or T10100- .
rig ht
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by lksw
The tensioning roller must be fitted with pin -T10115- and
cted agen
Prote AG.
locked right-hand.
Note

Turn camshaft sprocket in elongated holes to central position

-arrow-.
Fit toothed belt onto crankshaft toothed belt pulley, tensioning
roller, camshaft toothed belt pulley and idler roller.
Then fit toothed belt on coolant pump toothed belt pulley.

Note
Ensure that tensioning roller seats correctly in rear toothed beltn AG. Volkswagen AG do
guard -arrow-. olks
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Loosen tensioning roller securing nut and pull
tho out locking
r
pin eo
-T10115- . s au ra
c
s
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un
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an
d
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pe
ility
ot
wit
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Now turn carefully tensioning roller with two-hole pin wrench -
hole
T10020- clockwise until the indicator aligns over the lug
spec
-arrow- in the base plate.
es, in part or in w
t to the co
Ensure that securing nut does not turn as well.
Hold tensioning roller in this position and tighten tensioning
rrectness of i
roller securing nut as follows: 20 Nm and 45 (1/8 turn) further.
l purpos
nform
mercia
a
com
tion in
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thi
Fit counter-hold tool -T10172- with pins -T10172/4- as shown.
s
iva
do
Press counter-hold -T10172- in -direction of arrow- and hold
r
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fo
camshaft sprocket to pretension.
en
ng
t.
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In this position, tighten camshaft toothed belt pulley securing Cop py
t. rig
bolts -1- to 25 Nm. gh ht
pyri by
Vo
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by
Remove locking pin -3359- and crankshaft stop -T10050 or Prote
cted AG.
agen
T10100- .
Turn crankshaft two rotations in engine direction of rotation
until crankshaft is just before TDC No. 1 cylinder.
Lock hub with locking pin -3359- whilst turning engine in di

rection of rotation.
Check whether crankshaft can be locked with crankshaft stop
-T10050 or T10100- .
If crankshaft cannot be locked:
1. Cylinder head 69
Loosen securing bolts -1- for camshaft toothed belt pulley.

Lock hub using locking pin - 3359- .
Turn crankshaft slightly against engine direction of rotation

until the crankshaft stop pin is positioned just before the hole
in the sealing flange -arrow-.
Now turn crankshaft in engine direction of rotation until crank
shaft stop pin engages in sealing flange whilst turning.
AG. Volkswagen AG d
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un
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an
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erm
ab
Fit counter-hold tool -T10172- with pins -T10172/4- as shown.
ility
ot p
Press counter-hold -T10172- in -direction of arrow- and hold
wit
is n
camshaft sprocket to pretension.
h re
ole,
spec
In this position, tighten camshaft toothed belt pulley securing
bolts -1- to 25 Nm.
t to the co
Remove locking pin -3359- and crankshaft stop -T10050 or
T10100- .
rrectne
ss o
cial p
f
Repeat check.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Place engine bracket at cylinder block and tighten securing

bolts -arrows- to 40 Nm + 180 (1/2 turn).
Note
Before installing the assembly mounting, all engine mounting

bolts -arrows- must be tightened to prescribed torque.
Install assembly mounting engine/body (renew securing bolts)

page 23 .
Fit engine mounting to engine bracket page 23 . To do this
put the contact surfaces on the support device -10 - 222A- .
Install centre and lower parts of toothed belt guard.
Install belt pulley vibration damper. Tightening torque: 10 Nm
+ 90 (1/4 turn) further.
Install poly-V-belt page 29 .
Install upper toothed belt guard.
Install connecting pipes between charge air cooler and turbo
charger and between charge air cooler and intake connecting
flange page 183 .
Install front right wheel housing liner General body repairs,
exterior; Rep. Gr. 66 ; Wheel housing liner .
Vo lksw
Install coolant expansion tank
swa
gen A
G. page 119 . does
agen AG
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ot
wit
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
1. Cylinder head 71
1.3.2 Removing and installing toothed belt (on vehicles 06.05 )

equipment required
Locking pin for diesel injec
tion pump -3359 -
Mandrel -T10060 A-
Crankshaft stop -T10100-
Counter-hold tool -T10172-
Socket -T10264-
Locking tool -T10265-
AG. Volkswagen AG d
agen oes
olksw not
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or eo
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un
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ab
ility
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wit
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spec
t to the co
rrectne
Removing
ss

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inform

mer
atio
om
n
c
WARNING
i
or
n thi
te
sd
va
In extreme cases the fuel lines and the fuel can reach a
i
o
pr
cum
r
temperature of 100C on vehicles with unit injector engine.

fo
en
ng
Allow the fuel to cool down before disconnecting the lines

t.
yi Co
op
- danger of scalding.
C py
t. rig
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Wear protective gloves.
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by c lksw
cted agen
Prote
Wear eye protection.
AG.

Pull fuel supply hose -1- and fuel return hose -2- off fuel lines.
Pull off coolant line -3-.
Remove bolts -1-.
Remove connecting pipe between charge air cooler and intake

connecting pipe, to do this, lightly lift retaining clips -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
Disconnect fuel supply line
ss -3- and return line -2- by pulling c
release tabs.
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Pull fuel filter out of bracket -arrow-.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 73
Unscrew bolt at filler neck -2- for washer fluid reservoir.

Unscrew bracket -3- for fuel filter.
Separate electrical connector on coolant expansion tank -1-.
Remove coolant expansion tank, coolant hoses remain con
nected. Place it on engine.
Remove tensioning element for poly-V-belt.
Remove upper toothed belt guard, to do this, loosen retainingen AG. Volkswagen AG
clips -arrows-. ag does
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by ara
Remove front right wheel housing liner. ed nte
oris eo
h
ut ra
Remove belt pulley with vibration damper. ss a c
ce
e
nl
Remove lower and centre parts of toothed belt guard.
pt
du
an
itte
y li
Turn crankshaft to TDC No. 1 cylinder.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Turn crankshaft until marking on crankshaft pulley and tooth seg
l purpos
ment of camshaft pulley is on top. The marking on the rear toothed

belt guard must line up with the marking on the camshaft sender
nform
ercia
wheel -arrow-.
m
at
om
io
Lock hub using locking pin -3359- . To do this slide locking pin
n
c
in t
r
through the free elongated hole on left into hole in cylinder

o
his
e
head.
at
do
priv
cum
Lock crankshaft toothed belt pulley with crankshaft stop -

for
en
g
T10100- . To do this, push crankshaft stop into teeth of belt

n
t.
yi Co
op
pulley from face side. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Note
agen
Prote AG.
The marks on the crankshaft toothed belt pulley and the crank
shaft stop must align. When doing this, the pin of the crankshaft
stop must insert in the drilling of the sealing flange.
Mark direction of rotation of toothed belt.

Loosen securing bolts -1- of camshaft toothed belt pulley until

camshaft pulley can be moved within the elongated holes.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
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Loosen tensioning roller securing nut -1-.
h re
hole
spec
Turn eccentric of tensioning roller anti-clockwise -arrow- using
es, in part or in w
socket -T10264- until the tensioning roller can be locked with
t to the co
locking tool -T10265- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
Now turn eccentric of tensioning roller clockwise -arrow- to
te
sd
a
stop and tighten securing nut -1- hand tight.

iv
o
r
rp
cu
o
Remove toothed belt first from coolant pump and then from
f
en
ng
t.
yi
remaining toothed belt pulleys.
Co
Cop py
t. rig
gh
Installing
ht
pyri by
Vo
o
by c lksw
Camshaft locked with locking pin -3359- .
cted agen
Prote AG.
Crankshaft locked with crankshaft stop -T10100- .

Tensioning roller locked with locking pin -T10265- and se
cured to right stop with securing nut.
Note

Turn crankshaft toothed belt pulley in its elongated holes to

centre position -arrows-.
Guide toothed belt through gap between engine support and
engine.
Fit toothed belt onto crankshaft toothed belt pulley, tensioning
roller, camshaft toothed belt pulley and idler roller.
Then fit toothed belt on coolant pump toothed belt pulley.
1. Cylinder head 75
Note
Ensure that tensioning roller seats correctly in rear toothed belt

guard -arrow-.
Remove locking pin -T10265- from tensioning roller.

Loosen tensioning roller securing nut -1-.
Turn eccentric of tensioning roller clockwise -arrow- using

socket -T10264- until indicator -2- is in middle of gap in base
plate.
Note
Ensure that securing nut does not turn as well.
Hold tensioning roller in this position and tighten tensioning

AG. Volkswagen AG d
roller nut to 20 Nm + 45 (1/8 turn). ksw
agen oes
n ol ot g
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ris tee
tho or
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Fit counter-hold tool -T10172- with
ss pin -T10172/4- as shown
in illustration and keep the toothed belt under tension on pull
ce
e
nl
pt
du
ing side, by pressing in -direction of arrow-.
an
itte
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erm
ab
Tighten bolts -1- of camshaft toothed belt pulley to 25 Nm.
ility
ot p
Remove locking pin -3359- and crankshaft stop -T10100- .

wit
, is n
h re
hole

until the crankshaft is just before TDC again. spec
es, in part or in w
t to the co
rrectness of i
l purpos
Lock hub of camshaft with locking pin -3359- whilst turning

engine in direction of rotation.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4-cylinder diesel
wage
nAengine with
G. Volkswagenunit
AG dinjector
oe - Edition 05.2007
ks s no
Vol t gu
by ara
Check whether crankshaft can be lockedriwith
se
d crankshaft stop nte
-T10100- . tho eo
au ra
c
ss
If crankshaft cannot be locked
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
Loosen securing bolts -1- for camshaft toothed belt pulley.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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-.
Now turn crankshaft in engine direction of rotation until crank
shaft stop pin engages in sealing flange whilst turning.
1. Cylinder head 77
Fit counter-hold tool -T10172- with pins -T10172/4- asAshown.

G. Volkswagen AG d
Press counter-hold tool -T10172- in direction oflkarrow,
swa
gen keeping oes
not
camshaft toothed belt pulley under tension.
db
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ris tee
In this position, tighten camshaft toothed
tho belt pulley securing or
bolts -1- to 25 Nm. s au ac
s
ce
e
nl
Remove locking pin -3359- and crankshaft stop -T10100- .
pt
du
an
itte
y li
Turn crankshaft two rotations in engine direction of rotation erm
ab
ility
ot p
wit
, is n
Repeat check and adjustment if necessary.
h re
hole
spec
Install centre and lower parts of toothed belt guard.
es, in part or in w
t to the co
Install belt pulley vibration damper. Torque setting: 10 Nm +
90 (1/4 turn) further.
rrectness of i
Install upper toothed belt guard.
l purpos
Install connecting pipe between charge air cooler and intake

connecting pipe.
nf
ercia
orm
Install front right wheel housing liner.
m
atio
om
n in
Install coolant expansion tank.
or c
thi
te
sd
iva
Bolt fuel filter bracket to engine mount to 8 Nm torque
o
r
rp
cu
-arrows-.
o
m
f
en
ng
t.
yi Co
Engage fuel filter in bracket. t. Cop py
rig
gh ht
yri
Bolt on filler neck for window wash system. p by
o Vo
by c lksw
cted agen
Fit engine cover. Prote AG.

AG. Volkswagen AG d
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olksw not
d byV Jetta gu 2005 , Bora 2006 , Golf Variant 2007
ara
e
horis 4-cylinder diesel nteengine with unit injector - Edition 05.2007
eo
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ss c
1.4 Removing and installing cylinder head
ce
e
nl
pt
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itte
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erm
ab
ility
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equipment required
wit
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hole
spec
es, in part or in w
-VAS 6208-
t to the co
Torque wrench -
V.A.G 1331-
rrectness of i
Torque wrench -
l purpos
V.A.G 1332-
Diesel extractor -VAS
nf
ercia
5226- or hand-operated
or
vacuum pump with acces
m
m
atio
sories -V.A.G 1390- and
om
n in
or c
Water drainage container -
thi
te
V.A.G 1390/1 -
sd
iva
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cu
Retainer -T10014- (only ve
o
m
f
en
ng
hicles 05.05)
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Support bracket -10 - 222 A- with frames -10 - 222 A/8- (only
vehicles 05.05)
1. Cylinder head 79
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.
Caution

tions:
hot components.
Removing page 80
Installing page 82
1.4.1 Removing
Note
Before removing cylinder head, extract fuel using hand-operated

vacuum pump with accessories -V.A.G 1390- and water drainage
container -V.A.G 1390/1- page 166 .
wage es n
Remove engine cover. To do this, pull engine yV
olkscover upwards ot g
ua
abruptly at front -arrows A- and then pull e forwards out of rear
d b ran
ris
fastening -arrow B-. ut
ho
tee
or
sa ac
Remove bulkhead in plenum chamber s General Body Re
ce
e
pairs, Exterior; Rep. Gr. 50 ; Plenum chamber bulkhead .

nl
pt
du
an
itte
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erm
ab
ility
ot p
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pipe.
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
l purpos

nf

ercia
orm
m

atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


Drain off coolant page 127 .
Disconnect fuel supply and return lines as well as coolant line
on cylinder head.
Before removing the cylinder head, extract fuel on tandem
pump with diesel extractor -VAS 5226- or hand-operated vac
uum pump with accessories -V.A.G 1390- and water drainage
container -V.A.G 1390/1- page 166 .
Pull fuel filter module upwards out of bracket and lay it with
hoses to side.
Remove turbocharger support and oil return from turbocharg
er.
Remove oil supply pipe and lay oil supply pipe to side
page 114 .
Note
From 05.05 a modified engine support has been introduced; it is

no longer necessary to remove the engine support and support
the engine for the procedure removing, installing andagtensioning
en AG. V
olkswagen AG
does
toothed belt page 62 . Volksw not
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ris tee
Remove toothed belt page 62 . tho
or
au ac
ss
Remove tensioning roller for toothed belt.
ce
le
un
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an
Remove hub for camshaft pulley page 92 .

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Remove securing bolts for rear toothed belt guard -2- and
ot
wit
-4- .
, is n
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hole
Unscrew Hall sender -G40- -3-.

spec
es, in part or in w
Remove exhaust gas recirculation connecting pipe.

t to the co
Pull off or disconnect all other electrical connections as nec

essary from cylinder head and lay to one side.
rrectness of i
Separate all connection, coolant, vacuum and intake hoses

l purpos
from cylinder head.

Only vehicles 05.05
nform
mercia
a
com
tio
Note
n in
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te o
thi
s
Both lifting eyes for the support are located on the cylinder head,
iva
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so an additional bracket for supporting the engine must be se

rp
cum
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cured on the cylinder block.

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Cop py
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Prote AG.
1. Cylinder head
Screw retainer -T10014- into threaded hole above coolant

pump and tighten to 20 Nm.
Then lift the engine slightly using the spindle -A- until the spin
dle -B- is relieved.
Unhook spindle -B- and push it to side.
Remove cylinder head cover page 61 .
AG. Volkswagen AG d
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spec
Maintain sequence when loosening cylinder head bolts.
es, in part or in w
t to the co
Lift cylinder head slightly and remove from engine past toothed
belt guard.
rrectness of i
Note
l purpos
The cylinder head must be guided carefully to prevent damage.
nf
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or c
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1.4.2 Installing
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Cop py
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Note py by
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Prote AG.
Always renew cylinder head bolts.
In cases of repair carefully remove gasket remains from cyl
inder head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces. When using abrasive
paper do not use a grade less than 100.
Carefully remove remains of emery and abrasives.
Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
Set crankshaft to TDC mark before fitting cylinder head.

Turn crankshaft opposite engine direction of rotation until all
pistons are approximately equally placed below TDC.
Fit cylinder head gasket.
Note
Observe cylinder head gasket identification page 60 .

4-cylinderAdiesel engine with unit injector - Edition 05.2007
G. Volkswagen
n AG do
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Fit cylinder head and tighten all cylinder d by head bolts hand-tight.
V ua
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Tighten cylinder head in four stages
autho
in sequence shown as or
ac
follows: ss
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un
1- Tighten initially with torque wrench:
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Stage I = 35 Nm
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Stage II = 60 Nm
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2- Turn further with rigid wrench:
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spec
Stage III = 1/4 turn (90)
t to the co
Stage IV = 1/4 turn (90)
rrectne
Note
ss o
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f
It is not necessary to retighten cylinder head bolts after repairs.
inform
mer
atio
Further installation is carried out in the reverse order. In the proc
om
n
ess, note the following:
c
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After tightening the cylinder head, turn the camshaft hub so

i
o
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cum
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that the cam lobs -arrows- for cylinder No. 1 point evenly up
fo
en
ng
wards. Turn crankshaft, in engine direction of rotation, to TDC

t.
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op
marking before fitting toothed belt page 62 . C py
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Install camshaft sprocket hub page 92 .
p by
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Install toothed belt page 62 .
Prote AG.

Install oil supply line page 114 .
Gr. 50 ; Noise insulation .
Install bulkhead in plenum chamber General Body Repairs,
Exterior; Rep. Gr. 50 ; Plenum chamber bulkhead .
Carry out road test and then read fault memory page 243 .
1.5 Checking compression
Note
If ceramic glow plugs are fitted, before removing check idling

speed smooth running control using Vehicle diagnosis, testing
and information system -VAS 5051B- . The compression test is
warranted only if one or more cylinders stand out in this idling
speed check.
1. Cylinder head 83

equipment required
Jointed spanner -3220-
Torque wrench -
V.A.G 1331-
Adapter set -
V.A.G 1381/12-
Compression tester -
V.A.G 1763 -
lkswage es n
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Test prerequisites
Engine oil temperature min. 30C. rrectne
Test procedure
s
Pull off central connector for unit injectors.

s o
cial p
f inform
mer
Note
atio
om
n
c
i
or
If ceramic glow plugs are fitted, always observe notes on remov

thi
e
ing and installing ceramic glow plugs page 274 .

t
sd
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fo
Remove all glow plugs or ceramic glow plugs using jointed

en
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t.
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extension and socket -3220- . t. Cop py
rig
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Vo
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Prote AG.

Screw in adapter -V.A.G 1381/12 - in place of glow plugs or

ceramic glow plugs.
Check compression using compression tester -V.A.G 1763- .
Note
Using the compression tester operating instructions .
Operate starter until tester shows no further pressure in

crease.
Compression pressures:
New: 25...31 bar, wear limit: 19 bar.
Maximum permissible difference between all cylinders: 5 bar.
Note
If ceramic glow plugs are fitted, always observe notes on remov

ing and installing ceramic glow plugs page 274 .
Remove glow plugs or ceramic glow plugs using jointed ex

tension and socket -3220- .
Tightening torque: 15 Nm.
Interrogate engine control unit
en AG. V
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swagememory
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Disconnecting the central connector for unit injectors causes
ce
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nl
faults to be stored. Therefore read and clear fault memory.

pt
du
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itte
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erm
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ility
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spec
es, in part or in w
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nform
mercia
at
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ion
c
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or
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ate
do
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t.
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1. Cylinder head 85
2 Valve gear
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Note d byV ua
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When installing an exchange
ss
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cylinder head with fitted cam ac
shaft, the contact surfaces between the bucket tappets and
ce
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nl
the cam must be oiled before installing the cylinder head cov
pt
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The plastic protectors fitted to protect the open valves must
ility
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not be removed until immediately before fitting the cylinder
wit
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head.
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hole
spec
If the cylinder head is renewed, all the coolant in the system
es, in part or in w
must also be renewed.
t to the co
Cylinder heads with cracks between the valve seats may be
used without reducing engine life, provided the cracks are
rrectness of i
small and not more than 0.5 mm wide.
l purpos
Do not rework valve seats. Only lapping in of valves is permit

ted.
nform
ercia
Wait about 30 minutes after installing the camshafts before

starting the engine. Hydraulic compensation elements must
m
at
om
settle (otherwise valves will strike pistons).
ion
c
in t
or
After working on the valve gear, turn the engine carefully at
his
ate
least 2 rotations to ensure that none of the valves make con
do
priv
c
tact when the starter is operated.
um
for
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t.
Always renew gaskets and seals.
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. Volkinjector
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Assembly overview - valve gear page 87 ris
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Checking valve guides page 89 ss
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Renewing valve stem seals page 90
un
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Removing and installing camshaft page 92
erm
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Removing and installing camshaft seal page 95
wit
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2.1 Assembly overview - valve gear
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spec
t to the co
1 - 20 Nm + 90 (1/4 turn) fur
ther
rrectne
Renew.
s
s o
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page 92
f inform
mer
2 - Rocker arm shaft
atio
m
Do not interchange.
o
n
c
i
or
n
3 - Cylinder head bolt
thi
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sd
va
Renew.
i
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page 79 t. C rig
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Before installing, insert
op Vo
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washers cted agen
Prote AG.
Item 4 (page 87) in
cylinder head.
4 - Washer
For cylinder head bolts.
Insert in cylinder head
before installing bearing
caps
5 - Bucket tappet
Do not interchange.
With hydraulic valve
clearance compensa
tion.
Place down with contact
surface facing down
wards
Before installing check
camshaft axial clear
ance page 88
Oil contact surface.
Before removing, remove camshaft bearing caps
6 - Cotters
7 - Valve spring plate
8 - Outer valve spring
Removing and installing, cylinder head removed: using valve spring compressor -2037- .
Removing and installing, cylinder head installed: page 90
9 - Inner valve spring
Removing and installing, cylinder head removed: using valve spring compressor -2037- .
Removing and installing, cylinder head installed: page 90
2. Valve gear 87
10 - Valve stem oil seal

Renewing page 90 .
11 - Valve guide
Checking page 89 .
12 - Unit injector
13 - Cylinder head
See note page 86 .
14 - Oil seal
Do not additionally oil or grease sealing lip of oil seal
Before installing, remove residual oil from camshaft journal using a clean cloth.
Seal groove on camshaft taper when installing with commercially available sticky tape (e.g. Sellotape)
15 - Valves
Valve dimensions page 89
16 - Ball socket
Do not interchange used bearing shells (mark)
Ensure proper seating of retaining lugs in bearing caps and cylinder head.
17 - Camshaft agen
AG. Volkswagen AG d
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Checking axial clearance page 88 by V o gu
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Removing and installing page h92 oris. nte
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Check radial clearance with plastigage,
ss a wear limit: 0.11 mm c
ce
le
Runout: max. 0.01 mm.

un
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itte
18 - Bearing cap
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pe
Installation sequence page 92 ility

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To install seal bearing cap contact surfaces 1 and 5 seal with sealant, black -AMV 174 004 01- wit
, is n
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page 89
hole
spec
19 - 8 Nm + 90 (1/4 turn) further

es, in part or in w
t to the co
Renew.
rrectness of i
2.2 Checking axial clearance of camshaft

l purpos

nform
ercia
Universal dial gauge bracket -VW 387-

m
a
com
tio
Dial gauge
n in
r
te o
thi
Check with bucket tappets removed and with first, third and last
s
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do
bearing caps fitted.

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Wear limit: max. 0.15 mm.

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Cop py
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Vo
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Prote AG.

2.3 Seal bearing caps 1 and 5 contact sur

faces
Seal bearing cap contact surfaces 1 and 5 with sealant, black -
AMV 174 004 01-
Apply a thin even coat of sealant, black -AMV 174 004 01- onto
surfaces -1-.
Note
Observe that no sealant comes into the grooves -arrows-.
2.4 Valve dimensions AG. Volkswagen AG d

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Note horis nte
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Inlet and exhaust valves must not be machined. Only lapping-in
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nl
is permitted.
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ab
Dimension Inlet valve Exhaust valve
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a mm 35.95 31.45
h re
hole
b mm 6.980 6.956
spec
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c mm 89.95 89.95
t to the co
45 45
rrectness of i
2.5 Checking valve guides
l purpos
nform
ercia
Universal dial gauge bracket -VW 387-

m
at
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ion
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or
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ate
do
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for
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Cop py
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Prote AG.
Dial gauge
2. Valve gear 89
Test procedure
Insert new valve into guide. The end of the valve stem must
be flush with the guide. Due to differences in stem diameters,
use only an inlet valve in inlet guide and an exhaust valve in
exhaust guide.
Determine rock. Wear limit: max. 1.3 mm.
Cylinder head must be renewed if rock exceeds wear limit.
2.6 Renewing valve

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equipment requiredss
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Assembly device -2036-

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Puller -3047 A-
rm
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ility
Valve stem seal fitting tool
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-3129-
h re
hole
spec
Valve lever -VW 541/1A-
es, in part or in w
Thrust piece -VW 541/5- t to the co

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
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t.
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Cop py
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Removing page 90
Installing page 91
2.6.1 Removing
(with cylinder head installed)

AG. Volkswagen AG d
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Remove camshaft page 92 . olksw not
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Remove bucket tappets and lay them down withthothe contact
ri
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surface downwards. When doing this, ensuresthat
au tappets are ra
c
not interchanged. s
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un
pt
Set piston of respective cylinder to top dead centre (TDC).
an
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itte
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Insert valve assembly device -2036- and adjust mounting to
pe
ility
height of studs.
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wit
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Remove valve springs using lever -VW 541/1A- and thrust
hole
spec
piece -VW 541/5- .
es, in part or in w
t to the co
Note
rrectness of i
The valves are supported by the piston crown.
l purpos
nform
mercia
a
Pull off valve stem seals using puller -3047 A- .
com
tion in
r
te o
thi
s
iva
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fo
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t.
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Cop py
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co lksw
by
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Prote AG.
2.6.2 Installing
Place the plastic sleeve -A- supplied on the appropriate valve
stem. This will prevent the new valve stem seal -B- being
damaged.
Insert new valve stem seal in fitting tool -3129- .
Lubricate sealing lip of valve stem seal and carefully push on
valve guide.
Further installation is carried out in the reverse order.
2. Valve gear 91
2.7 Removing and installing camshaft

equipment required
Counter-hold tool -T10051-
Puller -T10052-
1331-
AG. Volkswagen AG d
Torque wrench -V.A.G lksw
agen oes
not
1332- d by
Vo gu
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Sealant, black -AMV 174 ut
ho eo
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004 01- ss a c
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erm
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ility
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spec
t to the co
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cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
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fo
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t.
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Cop py
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Vo
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by c lksw
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Prote AG.
Removing page 92
Installing page 94
2.7.1 Removing
Remove securing bolts for camshaft toothed belt pulley -1-.
Pull camshaft toothed belt pulley off hub.

Loosen hub securing bolt -1-.

To do this, use counter-hold tool -T10051- .
Loosen hub securing bolt about 2 turns.
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Apply puller -T10052- and screw securing bolts -1-byinto Vo hub.
l ot g
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Put the hub under pressure by tightening up theth puller until the
o tee
or
hub loosens from the camshaft taper. ss
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nl
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Note
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When doing this, hold puller with 30 mm spanner.
wit
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hole
Remove hub from taper of camshaft.
spec
es, in part or in w
t to the co
Remove cylinder head cover.
Mark the rocker shafts -arrows-, e.g. with a waterproofed felt
rrectness of i
tipped pen to avoid confusion and therefore the injection pump
basic setting.
l purpos
Remove rocker arm shafts.
nform
mercia
at
Note
om
ion
c
in t
or
First loosen both outer and then inner securing bolts respectively.
his
ate
do
priv
cum
or
Remove tandem pump page 166 .

f
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ng
t.
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Cop py
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First remove bearing caps 5, 1 and 3. Then loosen bearing p by
co Vo
caps 2 and 4 alternately and diagonally.
by lksw
cted agen
Prote AG.
Remove camshaft.
2. Valve gear 93
2.7.2 Installing
Note
When camshafts are installed, cams -arrows- for No. 1 cylin

der must point upwards.
Do not interchange used bearing shells (mark).
When installing the camshaft, ensure proper seating of retain
ing lugs in bearing caps and cylinder head.
Before installing bearing caps, ensure that cylinder head bolt
washers are inserted in the cylinder head.
Oil bearing shell running surface.

Install bearing caps 2 and 4 using new bolts.
Tighten bearing caps 2 and 4, using alternate and diagonal
sequence to 8 Nm + 90 (1/4 turn).
Install bearing caps 5, 1 and 3 using new bolts.
Note
Seal bearing cap contact surfaces 1 and 5 with sealant, black

-AMV 174 004 01- page 89 AG. Volkswagen AG d
agen oes
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Bearing cap 5 must align flush with outer edge by Vof the cylinder
o l not
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ara
head; otherwise this may lead to tandemripumpse
d leakage. nte
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1
Tighten bearing caps 5, 1 and 3 also to 8 Nm + 90 ( / turn).
s
4
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un
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Install camshaft oil seal page 95 .

itte
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ility
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Install rocker shafts and tighten inner -2- and then the outer wit
is n
-1- new securing bolts diagonally to 20 Nm + 90 (1/4 turn).

h re
ole,
spec
Place hub on camshaft.

t to the co
rrectness o
cial p
f inform
mer
atio
om
Tighten hub securing bolt -1- to 100 Nm.

n
c
i
or
n thi
e
To do this, use counter-hold tool -T10051- .

t
sd
iva
o
pr
cum
Push camshaft toothed belt pulley onto hub.

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t.
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Cop py
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Prote AG.

Note
The toothed segment -arrow- of the camshaft belt pulley must be

on top.
Align camshaft toothed belt pulley at centre of elongated

holes.
Hand tighten securing bolts -1- to camshaft toothed belt pulley
so that there is no play. swa
gen AG
. Volkswagen AG
does
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Lock hub using locking pined- b3359-
y
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Install and tension toothed
au
th belt page 62 . ra
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Install tandem pump page 166 .
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Note
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ility
ot
wit
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Wait about 30 minutes after installing the camshafts before start
h re
hole
ing the engine. Hydraulic compensation elements must settle
spec
(otherwise valves will strike pistons).
es, in part or in w
t to the co
2.8 Removing and installing camshaft oil seal
rrectness of i
l purpos

equipment required
nform
ercia
Fitting tool -10 - 203-

m
a
com
ti
Oil seal extractor -3240- on in
r
te o
thi

s
iva
1331-
do
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fo

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ng
t.
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1332-
Co
Cop py
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rig ht
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Prote AG.
2. Valve gear 95
Bolt/screw -M121,5 x 65-
Removing page 96
Installing page 96
2.8.1 Removing
Remove camshaft pulley and hub page 92 .
Unscrew inner part of oil seal extractor - 3240- two turns (ap
prox. 3 mm) out of outer part and lock with knurled screw.
Lubricate threaded head of oil seal extractor -3240- , place it
in position and exerting firm pressure screw it into oil seal as
far as possible. AG. Volkswagen n AG do
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Loosen knurled screw and turn innerypart Vol against camshaft ot g
ua
until the oil seal is pulled out. rised b ran
tee
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nl
pt
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ility
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spec
2.8.2 Installing
es, in part or in w
t to the co
Note
rrectness of i
The oil seal sealing lip must not be additionally oiled or greased.
l purpos
Remove oil residue from camshaft journal using a clean cloth.

nform
ercia
Tape over groove in taper of camshaft (e.g. with Sellotape).

m
at
om
io
Fit oil seal carefully on camshaft.

n
c
in t
or
his
e
Press in seal with pressure piece of pulling device -10 - 203-

at
do
riv
and screw -M121,5 x 65- onto limit stop.

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cum
for
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t.
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Cop py
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by lksw
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Prote AG.

17 Lubrication
1 Engine oil
Note
The oil level must not be above the max. mark, danger of damage
to catalytic converter!
Engine oil specification page 97

Oil capacities page 97
Checking engine oil level page 97
1.1 Engine oil specification

Maintenance ; Booklet 38
1.2 Oil capacities

Engine codes BKC and BXE
With oil filter change 3.8 l.
Without oil filter change 3.3 l.
Engine codes BLS and BRM
With oil filter change 4.3 l.
Without oil filter change 3.8 l.
Top up to max. marking if necessary page 97 .
1.3 Checking engine oil level

n AG. Volkswagen A
ge G do
swa es n
Test prerequisites
by
Vol
k ot g
ua
d ran
ise
Engine thoil
or temperature at least 60C. tee
or
au ac
ss must be level (horizontal)
Vehicle
ce
le
un
pt
Wait a few minutes after switching off the engine to allow the
an
d
itte
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oil to flow back into the sump.

rm
ab
pe
ility
Test procedure
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wit
, is n
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Pull out the dipstick, wipe off with a clean cloth and insert it
hole
again onto stop.

spec
es, in part or in w
Pull out the dipstick again and read off the oil level.
t to the co
Markings on oil dipstick

rrectness of i
1 - Max. mark
l purpos
2 - Min. mark
a - Area above grooved section up to max. mark: Do not top up
nform
ercia
with engine oil!

m
b - Oil level in grooved section: Can be topped up with engine oil.

com
tion in
c - Area from min. mark up to grooved section: Must be topped

r
te o
thi
up, max. 0.5 l of engine oil!

s
iva
do
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fo
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ng
t.
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Cop py
t. rig
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Prote AG.
1. Engine oil 97
2 Parts of lubrication system
Caution
AG. Volkswagen AG d
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Finding metal shavings or a large Vquantity
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w
of small metal pares not g
ticles during engine repair could d by indicate that the crankshaft ua
ran
ise
bearings or conrod bearings hor
are damaged. To prevent this tee
ut or
from causing further damage,
ss
a perform the following repairs: ac
ce
e
Thoroughly clean oil passages.

nl
pt
du
an
itte
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Replace oil cooler.
erm
ab
ility
ot p
Renew oil filter element.
wit
, is n
h re
hole
spec
Oil pump, oil sump - assembly overview, engine codes BKC, BLS,
es, in part or in w
BXE page 98
t to the co
Oil pump, oil sump - assembly overview, engine code BRM
page 100
rrectness of i
Removing and installing sump page 101
l purpos
Removing and installing oil pump page 104
nform
ercia
2.1 Oil pump, oil sump - assembly overview, engine codes BKC, BLS, BXE
m
at
om
ion
c
1 - 15 Nm
in t
or
his
ate
2 - Sealing flange
do
priv
cum
or
With oil seal

f
en
ng
t.
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Must seat on dowel
Co
op py
sleeves.
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Removing and installing cop Vo
by lksw
cted
page 35
agen
Prote AG.

ant -D 176 404 A2-
page 35
Do not additionally oil or
grease the oil seal seal
ing lip.
a clean cloth.
page 33
3 - Chain tensioner with ten
sioning rail, 15 Nm
When installing, pre-
tension spring and en
gage
4 - Oil dipstick
The oil level must not be
above the max. mark!
Markings page 97
5 - Dipstick guide
6 - Guide tube
98 Rep. Gr.17 - Lubrication

7 - Dowel sleeves
8 - O-ring
Renew.
9 - 15 Nm
10 - Suction line
Clean strainer if soiled
11 - Baffle plate
12 - 15 Nm
13 - 15 Nm
14 - Sump
Install with silicone sealant -D 176 404 A2-
Removing and installing page 101 . AG. Volkswagen AG d
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15 - Oil drain plug, 30 Nm d byV gu
ara
ise nte
With attached seal. hor eo
aut ra
Renew. ss c
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nl
16 - 10 Nm
pt
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17 - Oil level and oil temperature gauge -G266 -
erm
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ility
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Connector, black, 3-pin.
wit
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18 - Oil seal
hole
spec
Renew.
es, in part or in w
t to the co
19 - Oil pump
With 12 bar pressure relief valve.
rrectness of i
Before installing, check that both dowel sleeves Item 7 (page 98) are fitted for centralising oil pump/
cylinder block.
l purpos
Renew if running surfaces and gears are scored.

20 - Oil pump chain sprocket
nf
ercia
orm
21 - Retainer
m
atio
om
For Oil level and oil temperature sender -G266- wiring harness
n in
or c
thi
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22 - 20 Nm + 90 (1/4 turn) further

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Renew.
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23 - Chain
Co
Cop py
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24 - 25 Nm
rig by
copy Vo
by lksw
Insert without sealant. cted agen
Prote AG.
25 - Oil spray jet

For piston cooling
Note
2. Parts of lubrication system 99

2.2 Oil pump, oil sump - assembly overview, engine codes BRM
AG. Volkswagen AG d
1 - 15 Nm agen oes
olksw not
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2 - Sealing flange orise nte
th eo
With oil seals au ra
c
s
Must seat on dowel
ce
le
un
pt
sleeves.
an
d
itte
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rm
ab
pe
page 35
ility
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wit
, is n
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ant -D 176 404 A2-
hole
spec
page 35
es, in part or in w
Do not additionally oil or
t to the co
grease the oil seal seal
ing lip.
rrectness of i
l purpos

a clean cloth.
nform
ercia

m
a
page 33
com
tion in
r
te o
3 - Chain tensioner with ten

thi
sioning rail, 15 Nm s
iva
do
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rp
When installing, pre-

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tension spring and en

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gage Cop py
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4 - Oil dipstick py by
co Vo
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cted
The oil level must not be
agen
Prote AG.
above the max. mark!
Markings page 97
5 - Dipstick guide
6 - Guide tube
7 - Dowel sleeves
8 - O-ring
Renew.
9 - 15 Nm
10 - Suction line
11 - Baffle plate
12 - 15 Nm
13 - 15 Nm
14 - Sump
Install with silicone sealant -D 176 404 A2-
Removing and installing page 101
15 - Oil drain plug, 30 Nm
With attached seal.
Renew.

16 - Oil pump
With 12 bar pressure relief valve.
Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
Renew if running surfaces and gears are scored.
17 - Oil pump chain sprocket
18 - 20 Nm + 90 (1/4 turn) further
wage es n
Renew. yV
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d b ua
ran
19 - Chain ir se tee
tho
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20 - 25 Nm ss
ce
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Insert without sealant.

nl
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an
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21 - Oil spray jet
erm
ab
ility
For piston cooling
ot p
wit
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Note
hole
spec
es, in part or in w
t to the co
2.3 Removing and installing sump
rrectness of i
l purpos

equipment required
nform
ercia
U/J extension and socket,

10 mm -3185-
m
at
om
io
Tool insert 5 mm -3249-
n
c
in t
or
his
e

at
do
riv
1331-
p
cum
for
en
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Drip tray for workshop hoist

n
t.
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op
-VAS 6208 - C py
t. rig
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yri
Silicone sealant -D 176 404
p by
co Vo
by lksw
A2- Prote
cted AG.
agen
Hand drill with plastic brush

attachment
Eye protection
Flat scraper

Removing page 102

Installing page 103
2.3.1 Removing
Remove intake hose air filter/exhaust turbocharger.
Carefully cut through cable tie -1-.

Open wiring retainer -2- and unhook wiring harness.
pipe.

G. Volkswagen AG d
Pull breather hose -1- and air duct hoses -3- and
lksw
-5-
ageoff.
nA oes
not
o
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ris
ed
b ara
nte
tho eo
Vehicles with engine codes BLS, BRMs au ra
c
s
ce
le

un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co

rrectness of i

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nform
ercia

m

com
tion in
r
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thi
s
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Remove both bolts -arrows- from upper charge air pipe -A-.
Remove the bolt -arrows- of the charge air pipe -A- from the
oil sump.
If fitted, pull connector off oil level and oil temperature sender
-G266- .
Drain engine oil.
Note
Observe environmental regulations for disposal.
Remove connecting bolts for sump and gearbox. agen

AG. Volkswagen AG d
oes
olksw not
V gu
Install sump bolts using 10 mm jointed wrench ed -3185- . (Re
by ara
nte
move using socket insert 5 mm -3249- .)tho ris
eo
au ra
Remove sump. Loosen sump with light s blows of a rubber-
s c
ce
e
headed hammer if necessary.

nl
pt
du
an
itte
Remove sealant residue on cylinder block with a flat scraper. y li

erm
ab
ility
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Remove sealant residue on sump with a rotating brush, e.g. a

wit
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hand drill with plastic brush attachment (wear eye protection).

h re
hole
spec
Clean the sealing surfaces. The sealing surfaces must be free

es, in part or in w
of oil and grease.

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
2.3.2 Installing
in t
or
his
ate
do
priv
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for
Note
en
ng
t.
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Cop py
. rig
Observe the use-by date of the sealing compound.
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rig by
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The sump must be installed within 5 minutes of applying sili
by
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cone sealing compound.
AG.

Cut off tube nozzle at forward marking (approx. 3 mm nozzle

).
Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealant bead -arrows- must be:
2...3 mm thick.
Volkswa
Run bead along inner side of bolt
swa
holes
gen AG.-arrows-.
gen AG
does
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Vol gu
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ris
Note utho eo
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The sealing compound bead must not be thicker, otherwise

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pt
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excess sealing compound will enter the oil sump and may
an
itte
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block the oil suction line strainer.
erm
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ility
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If gearbox is removed, sump must align smoothly with cylinder
wit
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block.
h re
hole
spec
If gearbox is installed, sump must rest against gearbox.
es, in part or in w
t to the co
Apply silicone sealing compound bead as shown to the clean
sealing surface of the sump. (The figure shows the position of
rrectness of i
the sealant bead on the cylinder block.)
l purpos
Install sump immediately and tighten all sump bolts lightly.

Ensure that the oil sump is in flush with the intermediate plate/
gearbox flange.
nform
mercia
at
om
Note ion
c
in t
or
his
ate
When installing sump with engine out of vehicle, ensure that sump
do
priv
is flush with cylinder block at flywheel end.

um
for
en
ng
t.
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op
Tighten sump bolts diagonally to 15 Nm.
C py
t. rig
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Tighten sump to gearbox bolts to 45 Nm. cop Vo
by lksw
cted agen
Prote AG.
Note
After fitting sump assembly, the sealant must dry for approx. 30
minutes. Then (and only then) fill the engine with engine oil.
The rest of the assembly is basically a reverse of the dismantling

sequence.
2.4 Removing and installing oil pump

Removing page 104
Installing page 105
2.4.1 Removing
Remove the oil sump and the baffle plate page 101 .

AG. Volkswagen AG d
agen oes
olksw not
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thor Jetta 2005 , Bora 2006 , Golf Variant
e o 2007
u
a4-cylinder diesel engine with unit injector - Edition ra
ss c05.2007
ce
le
un
pt
Remove bolts -2-.
an
d
itte
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rm
ab
Pull sprocket off oil pump shaft.
pe
ility
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Remove bolts -1- and -3- and remove oil pump.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
2.4.2 Installing
m
a
com
t
ion in
r
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Insert dowel sleeves Item 7 (page 100) on top of oil pump.
thi
s
iva
do
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Chain sprocket can only be fitted in one position on oil pump

rp
cum
fo
shaft.
en
ng
t.
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op
Install sump page 101 . C py
t. rig
gh ht
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Torque settings cop Vo
by lksw
cted agen
Prote AG.
Component Nm
Sprocket to oil 20 + 901)
pump shaft
Oil pump to cyl 15
inder block
1) Renew bolt.

3 Oil filter bracket, oil pressure, oil cool

er and oil supply line
Oil filter bracket and oil cooler - Assembly overview page 106
Removing and installing oil filter bracket and oil cooler
page 107
Checking oil pressure and oil pressure switch page 112
Oil supply pipe to turbocharger - Assembly overview
page 113
Removing and installing oil supply line to turbocharger wagen AG. Volkswagen AG does
page 114 olks not
yV gu
db ara
ise nte
3.1 Assembly overview - oil
au
thfilter
or bracket and oil cooler e or
ac
ss
ce
le
un
pt
1 - Oil filter bracket
an
d
itte
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erm
2 - 15 Nm + 90 (1/4 turn) fur
ab
ility
ot p
ther
wit
is n
Renew.
h re
ole,
spec
First fit upper left and
lower right bolts and
t to the co
then tighten all four bolts
diagonally.
rrectne
3 - Seal
Renew.
ss
4 - Oil seal
o
cial p
f in
Renew.
form
mer
atio
5 - Pipe union, 35 Nm
om
n
c
i
6 - Oil supply line, 22 Nm
or
n thi
te
sd
a
To turbocharger
iv
o
pr
cum
r

fo
en
ng
page 114 .
t.
yi Co
Cop py
7 - Cap, 25 Nm
t. rig
gh ht
pyri by
Loosen and tighten with
co Vo
by lksw
cted agen
socket -T10125 - Prote AG.
8 - Oil seal
Renew.
9 - Oil filter element
Ensure that "Top" is up
permost when fitting.
10 - Plug, 10 Nm
If sealing ring is leaking,
nip open and renew.
11 - Oil pressure switch -F1-
0.7 bar switch: brown.
Tighten to 20 Nm torque
If sealing ring is leaking, nip open and renew.
Checking page 112 .

12 - Plug, 25 Nm
13 - Seal
Renew.
14 - Oil cooler
Ensure clearance to adjacent components.
See note page 98 .
Checking oil cooler for leaks page 140
15 - Seal
Renew.
16 - Retainer
17 - 10 Nm
3.2 Removing and installing oil filter bracket with oil cooler

equipment required
Hose clamps up to 25
mm -3094-
Torque wrench -
V.A.G 1331-
Torque wrench -
V.A.G 1410-
5024A-
-VAS 6208 -
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Oil filter bracket, oil pressure, oil cooler and oil supply line 107
Removing page 108

Installing page 111
3.2.1 Removing
pipe. agen
AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m

o
n
c
i
or
n
thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Pull intake manifold -5- off the air duct. Cop py
t. rig
gh ht
yri
Unscrew bolt -4- and take off air filter housing. p by
co Vo
by lksw
cted agen
Prote AG.
Unbolt air duct from lock carrier -arrows-.


Disconnect connector -arrow- for magnetic coupling on air

conditioner compressor.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
Remove lower left air duct hose from front air duct pipe. To do
ole,
this lift retaining clip -2- lightly.
spec
t to the co
Remove bolts -1-.
rrectne
Unclip coolant hose on air duct pipe -arrow-.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
t
sd
iva
o
pr
cum
r
fo
en
ng
oil sump.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Pull coolant hose -arrow- off.
Pull off or disconnect coolant hoses on oil cooler with hose

clamps up to 25 mm -3094- -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
Disconnect connector -arrow- on engine speed sender -G28- .
un
pt
an
d
itte
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Free wiring on wiring retainer.
erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f
Disconnect connector on oil pressure switch -F1- -1-.
inform
mer
Remove oil pressure switch -1-.
atio
om
n
Remove oil supply pipe to turbocharger on retainer -3- and on
c
i
or
n
oil filter bracket -2-.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Unscrew bolts -arrows-.

Remove oil filter bracket.

3.2.2 Installing
Note
Renew gaskets, seals and O-rings.

AG. Volkswagen AG d
agen
Hoses must be locked
Vol with clamps Electronic parts
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oes
not cata
logue ETKA . sed by g ua
ran
ri tee
ho
ut or
When installing
pipes with plug-in connectors, ensure thatac
ss
a
air
the securing clip -arrow- engages audibly on the retaining lug
ce
le
un
pt
-A-.
an
d
itte
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rm
Fill up cooling system if the oil cooler has been renewed (use
ab
pe
ility
fresh coolant if necessary) page 127 .
ot
wit
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Fill up with engine oil and check oil level.
h re
hole
spec
Torque settings
es, in part or in w
t to the co
Component Nm
Oil filter bracket to cylinder block 15 + 902)
rrectness of i
Oil pressure switch to oil filter bracket 20
l purpos
Oil supply pipe to oil filter bracket 22

Lower air duct pipe to cylinder block 15
nform
ercia
Upper air duct pipe on retainer 8

m
a
com
tio
2) Renew bolts.
n in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.3 Checking oil pressure and oil pressure switch

equipment required
Oil pressure tester -V.A.G
1342- n AG. Volkswagen A ge G do
swa es n
Voltage tester -V.A.G
by
Vol 1527
k ot g
ua
B- ris
ed ran
tee
tho or
Auxiliary
ss
ameasuring
u
set - ac
V.A.G 1594C-
ce
e
nl
pt
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
Test procedure
Note
Functional check and servicing the optical and acoustic oil pres
sure warning Current flow diagrams, Electrical fault finding and
Fitting locations,Guided functions with Vehicle diagnosis, test
ing and information system -VAS 5051B - .

Remove oil pressure switch -F1- and screw into tester.

Screw tester into oil filter bracket in place of the oil pressure
switch.
olkswagen AG
en AG. V
Connect brown wire of tester to earth (-). olkswag does
not
V gu
by ara
Connect voltage tester -V.A.G 1527risB-
ed using adapter cables nte
from adapter set -V.A.G 1594C -auto
thobattery positive (+) and oil eo
ra
pressure switch. LED must nots light up.
s c
ce
le
un
Start engine and increase speed slowly.
pt
an
d
itte
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At 0.55...0.85 bar the LED must light up, otherwise renew oil
rm
ab
pe
pressure switch.
ility
ot
wit
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Increase engine speed further. At 2000 1/min and an oil tem
h re
hole
perature of 80C the oil pressure should be min. 2.0 bar.
spec
es, in part or in w
t to the co
At higher engine speed, oil pressure must not exceed 7.0 bar. If
necessary renew oil filter bracket.
rrectness of i
3.4 Assembly overview - oil supply line to turbocharger
l purpos
1 - Retaining clamp
nform
ercia
2 - 25 Nm
m
a
com
tio
3 - Oil supply line
n in
r
te o
To turbocharger
thi
s
iva
do
4 - 10 Nm
r
rp
cum
fo
en
g
5 - Retainer
n
t.
yi Co
Cop py
6 - Union nut, 22 Nm
t. rig
gh ht
pyri by
Vo
o
by c
7 - 10 Nm
lksw
cted agen
Prote AG.
. Volkswagen AG
gen AG
3.5 Removing and installing yoilVol supply line
a does
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to turbocharger d b ara
ise nte
or h eo
ut ra
Special tools and workshop equipment
ss
a
required c
ce
e
nl
pt
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an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Drip tray for workshop hoist -VAS 6208 -
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing page 114

Installing page 116
3.5.1 Removing
pipe.



lkswage es n
o ot g
Remove lower left air duct hose from frontd bair y V duct pipe. To do ua
ran
this lift retaining clip -2- lightly. orise
tee
th or
u
Vehicles with engine codes BKC, BXE ss
a ac
ce
le
un
Remove bolts -1-.
pt
an
d
itte
y li
Unclip coolant hose on air duct pipe -arrow-.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
oil sump.
nform
ercia
Loosen securing bolts for retaining clips.

m
a
com
tion in
Loosen oil supply line union nuts on oil filter bracket and tur
r
te o
thi
bocharger.
s
iva
do
r
Remove oil supply line.

rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.5.2 Installing
Note
The procedure must be followed to ensure that oil supply line is

installed tension-free.
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Loosen securing nut -2- on retainer -5-.

Start union nuts for oil supply line on connections.
Tighten union nut -8- on oil filter bracket hand-tight.
Tighten union nut -6- on turbocharger hand-tight.
First tighten union nut -8- on oil filter bracket and then union
nut -6- on turbocharger to 22 m.
Attach retaining clips -1- to brackets and tighten securing bolts
to 10 Nm.
Tighten securing nut -2- to 25 Nm.
Further installation is basically the reverse of the removal proce
dure.

19 Cooling
1 Parts of the cooling system
WARNING
Steam may escape when expansion tank is opened. Wear eye

protection and protective clothing to avoid eye injuries and
scalding. Cover cap with cloth and open carefully.
tions:
. Volkswagen AG
gen AG d
All wirings (e.g.Vofor
lkswfuel, hydraulic system, ecoolant
a o s
not and re
frigerant liquid,
ed by brake liquid, vacuum) and electrical
gu
ara wir
ings must
tho
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Ensure
ss that there is sufficient clearance to all moving orc
hot components.
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Note
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spec
When the engine is warm, the cooling system is under pres
es, in part or in w
sure. If necessary, release pressure before beginning repair t to the co

work.
Hoses are secured with spring-type clips. In case of repair,
rrectness of i
only use spring-type clips Electronic parts catalogue ET

KA .
l purpos
Spring-type clip pliers -VAS 5024A- or hose clip pliers -

V.A.G 1921- are recommended for installation of spring-type
nform
ercia
clips.
m
a
com
When installing coolant hoses, route stress-free so that they

ion in
do not come into contact with other components (observe

r
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markings on coolant connection and hose).

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1. Parts of the cooling system 117

Carry out leak test of cooling system with cooling system tester -
V.A.G 1274- and the adapter -V.A.G 1274/8- and adapter -
V.A.G 1274/9- .
Parts of cooling system - body side, engine codes BLS, BRM
page 118
Parts of cooling system - body side, engine codes BKC, BXE
page 119
Parts of cooling system - engine side, engine codes BLS, BRM
page 120
Parts of cooling system - engine side, engine codes BKC, BXE
page 123
Coolant hose schematic diagram page 125
Draining and filling coolant page 127
Removing and installing radiator fan - V7- and radiator fan 2 -
V177- page 130
Removing and installing radiator page 132
Removing and installing coolant pump page 134
Removing and installing thermostat page 136
Checking cooling system for leaks page 138
Checking oil cooler for leaks page 140
1.1 Parts of cooling system - body side, engine codes BLS, BRM
1 - Radiator
page 132 .
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2 - O-ring ut
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3 - Coolant hose (top)

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Coolant hose schematic

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diagram page 125 .

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4 - Cap
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Check with cooling sys

spec
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tem tester -V.A.G 1274 -

t to the co
and adapter for cap -

V.A.G 1274/9-
page 139
rrectness of i
Test pressure: 1.4...1.6

bar.
l purpos
5 - Connector
nf
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6 - 3 Nm
rm
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7 - Expansion tank
o
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With coolant tempera

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tem tester -V.A.G 1274 - Cop py
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page 138 Prote
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118 Rep. Gr.19 - Cooling

8 - Lower coolant hose

Coolant hose schematic diagram page 125 .
9 - 5 Nm
10 - 5 Nm
11 - Radiator fan 2 -V177-
Only vehicles with optional equipment.
12 - Connector
13 - Connector
14 - Radiator fan -V7-
With radiator fan control unit -J293-
15 - Cowling
1.2 Parts of cooling system - body side, engine codes BKC, BXE

diagram page 125 .
2 - O-ring n AG. Volkswagen AG do
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Renew if damaged.
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3 - Radiator horis nte
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Removing au and installing ac
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page 132 .
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If renewed, change
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coolant in entire system.

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4 - Cap
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h re
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tem tester -V.A.G 1274-

spec
and adapter for cooling

t to the co
system -V.A.G 1274/9-

page 139
Test pressure: 1.4...1.6
rrectne
bar
5 - Connector
ss o
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6 - 3 Nm
inform
mer
7 - Expansion tank
atio
m

o
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c
ture display sender -

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4-cylinder diesel engine with unit
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8 - 5 Nm
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9 - 5 Nm
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10 - Fan support
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11 - Radiator fan 2 -V177-
h re
Only vehicles with optional equipment. ole,
spec
t to the co
12 - Radiator fan -V7-
With radiator fan control unit -J293-
rrectne
ss
13 - Connector
o
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f in
form
mer
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15 - Securing clip
c
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16 - Radiator outlet coolant temperature sender -G83-
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1.3 Parts of cooling system - engine side, engine codes BLS, BRM
py by
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1 - 10 Nm
2 - To exhaust gas recircula
tion cooler
diagram page 125 .
3 - Coolant pipe
diagram page 125 .
4 - Coolant pipe
diagram page 125 .
5 - To heat exchanger
diagram page 125 .
6 - To auxiliary heater
diagram page 125 .
7 - O-ring
Renew.
8 - Securing clip
Check for secure seat
ing.
9 - Coolant temperature send
er -G62-
ture gauge sender -G2-
tion cooler
diagram page 125 .

11 - Connection
AG. Volkswagen AG d
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12 - 10 Nm Volksw
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13 - Connecting hoseorise nte
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14 - T-piece ss a c
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15 - To top of radiator
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16 - To gearbox oil cooler
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17 - Gearbox oil cooler
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19 - 40 Nm
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20 - From gearbox oil cooler
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21 - Coolant pipe
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To oil cooler for engine oil Prote
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24 - To bottom of expansion tank

25 - Coolant hose
From oil cooler for engine oil to distributor piece Item 14 (page 121)
26 - Radiator outlet coolant temperature sender -G83-
27 - To bottom of radiator
28 - 15 Nm
29 - Connection
For thermostat.
30 - Thermostat
Opening begins at approx. 85C.
Ends at approx. 105C
31 - Cylinder block
With attachments
32 - 15 Nm
33 - Coolant pump
Check for ease of movement

34 - O-ring
Renew.
Moisten with coolant before installing
35 - To top of expansion tank
36 - Cylinder head
With attachments
37 - To bypass flap.
Coolant hose schematic diagram wage
olks page 125 .
es n
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38 - Coolant hose ris
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From cylinder heads ato
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40 - T-piece
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Prote AG.

1.4 Parts of cooling system - engine side, engine codes BKC, BXE
1 - To top of expansion tank

diagram page 125 .
2 - Coolant pipe (top)
Bolted to cylinder head
cover.
3 - To bypass flap.
diagram page 125 .
4 - O-ring
Renew.
5 - Securing clip
ing.
6 - Coolant temperature send
er -G62-
ture gauge sender -G2-
tion cooler
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diagram page 125 . d byV gu
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8 - Connection ut
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diagram page 125 .

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11 - 40 Nm
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12 - T-piece
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14 - T-piece
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16 - 15 Nm
m
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17 - To bottom of expansion tank

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18 - Coolant pipe
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19 - To bottom of radiator
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20 - Connection
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For thermostat.
AG.
21 - Thermostat

Opening begins at approx. 85C.
Ends at approx. 105C
23 - Rear coolant pipe
24 - 10 Nm
25 - To auxiliary heater
26 - Coolant pipe
27 - To exhaust gas recirculation cooler
28 - Oil cooler
29 - Coolant pump
Check for ease of movement
Note installation position. AG. Volkswagen AG d
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1.5 Coolant hose connection diagram

Connection diagram, engine codes BKC, BXE page 125
Connection diagram for engine codes BLS, BRM page 126
1.5.1 Connection diagram, engine codes BKC, BXE
1 - Expansion tank AG. Volkswagen AG d

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2 - Bypass flap by
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3 - Exhaust gas recirculation ut
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4 - Heater unit heat exchanger

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5 - Cylinder head/cylinder
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block
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6 - Oil cooler
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For gear oil
spec
Only models with an au
t to the co
tomatic gearbox
rrectne
8 - Radiator
s
s o
cial p
f
10 - Oil cooler
inform
mer
For engine oil.
atio
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11 - Coolant pump and ther

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mostat
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12 - Auxiliary heater
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1.5.2 Connection diagram, engine codes BLS, BRM
1 - Expansion tank
block
3 - Exhaust gas recirculation
cooler
4 - Heater unit heat exchanger
5 - Oil cooler
For automatic transmis
sion fluid
Only models with an au
tomatic gearbox
7 - Radiator
AG. Volkswagen AG d
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9 - Oil cooler Volksw
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For engine oil. rised
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10 - Coolant pump and ther
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11 - Auxiliary heater
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1.6 Draining and filling coolant

equipment required
Refractometer -T10007-
-VAS 6208-
5024A-
n AG . Volkswagen AG
Cooling system chargeksunit
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-VAS 6096 - Vol gu
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Adapter -V.A.G
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es, in part or in w
t to the co
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tion in
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Draining page 127 cted agen
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Filling page 129
1.6.1 Draining
Note
Collect drained coolant in a clean container for re-use or dis

posal.
Observe waste disposal regulations.
WARNING


Open cap on coolant expansion tank.

To drain coolant from radiator, open drain plug -arrow-.
Raise retaining clip -arrow- slightly and pull coolant hose from
radiator.
AG. Volkswagen AG d
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To drain coolant from engine also remove coolant oris hose at oil
e nte
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cooler -arrow-. aut
h
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nf
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1.6.2 Filling
s
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Note
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Only use coolant additive G 12 in accordance with
h re
hole
TL VW 774 F. Identification: coloured lilac.
spec
es, in part or in w
G 12 purple (in accordance with TL VW 774 F) can be mixed
t to the co
with the previous coolant additive G 12 red!
G 12 and coolant additives marked In accordance with TL
rrectness of i
VW 774 F prevent frost and corrosion damage, scaling and
also raise boiling point of coolant. Therefore, the cooling sys
l purpos
tem must be filled all year round with frost and corrosion
protection additives.
nform
ercia
Because of its high boiling point, the coolant improves engine

m
reliability under heavy loads, particularly in countries with trop
at
om
io
ical climates.
n
c
in t
or
his
Frost protection is required down to about -25C (in countries
ate
do
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with arctic climates: down to about -35C).

p
cum
for
The coolant concentration must not be reduced by adding wa
en
ng
t.
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ter even in warmer seasons and in warmer countries. The
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antifreeze percentage must be at least 40%.
t. rig
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If for climatic reasons greater frost protection is required, the
c by lksw
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amount of G 12 can be increased, but only up to 60% (frost
Prote AG.
protection to about -40C). Otherwise frost protection and

cooling effectiveness are reduced again.
The refractometer -T10007- is recommended to determine the
freezing temperature of the coolant.
If radiator, heat exchanger, cylinder head or cylinder head
gasket is replaced, do not reuse old coolant.
Recommended mixture proportions:

Frost protection Anti-freeze G 123) Water3)
to quantity
-25C 40% 3.2 l 4.8 l
-35C 50% 4.0 l 4.0 l
3) The quantity of coolant can vary depending upon vehicle equipment.
Screw drain plug into radiator -arrow-.


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Jetta 2005 , Bora 2006 , Golf Variant 2007 yV
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Fit coolant hose on radiator and lock retaining clip -arrow-.
ss
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un
pt
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Connect coolant hoses to oil cooler.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Filling with cooling system charging unit -VAS 6096-
es, in part or in w
t to the co
Screw adapter for cooling system tester -V.A.G 1274/8- onto
expansion tank.
rrectness of i
Fill coolant circuit using cooling system charging unit -
VAS 6096- manual for cooling system charging unit
l purpos
VAS 6096 .
Filling without cooling system charging unit -VAS 6096-
nform
mercia
Fill with coolant slowly up to upper marking of hatched field on
a
com
tio
expansion tank -arrow-.
n in
r
te o
thi
Fit expansion tank cap.
s
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c
Switch off heater and air conditioner.
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Start engine and maintain an engine speed of about 2000 rpm
Co
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for approx. 3 minutes. t. C rig
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Run engine until radiator fan cuts in.
co Vo
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cted agen
Prote AG.
WARNING

Check coolant level and top-up if necessary.

When the engine is at normal operating temperature the cool
ant level must lie on the upper marking of the hatched field
-arrow-.
On cold engine, coolant level should be roughly in middle of
hatched area.
1.7 Removing and installing radiator fan -

V7- and radiator fan 2 -V177-
Removing page 130
Installing page 131
1.7.1 Removing
Remove lower radiator connection (quick release coupling).
Unclip lower coolant hose out of the air ducting.

Disconnect connector -1- and remove securing bolts

-arrows- of the air ducting.
Remove cowling downwards. lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
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pt
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ility
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spec
es, in part or in w
Separate connection -1- and free wiring. Installation position
t to the co
differs from the figure.
Remove nuts -arrows- and remove fans.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
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ate
do
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or
1.7.2 Installing
f
en
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Torque settings: Prote AG.
Component Nm
Radiator fan to cowling 5
Cowling to radiator 5

1.8 Removing and installing radiator

equipment required
-VAS 6208-
Torque wrench -
V.A.G 1331-
5024A- lkswage es n
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Adapter set -V.A.G 1274/8- ir se
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tee
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or
Cooling system charge unit au ac
ss
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Removing page 132 cop Vo
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Installing page 133
AG.
1.8.1 Removing
Bring lock carrier into service position General body repairs,
exterior; Rep. Gr. 50 ; Lock carrier .

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ir se 4-cylinder diesel nteengine with unit injector - Edition 05.2007
eo
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ss
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un
pt
Detach connector -2-.
an
d
itte
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rm
ab
Remove coolant connection. To do this lift retaining clips -1-
pe
ility
lightly.
ot
wit
, is n
h re
hole
spec
Disconnect coolant connection to upper radiator (quick re
es, in part or in w
t to the co
lease coupling).
Remove cowling with radiator fans page 130 .
rrectness of i
l purpos
Note
To prevent damage to condenser or to refrigerant pipes and ho
nform
ercia
ses, ensure that pipes and hoses are not stretched, kinked or
m
bent.
a
com
tion in
r
te o
thi
Remove bolts -arrows- from radiator mounting.
s
iva
do
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rp
cum
Swing radiator slightly towards rear.
fo
en
ng
t.
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Unscrew condenser securing bolts. t. Cop py
rig
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pyri by
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Remove bolt -arrow- for fitting refrigerant pipe.

Remove radiator downwards.
1.8.2 Installing
Renew coolant if a new radiator has been installed.
Fill with coolant page 127 .
Torque settings:
Component Nm
Radiator mounting to lock carrier 5
Condenser to radiator 5
Cowling to radiator 5

1.9 Removing and installing coolant pump

equipment required
-VAS 6208-
Torque wrench -
V.A.G 1331-
5024A-
Adapter set -V.A.G 1274/8-
Cooling system charge unit
-VAS 6096 -
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Removing page 134

t to the co
Installing page 135

rrectne
1.9.1 Removing
ss
Caution
o
cial p
f inform
mer

atio

om
tions:
c
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or
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te

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To avoid damages to the wiring ensure sufficient clear C py
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ance to all moving or hot components.
gh ht
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co lksw
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Prote AG.

Note
Always renew seals and gaskets.

Remove securing bolts -1- for coolant pump -2- and carefully
remove coolant pump.
1.9.2 Installing
Moisten new O-ring -3- with coolant.
AG. Volkswagen AG d
Note agen oes
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The coolant pump plug faces
thor downwards. eo
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Insert coolant pump -2- in cylinder block and tighten securing
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nl
pt
du
bolts -1- to 15 Nm.

an
itte
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Install toothed belt page 62 .

ab
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es, in part or in w
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1.10 Removing and installing

lksw
agen
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ho or
equipment requiredss
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ab
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-VAS 6208-
wit
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Torque wrench -
hole
spec
V.A.G 1331-
es, in part or in w
t to the co
5024A-
rrectness of i
Adapter set -V.A.G 1274/8-
l purpos
Cooling system charge unit

-VAS 6096 -
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
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for
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Removing page 136

Installing page 137
1.10.1 Removing
WARNING

Note
Always renew seals and gaskets.

Remove alternator Electrical system; Rep. Gr. 27 ; Alter

nator 1.9 l TDI engine .
Pull coolant hose off connection.
Pull connector -6- off radiator outlet coolant temperature send
er -G83- -5-.
Remove securing bolts -1- of connection -2- and remove con
nection -2- with thermostat -4-.
Turn thermostat -4- 1/4 turn (90) to left and remove from con
nection -2-.
1.10.2 Installing
AG. Volkswagen AG d
agen
Moisten new O-ring -3- with coolant. olksw
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rise 1
Insert thermostat -4- into connection -2- andhoturn /4 turn (90) nte
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to right. s au ra
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The brace on the thermostat must be almost vertical.
wit
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Insert connection -2- with thermostat -4- in cylinder block.

spec
Tighten securing bolts -1- to 15 Nm.

t to the co
Fit connector -6- on radiator outlet coolant temperature sender
-G83- -5-.
rrectne

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Jetta 2005ho r , Bora 2006 , Golf Variant 2007 ntee
is
t or
4-cylinderau diesel engine with unit injector - Edition 05.2007 ac
ss
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un
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1.11 Checking cooling system for leaks
an
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equipment required
h re
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spec
Cooling system tester -
es, in part or in w
V.A.G 1274-
t to the co
Adapter for cooling system
-V.A.G 1274/8-
rrectness of i
l purpos
-V.A.G 1274/9-
nform
mercia
a
com
tion in
r
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thi
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Test prerequisites
Engine at operating temperature.
Test sequence:
WARNING

Open cap on coolant expansion tank.

Fit coolant system tester -V.A.G 1274- using adapter -

V.A.G 1274/8- on expansion tank.
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Use hand pump on tester to create a pressure of about 1.0 Vbar.
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If pressure drops: ed nte
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Find leaks and rectify. au ra
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nl
Checking pressure relief valve in filler cap
pt
du
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hole
spec
Fit coolant system tester -V.A.G 1274- onto sealing cap using es, in part or in w
t to the co
adapter -V.A.G 1274/9- .
Use hand pump on cooling system tester -V.A.G 1274- to cre
rrectness of i
ate a pressure of max. 1.4 bar.
l purpos
The pressure relief valve must not open.

If the pressure relief valve opens prematurely:
nf
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o
Renew sealing cap.
rm
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atio
m
Increase pressure by 1.4...1.6 bar.

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or c
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Pressure relief valve must open.
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If pressure relief valve does not open:

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Renew sealing cap. Cop
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1.12 Checking oil cooler for leaks

equipment required
Hose clamps up to 25
mm -3094-
Cooling system tester -
V.A.G 1274-
-V.A.G 1274/8-
5024A-
AG. Volkswagen AG d
Drip tray -V.A.G 1306- or lksw
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not
drip tray for workshop hoist d by Vo gu
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-VAS 6208- or
ise nte
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du
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ab
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for

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Not illustrated
Expansion tank -1K0 121 407 A or 6Q0 121 407 A or 1J0 121
407 B-
Plug -191 211 343-

Cap -1J0 121 324-

Coolant hose -251 265 056-
Test requirement: n AG. Volkswagen AG do
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Engine cold d byV ua
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Test procedure utho
or
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du
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Clamp supply and return lines off oil cooler using hose clamps
erm
ab
to 25 mm -3094- .
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Loosen hose clamps -arrows- using spring-type clip pliers -
h re
VAS 5024A- .
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Collect escaping coolant with drip tray - V.A.G 1306- or drip tray
-VAS 6208- .
l purpos
Pull coolant hoses off oil cooler.
nform
ercia
Slide sealing cap -5- to rear connection of oil cooler -4-.

m
at
om
ion
c
Secure sealing plug -2- to breather connection of expansion
in t
or
tank -1-.
his
ate
do
riv
Secure coolant hose -3- to oil cooler and expansion tank.

p
cum
for
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ng
t.
Fill expansion tank up to Max marking.
yi Co
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Attach cooling system tester -V.A.G 1274- with cooling system gh ht
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tester adapter -V.A.G 1274/8- to expansion tank. cop Vo
by lksw
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Use hand pump on tester to create a pressure of about 1.6 bar.
Watch pressure drop on pressure gauge. A pressure drop
within 10 minutes is not permitted.
If pressure drops:
Renew oil cooler page 106 .
Carry out installation in the reverse sequence, noting the follow
ing:
Check coolant level, if necessary replenish coolant
page 127 .

20 Fuel supply system

1 Safety precautions when working on
fuel supply system
WARNING n AG. Volkswagen AG do

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When doing any repair work, especially in the engine compartorise
ran
tee
auth or
ac
tions: ss
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du
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ab
ility
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hot components.
hole
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es, in part or in w
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nf
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orm
m
atio
The fuel pump is activated when switching on the ignition and by
om
n in
the driver's door contact switch. For safety reasons, the connector
or c
thi
-arrow- must be removed from the fuel delivery unit before open
te
sd
a
ing the fuel system, if the battery is not disconnected.

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When removing and installing fuel gauge sender or fuel pump
f
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t.
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(fuel delivery unit) from a full or partly full fuel tank, observe the
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Before beginning work, place an extraction hose close to
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sender opening in fuel tank to extract escaping fuel fumes and Prote AG.
switch on exhaust extraction system. If no exhaust extraction
system is available, a radial fan with a displacement greater
than 15 m3/h can be used providing that motor is not in air flow.
Prevent skin contact with fuel! Wear fuel-resistant gloves!
142 Rep. Gr.20 - Fuel supply system

2 Rules for cleanliness

When working on the fuel supply and injection systems, pay care
ful attention to the following 6 rules for cleanliness:
Thoroughly clean all unions and adjacent areas before dis
connecting.
Place removed parts on a clean surface and cover. Do not use
fluffy cloths!
Carefully cover opened components or seal if repairs cannot
be carried out immediately.
Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes, etc.).
When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec
essary.
Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
lkswage es n
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es, in part or in w
t to the co
rrectness of i
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or c
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2. Rules for cleanliness 143

AG. Volkswagen AG d
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3 Fuel tank, models with front-wheel d byV
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Note
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Hose connections are secured with either spring-type or
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clamp-type clips.
wit
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Always renew clamp-type clips with spring-type clips.
ole,
spec
Spring-type clip pliers -VAS 5024A- or hose clip pliers -V.A.G
t to the co
1921- are recommended for installation of spring-type clips.
rrectness o
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mer
atio
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. Volkswage
Jetta 2005 , Bora wage2006 , Golf Variant
n AG n AG d
oes 2007
olks not
4-cylinder diesel engine
d by V with unit injector - Edition 05.2007
gu
ar
e an
ris tee
ho
Observe safety precautions page 142 au
t or
ac
ss
Observe rules for cleanliness page 143
ce
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nl
pt
du
an
itte
Assembly overview - fuel tank page 145
y li
erm
ab
ility
Emptying fuel tank page 147
ot p
wit
, is n
Removing and installing fuel tank page 149
h re
hole
spec
Removing and installing fuel delivery unit page 152
es, in part or in w
t to the co
Removing and installing fuel gauge sender page 154
Checking fuel pump page 154
rrectness of i
3.1 Assembly overview - fuel tank
l purpos
1 - Cap
nform
ercia
2 - 1.5 Nm
m
at
om
ion
3 - Earth connection
c
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at
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ing.
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4 - 10 Nm
n
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5 - Cable guide
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6 - Fuel tank
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AG.
page 149 .
7 - 25 Nm
Renew.
8 - Clamping washer
9 - Securing strap
Note installation posi
tion.
10 - Heat shield
For fuel tank.
11 - Oil seal
Renew.
Moisten with fuel when
installing.
12 - Fuel delivery unit
With fuel gauge sender
-G -
tion in fuel tank
page 146
page 152 .
Checking fuel pump page 154 .
Removing and installing fuel gauge sender -G- page 154 .
13 - Locking ring, 110 Nm
Remove and install using fuel tank sender wrench -T10202-
14 - Supply line
To fuel filter Item 1 (page 158) .
3. Fuel tank, models with front-wheel drive 145

Clipped onto fuel tank.
Black.
To pull off, press release buttons on connecting piece AG. Volkswagen AG d
agen oes
lksw not
15 - Return line d by
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From fuel cooler horis
eo
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Blue or with blue marking ss a c
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Clipped onto fuel tank.
un
pt
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ab
To pull off, press release buttons on connecting piece
ility
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16 - Tank flap unit
h re
ole,
Removing and installing General body repairs, exterior; Rep. Gr. 55 ; Tank flap unit .
spec
t to the co
Installation position of fuel delivery unit:
rrectne
The tab -2- on the fuel delivery unit must lie between the tongues
-1- and -3-.
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f in
Note
form
mer
atio
The -arrow- points in direction of travel.
om
n
c
i
or
n
The fuel delivery unit can only be installed in this position.
thi
te
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3.2 Draining fuel tank

equipment required
Torque wrench -V.A.G AG. Volkswagen AG d
agen oes
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Fuel extractor unit -VAS hor eo
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5190- ss a ra
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Insert -T10202-
un
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spec
t to the co
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cial p
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mer
atio
om
n
c
i
or
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te
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Cop py
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Prote AG.
Note safety precautions before beginning work page 142

Emptying fuel tank if it is more than 3/4 full page 147
Empty fuel tank if it is less than 3/4 full page 148
3.2.1 Emptying fuel tank if it is more than 3/4

full
Caution
Secure earth wire of fuel extractor -VAS 5190- to a bare metal

part of the body.

Remove cotter -2- from shaft piece -1- of fuel extractor -

VAS 5190 - .
Use insulating tape to mark the extraction hose -arrow- at a
distance of -a- = 1,180 mm from the end of the hose.
Remove filler cap from fuel tank filler neck.

Screw shaft -1- of fuel extractor -VAS 5190- onto fuel tank filler
neck.
Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
Note
G. Volkswagen AG d
A ball valve -2- is located at the lower end of filler neck in fuel tank wage
nA oes
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-1-, which must not be damaged by the extraction hose -3-. by
V gu
ara
Therefore push hose into filler neck only as far as marking oris
ed nte
-arrow-. au
th eo
ra
ss c
ce
le
Empty fuel tank as far as possible.

un
pt
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d
itte
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Carefully pull out extraction hose.
erm
ab
ility
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wit
is n
Note
h re
ole,
spec
If no fuel is be sucked any more, the fuel tank is just sufficiently
t to the co
vacant to open the fuel delivery unit without danger.
If you have to empty the fuel tank completely page 148 . rrectnes
3.2.2 Emptying fuel tank if it is less than 3/4 full

s o
cial p
f inform
Remove seat bench General body repairs, interior; Rep.

mer
Gr. 72 ; Rear seat; Removing and installing seat bench .

atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
orise Jetta
nte2005 , Bora 2006 , Golf Variant 2007
h eo
aut 4-cylinder diesel r a engine with unit injector - Edition 05.2007
c
ss
ce
e
nl
Remove cover -1- from fuel delivery unit. The arrow -2- points
pt
du
an
in direction of travel.
itte
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erm
ab
ility
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WARNING
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
Remove connector -1-, the supply line -2- and the return pipe
om
ion
-3- from the fuel delivery unit. Press locking ring inwards to
c
in t
or
release fuel lines.
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
Open locking ring using fuel tank sender tool -T10202- .

Pull out the fuel delivery unit a bit.
Insert extraction hose of fuel extractor -VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If the fuel tank must only be emptied, install fuel delivery unit
again.
3.3 Removing and installing fuel tank

Removing
Fuel tank should be no more than1/4full.

Note
If necessary, empty fuel tank using fuel extractor -VAS 5190-

page 147 .
Note safety precautions before beginning work page 142 .
Observe rules for cleanliness page 143 .
Before carrying out further work, disconnect battery earth
strap. First check whether a coded radio is fitted. Obtain anti-
theft code first if necessary.
The fuel tank must be guided carefully when lowering to pre
vent damage.
If necessary, take the adapter for the rim lock out of the lug
gage compartment.
Open fuel flap and remove fuel tank cap.
With ignition switched off, disconnect battery earth wire
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
Unscrew tank flap unit securing bolt and remove tank flap unit
General body repairs, exterior; Rep. Gr. 55 ; Tank flap unit .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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le
un
pt
an
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erm
ab
ility
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is n
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ole,
Pull off connector -1-. spec

Remove right rear wheel.

t to the co
Remove rear right wheel housing liner General body re

pairs, exterior; Rep. Gr. 66 ; Wheel housing liner; Removing
rrectne
and installing rear wheel housing liner .

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Unscrew bolts -1- for fuel filler neck.

Unhook electrical wiring -2- of ABS speed sensor on filler neck
bracket.
Remove front silencer, separate front and rear silencer first, if
necessary page 259 .
Remove heat shield from fuel tank.
WARNING
Separate the black supply line and the blue return hose
-arrows- on front right of fuel tank.
Note
To do this, press buttons on hose couplings downwards.
In vehicles with additional heater, disconnect connector of the agen AG. Volkswagen AG do
metering pump and unclip cable Additional heater; Rep.VGr.olks
w es n
ot g
82 ; Fuel supply system of additional heaters ThermoseTop
d by
V; ua
ran
Removing and installing metering pump -V54- . thori tee
o
au ra
c
ss
ce
e
nl
pt
Note
du
an
itte
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erm
ab
Press locking ring inwards to release fuel lines.
ility
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wit
A second mechanic is required to assist when supporting the
, is n
h re
fuel tank.
hole
spec
es, in part or in w
t to the co
Remove tensioning strap and securing bolts -arrows-.
Slowly lower fuel tank. rrectness of i
Remove fuel tank from side.

l purpos
Installing
Installation is performed in the reverse sequence. In the process,
nf
ercia
note the following:

rm
m
atio
m
Fuel lines are to be installed free of kinks.

o
n in
or c
thi
Do not interchange supply and return lines (return line blue,

te
sd
a
supply line black).

iv
o
r
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cu
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m
f
Ensure that fuel line connections are tight.

en
ng
t.
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op
Check earth connection on fuel tank and body to filler neck.
C py
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rig ht
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After installing fuel tank, check that the supply and return lines co Vo
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are still clipped onto the fuel tank.
agen
Prote AG.

3.4 Removing agand

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Volkswagen AGfuel delivery
does
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is nte
or
Special tools
au and workshop equipment required
th eo
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ss c
Fuel tank sender unit tool -T10202-
ce
e
nl
pt
du
an
itte
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erm
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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ion
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Cop py
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rig ht
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Prote AG.
Removing page 152

Installing page 153
3.4.1 Removing
Fuel tank should be no more than3/4full.
Note
If necessary, empty fuel tank using fuel extractor -VAS 5190-

page 147 .
First check whether a coded radio is fitted. If so, obtain anti-

theft coding.
With ignition switched off, disconnect battery earth wire
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .

WARNING
Remove the connector -1-, the black supply line -2- and the
blue return pipe -3- from the fuel delivery unit. Press locking
ring inwards to release fuel lines.
Open locking ring using wrench -T10202- .

Pull fuel delivery unit and seal out of opening in fuel tank.
en AG. V
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Note tho
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When removing fuel delivery unit, ensure that fuel gauge
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nl
sender is not bent.

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du
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itte
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If the fuel delivery unit is to be renewed, drain old fuel delivery

erm
ab
unit before disposal.

ility
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, is n
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hole
spec
es, in part or in w
3.4.2 Installing
t to the co
Installation of fuel delivery unit is carried out in reverse order. In

the process, note the following:
rrectness of i
l purpos
nform
mercia
at
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ion
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Cop py
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pyri by
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cted agen
Prote AG.

Insert new fuel delivery unit seal dry into fuel tank opening.
Moisten inner edges of seal with fuel only when installing fuel
delivery unit.
When inserting fuel delivery unit, ensure that fuel gauge send
er is not bent.
Check installation position of the fuel delivery unit: Tab -2- on
the fuel delivery unit must be between cogs -1- and -3-. The
-arrow- points in direction of travel.
Tighten lock ring to 110 Nm.
Do not interchange the black supply line and the blue return
line (arrows on the flange of the fuel delivery unit).
Ensure that fuel lines are tight.
After installing the fuel delivery unit, check that the supply and
return lines are still clipped onto the fuel tank.
Follow procedure after reconnecting battery Electrical sys
tem; Rep. Gr. 27 ; Disconnecting and reconnecting battery .
3.5 Removing and installing fuel gauge

sender
Removing
Remove fuel delivery unit page 152 .
Release and remove line connectors -13-.
Lift up retaining lugs -4- and -5- using a screwdriver and pull
fuel delivery unit off downwards -arrows-.
Installing
Insert fuel gauge sender -G- into guides on fuel delivery unit
and press upwards until it engages. wage
es ks not
Vol gu
Reconnect connector and check that it has engagededcorrectly.
by ara
nte
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un
pt
an
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itte
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erm
ab
ility
ot p
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is n
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ole,
spec
t to the co
3.6 Checking fuel pump

rrectne

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

Voltage tester -V.A.G 1527 B-
AG. Volkswagen AG d
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
Auxiliary measuring set -V.A.G 1594C-
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
Vehicle diagnosis, testing and information system -VAS

i
o
pr
cum
5051B-
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Test prerequisites
Fuses must be OK.
The battery voltage must be at least 11.5 V.
All electrical consumers, e.g. lights and rear window heating,
must be switched off.
Checking function and voltage supply page 155
Check the current draw of the fuel pump page 156
3.6.1 Checking function and voltage supply

Switch on ignition.
Fuel pump must be heard to run briefly.
Note
The fuel pump runs very quietly.

Switch off ignition.

If fuel pump does not run:
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
Pull off connector -1-. ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Connect voltage tester -V.A.G 1527 B- to outer contacts of

connector using auxiliary cables from auxiliary measuring set
nform
ercia
-V.A.G 1594C- .
m
at
Switch ignition on.

om
ion
c
in t
r
The LED must light up briefly.

o
his
ate
do
riv
LED does not light up briefly:

p
cum
for
en
Locate and eliminate open circuit using current flow diagram

ng
t.
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Current flow diagrams, Electrical fault finding and Fitting lo Cop py
cations.
t. rig
gh ht
pyri by
Vo
co
LED lights up briefly (voltage supply OK.):
by lksw
cted agen
Prote AG.
Remove fuel delivery unit page 152 .
Check that the electrical wires between flange and fuel pump
are connected and for continuity.
If no open circuit can be found
Renew fuel delivery unit page 152 .
3.6.2 Checking current consumption of fuel

pump

Connect the current clamp -A- of the Vehicle diagnosis, testing

and information system -VAS 5051B - to the cableagen -B- to con AG does
AG. Volkswagen
tact 1 of the 5-pin connector. yV
olksw not
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ed ran
Start engine and run at idling speed.
ho
ris tee
t or
au ac
Measure current draw of fuel pump.
ss Specification: max. 7.5
Ampere.
ce
le
un
pt
an
d
itte
If the values measured lie outside the specifications
y li
rm
ab
pe
ility
Renew fuel delivery unit page 152 .
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4 Repairing fuel supply system

Assembly overview - fuel filter page 158
Removing and installing fuel cooler page 159
Check tandem pump page 160
Removing and installing tandem pump page 166
4.1 Assembly overview - fuel filter
1 - Supply line
From fuel tank
Item 14 (page 145) .
White or with white
marking.
ing.
2 - 8 Nm
3 - Return line
To fuel cooler
ing.
Blue or with blue mark
ing
4 - Sealing plug for water evac
uation, 4 Nm
Remove and evacuate
approx. 100 cm3 liquid
using diesel extractor -
VAS 5226- or hand-op
erated vacuum pump AG. Volkswagen AG d
with accessories -V.A.G agen oes
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1390- and water drain ed by
V gu
ara
age container -V.A.G horis nte
eo
1390/1- s aut ra
c
s
5 - Oil seal
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du
an
Renew.
itte
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erm
ab
6 - Return line
ility
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From tandem pump.

, is n
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Blue marking
hole
spec

es, in part or in w
t to the co
ing.
7 - Upper part of fuel filter
rrectness of i
8 - Fuel temperature sender -G81-

l purpos
9 - Oil seal
Renew.
nf
ercia
10 - Filter insert
rm
m
atio
m
Observe change intervals.

o
n in
or c
11 - Oil seal
thi
te
sd
iva
Renew.
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Cop py
t. rig
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pyri by
Vo
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cted
158
agen
Prote AG.
Rep. Gr.20 - Fuel supply system
12 - Lower part of fuel filter

13 - 8 Nm
14 - Retainer
15 - Oil seal
Renew.
16 - Securing clip
17 - Supply line
With pipe union for fuel temperature sender -G81-
18 - To tandem pump
4.2 Removing and installing fuel cooler

AG. Volkswagen AG d
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erm
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ility
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ole,
Drip tray for workshop hoist -VAS 6208 -

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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Removing page 159

um
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fo
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ng
t.
Installing page 160
yi Co
Cop py
ht. rig
4.2.1 Removing
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
The fuel cooler is located in the return line to fuel tank. It is located
on the vehicle underbody.
4. Repairing fuel supply system 159

Remove right underbody panel -arrows-.

Place drip tray for workshop crane under the vehicle.
WARNING
The fuel system is also under pressure! Then release
pressure by carefully loosening the connection.
Separate fuel lines at fuel cooler.
Unscrew securing nuts -arrows-.
AG. Volkswagen AG d
agen oes
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ab
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ility
ot
wit
, is n
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spec
4.2.2 Installing
es, in part or in w
t to the co

Tighten fuel cooler securing nuts to 15 Nm.
rrectness of i
4.3 Checking tandem pump

l purpos
Checking delivery pressure page 160

nform
ercia
Checking for internal leaks page 163

m
a
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tio
4.3.1 Checking delivery pressure

n in
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s

iva
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fo
Tandem pump tester -VAS 5187 -

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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cted agen
Prote AG.

olkswagen AG
Torque wrench (5..0.50 Nm) en AG. V 1331
ag-V.A.G - does
lksw n o ot g
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du
an
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erm
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ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
5051B-
l purpos
Diagnosis cable -VAS 5051/6A-

Test prerequisites
nform
ercia
Coolant temperature must be at least 85C.

m
at
om
i
Unit injectors OK
on
c
in t
or
Fuel filter and fuel lines must not be blocked.
his
ate
do
priv
The non-return valve in the fuel supply hose must be OK.
cum
for
en
ng
t.
Procedure
yi Co
Cop py
t. rig
Remove engine cover. To do this, pull engine cover upwards gh ht
yri by
abruptly at front -arrows A- and then pull forwards out of rear cop Vo
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agen
Prote AG.

pipe.



Pull intake manifold -5- off the air duct. agen
AG. Volkswagen AG d
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V
Unscrew bolt -4- and take off air efilter
d b housing.
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ara
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Continuation for all models auth eo
ra
ss c
ce
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nl
pt
WARNING
du
an
itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Remove screw plug -arrow-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Connect tandem pump tester -VAS 5187- as shown.

Install air cleaner housing with air mass meter and connecting
pipe.
Start engine and run at idling speed.
Connect Vehicle diagnosis, testing and information system -
VAS 5051B- and select operating mode Vehicle self-diagno
sis.
Press button 01 - Engine electronics on display.
Press diagnosis function 08-Read measured value block.
Enter display group 1 using number block (key pad) and
confirm entry with Q button.
Read engine idling speed in display zone 1.
Increase engine speed to 4000 rpm.
Observe pressure indicated on pressure gauge.
Specification: min. 7.5 bar
If the specification is not attained:
Using a hose clamp, clamp-off return line between fuel filter gen AG. Volkswagen AG d
and tandem pump. Vol
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a oes
not
by gu
ara
Increase engine speed to 4000 rpm. ed nte
oris eo
th
Observe pressure indicated on pressure gauge.au ra
c
ss
ce
le
Specification: min. 7.5 bar

un
pt
an
d
itte
y li
If specification is now obtained:
rm
ab
pe
ility
Pressure loss at unit injectors.
ot
wit
, is n
h re
Renew O-rings on unit injectors page 219 .
hole
spec
If the specification is not attained:
es, in part or in w
t to the co
Renew tandem pump page 166 .
rrectness of i
Note
l purpos
After removing pressure gauge, tighten plug to 25 Nm. Always

renew seal.
nform
mercia
a
com
tio
4.3.2 Checking for internal leaks

n in
r
te o
thi
s
iva
do
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rp
cum
Note
fo
en
ng
t.
yi Co
op
The tandem pump must be checked for internal leaks between
C py
t. rig
gh
fuel side and oil side after reinstalling a used tandem pump, for
ht
pyri by
Vo
o
example after renewing or repairing a cylinder head and/or when
c by lksw
cted agen
installing a "short" engine. When leaking it is possible for the fuel Prote AG.
to mix with the oil, which may cause the engine to fail.

Charge air system tester -V.A.G 1687-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Procedure
spec
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos

nform
ercia

m
at
om
io
n
c
in t
or
his
ate
do
riv
Pull fuel supply hose (white marking) Item 26 (page 59) and
p
cum
for
fuel return hose (blue marking) Item 27 (page 59) off tandem
en
ng
t.
yi
pump.
Co
Cop py
t. rig
gh
Seal fuel return union on tandem pump with a plug. Secure
ht
pyri by
Vo
o
sealing plug with a spring-type clip.
c by lksw
cted agen
Prote AG.
Prepare this as follows:
Unscrew pressure regulating valve -2- and close valves -3-
and -4-.
Connect test connection -5- charge air system tester -V.A.G
1687- to fuel supply union of tandem pump using a commer
cially available compressed air connection and a section of
fuel hose. Use a spring-type clip to secure.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.

Connect compressed air hose -1- (compressed air source) to

charge air system tester -V.A.G 1687 - .
Note
If there is water in the sight glass, drain at water drain screw -6-.
Open valve -3-.

Adjust pressure to 1.0 bar with pressure regulating valve -2-.
Caution
The maximum test pressure is 1.3 bar and this must not be
exceeded.
Open valve -4- and wait until the test circuit is filled. If neces
sary readjust pressure to 1.0 bar.
Close valve -3- to retain pressure and observe the pressure
drop over a period of 1 minute.
If the pressure does not drop the tandem pump can be reused, if
the pressure drops the tandem .pump must be renewed.
Volkswage n AG n AG d
wage oes
Volks not
gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4.4 Removing and installing tandem pump

equipment required
1331-
Diesel extractor -VAS
5226- or
Hand-operated vacuum
pump with accessories -
V.A.G 1390- and
Water drainage container -
V.A.G 1390/1-
5024A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Removing page 166

m
at
om
io
Installing page 168

n
c
in t
or
his
4.4.1 Removing
ate
do
priv
cum
or

f
en
ng

t.
yi Co
op
fastening -arrow B-. C py
t. rig
gh ht
yri by
Vehicles with engine codes BKC, BXE cop Vo
by lksw
cted agen
Prote
AG.
pipe.

AG. Volkswagen A4-cylinder diesel engine with unit injector - Edition 05.2007
agen G do
es n
olksw ot g
y V ua
Disconnect ris
econnector
db -2- on air mass meter -G70- ran.
tee
tho
or
Pull breather
au hose -1- and air duct hoses -3- and -5- off. ac
ss
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
m
at
om
ion
c
in t
r

o
his
ate
do
riv

p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Carefully cut through cable tie -1-. Prote
cted AG.
agen
Open wiring retainer -2- and unhook wiring harness.
oil sump.
WARNING
Pull supply hose (white marking) and return hose (blue mark
ing) off fuel lines.

Connect diesel extractor -VAS 5226 - or hand-operated vac

container -V.A.G 1390/1- to return hose -2-.
Operate diesel extractor -VAS 5226 - or hand-operated vac
uum pump -V.A.G 1390- until no more fuel comes out of return
hose. Be careful that no fuel is sucked into hand-operated
vacuum pump.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
Pull vacuum line from brake servo -1- off tandem pump -4-. nl
pt
du
an
itte
y li
Pull supply hose -2- (white marking) and return hose -3- (blue
erm
ab
marking) off tandem pump -4-.
ility
ot p
wit
, is n
Unbolt securing bolts -arrow-.
h re
hole
spec
Remove tandem pump -4- from cylinder head.
es, in part or in w
t to the co
rrectness of i
l purpos
4.4.2 Installing
nform
mercia
at
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
g
Ensure that tandem pump coupling seats properly in cam

n
t.
yi Co
op
shaft. C py
t. rig
gh ht
yri
Always renew tandem pump seals.
p by
co Vo
by lksw
cted agen
Prote AG.
Install tandem pump and tighten top securing bolts to 20 Nm.
Tighten bottom securing bolts to 10 Nm.
Attach return hose (blue marking) to return connection -3- of
tandem pump.
Connect supply line (white marking) to the supply connection
-2- and the vacuum line of brake servo -1- to the tandem pump
-4-.
Connect supply hose (white marking) to the fuel filter.


container -V.A.G 1390/1- to return hose -2-.
Operate diesel extractor -VAS 5226 - or hand-operated vac
uum pump -V.A.G 1390- until fuel comes out of return hose.
Be careful that no fuel is sucked into hand-operated vacuum
pump.
Attach return hose (blue marking) to fuel filter.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5 Electronic power control (EPC)

Function of EPC system page 170
Assembly overview - accelerator pedal module page 171
Removing and installing accelerator pedal module page 171
5.1 Function of EPC system

With the EPC system, the throttle valve is not operated by a cable.
There is no mechanical connection between the accelerator pedal
and the throttle valve.
The position of the accelerator pedal is transmitted to the engine
control unit by two accelerator pedal position senders (variable
resistors together in one housing) connected to the accelerator
pedal.
The position of the accelerator pedal (driver's requirement) is a
main input value for the engine control unit.
The throttle valve is actuated by a servomotor (throttle valve po
sitioner) in the throttle valve control part over the full range of wagen AG. Volkswagen AG doe
engine speeds and load conditions. yV
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b ara
ed
The throttle valve is operated by the throttle valve positioner,
ris nte
tho e
which is controlled by the engine control unit. sa
u or
ac
s
When the engine is not running and the ignition is switched on,
ce
le
un
pt
the engine control unit moves the throttle valve exactly as pre
an
d
itte
y li
scribed by the accelerator pedal position sender. That is, when
rm
ab
the accelerator is depressed halfway, the throttle valve positioner
pe
ility
opens the throttle valve by the same amount. The throttle is then
ot
wit
, is n
approximately half open.
h re
hole
spec
When the engine is running (under load), the engine control unit
es, in part or in w
can open or close the throttle valve independently of the accel
t to the co
erator pedal position sender.
This means that the throttle valve can already be completely open
rrectness of i
even though the accelerator pedal is only depressed half way.
This has the advantage of preventing throttling losses at the throt
l purpos
tle valve.
After evaluating the torque requirements of various components
nform
ercia
(e.g. air conditioning system, automatic gearbox, ABS/ESP...),

the engine control unit calculates the optimal throttle valve open
m
a
com
ti
ing angle for the respective situation.

on in
r
te o
thi
This also results in significantly improved consumption and ex

s
iva
haust emission values under certain load conditions.

do
r
rp
cum
fo
EPC is a system comprising all components which contribute to

en
ng
t.
yi
determining, controlling or monitoring the position of the throttle
Co
op py
valve, e.g. accelerator pedal position sender, the throttle valve
t. C rig
gh ht
yri
control module, the EPC warning lamp, the engine control unit p by
co Vo
and so on.
by lksw
cted agen
Prote AG.

5.2 Assembly overview - accelerator pedal module
1 - Connector
Black, 6-pin AG. Volkswagen AG d
agen oes
olksw not
yV gu
2 - Accelerator spedal
ed b position ara
nte
sender -G79- hoand
ri
accelerator eo
ut
pedal position
ss a sender 2 -G185- ra
c
Not adjustable
ce
e
nl
pt
du
an
The accelerator position
itte
y li
sender passes the posi
erm
ab
tion of the accelerator
ility
ot p
on to the engine control
wit
, is n
h re
unit.
hole
spec
-A- Openings for re
es, in part or in w
lease tool -T10238- or
t to the co
release tool - T10240-
page 171 .
rrectness of i
3 - 10 Nm
l purpos
4 - Cap
nf
ercia
orm
m
atio
om
n in
or c
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sd
iva
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f
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ng
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5.3 Removing and installing accelerator

pedal module
Release tool -T10238- or release tool -T10240-
5. Electronic power control (EPC) 171

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Jetta 2005 , Bora 2006 ho, Golf Variant 2007
ris nte
eo
t
s au unit injector - Edition 05.2007 ra
c
s
ce
le
un
pt
Removing
an
d
itte
y li
Remove steering column cover -arrows-.
erm
ab
ility
ot p
Lever out cap Item 4 (page 171) using a screwdriver.
wit
is n
h re
ole,
Remove securing bolt Item 3 (page 171) .
spec
Release accelerator pedal module
t to the co
rrectness o
cial p
f inform
mer
Push release tool -T10238 - (for right-hand drive vehicles re
atio
m
lease tool -T10240- ) into intended holes as shown to stop and

o
n
c
i
or
n
remove accelerator pedal module.
thi
te
sd
va
Separate electrical connection and pull wiring guide off accel

i
o
pr
cum
erator pedal module.
r
fo
en
ng
t.
yi Co
Installing . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Fit connector -2- to the accelerator pedal module -5- and slide
the rubber grommet -1- onto the connector again.
Press accelerator pedal module onto securing pins -6-.
Insert centring pin -7- into hole in floor of vehicle.
Secure accelerator pedal module with the bolt -3- and fit cover
cap -4-.
Install steering column trim.
If the accelerator pedal module has been renewed, adapt the
accelerator pedal module to the engine control unit Vehicle
diagnosis, testing and information system -VAS 5051B- Gui
ded functions.
If the accelerator pedal module has been renewed on vehicles
with automatic gearbox or direct shift gearbox, the kick-down
function must be programmed Vehicle diagnosis, testing
and information system -VAS 5051B- Guided functions.
Tightening torque:
Component Nm
Accelerator pedal module to body 10

21 Turbocharging/supercharging
1 Charge air system with turbocharger
AG. Volkswagen AG d
Observe safety precautions page 173 agen oes
olksw not
V gu
by ara
Observe rules for cleanliness page 173 rised
nte
ho eo
ut
Charge air system with turbocharger,
ss a engine codes BKC, BXE ra
c
page 175
ce
e
nl
pt
du
an
Charge air system with turbocharger, engine codes BLS, BRM
itte
y li
page 185
erm
ab
ility
ot p
Hose connections page 200
wit
, is n
h re
Removing and installing charge air cooler page 202
hole
spec
es, in part or in w
Checking charge air system for leaks page 204
t to the co
1.1 Safety precautions
rrectness of i
Caution
l purpos

nform
ercia
tions:
m
at
om
i
Route all the various lines (e.g. for fuel, hydraulics, cool
on
c
in t
ant, refrigerant, brake fluid and vacuum) and electrical
or
his
e
wiring in their original positions.

at
do
priv
c
um
for
en
g
hot components.
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
Observe following if test and measuring instruments are required
o
by c lksw
cted agen
during a road test: Prote AG.
WARNING
Test and measuring instruments must be secured to rear

seat and operated by a second person from this location.
If test and measuring instruments are operated from front
passenger seat and the vehicle is involved in an accident,
there is a possibility that the person sitting in this seat will
receive serious injuries when the airbag is triggered.
1.2 Rules for cleanliness

When working on the turbocharger, pay careful attention to the
following rules of cleanliness:
Thoroughly clean all joints and surrounding areas before dis
mantling.
Place parts that have been removed on a clean surface and
cover. Use lint-free cloths only!
tool boxes, etc.).
1. Charge air system with turbocharger 173

Existing transport and protective packaging and sealing caps

must only be removed immediately prior to installation.
When making repairs, remove oil from connection and hose
ends.
essary.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
174 Rep. Gr.21 - Turbocharging/supercharging

2 Charge air system with turbocharger,

engine codes BKC, BXE
Observe safety precautions page 173
Hose connections page 200
Turbocharger - Assembly overview, engine codes BKC, BXE
page 175
Removing and installing turbocharger, engine codes BKC, BXE
page 177
Parts of charge air cooling - Assembly overview, engine codes
BKC, BXE page 183
Removing and installing charge air cooler page 202
en AG 204 . Volkswagen AG
Checking charge air system for leaks
ksw
agpage does
not
Vol gu
by
2.1 Turbocharger - Assembly overview, en
ara
ed nte
oris eo
gine codes BKC, BXE
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
All hose connections are secured.
wit
, is n
h re
Charge air system must be free of leaks.
hole
spec
Renew self-locking nuts.
es, in part or in w
t to the co
Before screwing on oil supply line, fill turbocharger at connec
tion with engine oil.
rrectness of i
After installing turbocharger, run engine for about 1 minute at
idling speed to insure that oil is supplied to turbocharger.
l purpos
Observe safety precautions page 173 .

nf
ercia
orm

m
atio
om
n in
or c
thi
te
sd
iva
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cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Charge air system with turbocharger, engine codes BKC, BXE 175
1 - 10 Nm
3 - Oil supply line
Before installing oil sup
ply line, ensure that it is
not blocked.
Before installing, fill tur
bocharger with engine
oil through oil supply line
connection.
page 114 .
5 - Seal
Renew.
tion.
6 - Washer
7 - 25 Nm
Renew.
8 - Support
Between turbocharger
and cylinder block
9 - 40 Nm
First hand tighten all
bolts.
10 - Connecting pipe AG. Volkswagen AG d
agen oes
Air filter/turbocharger olksw not
V gu
d by ara
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11 - Connector horis
eo
aut ra
12 - Seal ss c
ce
e
nl
Renew.
pt
du
an
itte
y li
13 - Oil seal
erm
ab
ility
ot p
Renew.
wit
, is n
h re
hole
spec
15 - Oil return line

es, in part or in w
t to the co
To cylinder block.
Tighten union nut to 30 Nm
rrectness of i
16 - 17 Nm
l purpos
17 - Vacuum hose
To solenoid valve block.
nf
ercia
18 - Turbocharger
rm
m
atio
Can only be renewed with exhaust manifold.

om
n in
c
To remove turbocharger take right-hand drive shaft off Running gear, axles, steering; Rep. Gr. 40 ;
or
thi
e
Servicing drive shaft; Removing and installing drive shafts .

t
sd
iva
o
r
rp
cu
19 - 20 Nm
o
m
f
en
ng
First hand tighten all bolts.

t.
yi Co
Cop py
t. rig
20 - 20 Nm opyri
gh by
Vo
ht
Renew. by c lksw
cted agen
Prote AG.

21 - Heat shield
22 - Seal
Renew.
23 - Clamp, 7 Nm
24 - Front exhaust pipe
25 - Retainer
For oil supply line Item 3 (page 176) .
Before installing, secure oil supply pipe.
26 - 22 Nm
Renew.
27 - Connecting pipe
To bypass flap.
Renew.
Coat threads and bolt head contact surface with hot bolt paste -G 052 112 A3- .
2.2 Removing and installing turbocharger,

engine codes BKC, BXE
gen AG
. Voequipment
lkswagen AG required
a does
lksw not
Torque dwrench
by
Vo -V.A.G 1331- gu
ara
e nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Spring-type clip pliers -VAS 5024A-

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
. Volkswagen AG
gen AG does
Jetta 2005 , Bora 2006 , Golf Variant 2007 olks
wa not
yV gu
ise
d b ara
nte
r
ho eo
aut ra
ss c
Caution
ce
e
nl
pt
du
an
itte
y li
If mechanical damage is found on the turbocharger, e.g. a bro
erm
ab
ken compressor wheel, it is not sufficient to replace the turbo
ility
ot p
charger. To prevent further damage, carry out the following
wit
, is n
repairs:
h re
hole
spec
Check air cleaner housing, air filter insert and intake hoses
es, in part or in w
for dirt.
t to the co
Check entire charge air duct and charge air cooler for for
eign bodies.
rrectness of i
If foreign bodies are found in the charge air system, the charge
l purpos
air duct must be cleaned and the charge air cooler renewed if
necessary.
nform
mercia
Removing page 178
at
om
ion
c
Installing page 182
in t
or
his
ate
2.2.1 Removing
do
priv
cum
for
en
g

n
t.
yi Co
op
abruptly at front -arrows A- and then pull forwards out of rear C py
t. rig
fastening -arrow B-. gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Disconnect connector -1- on oil pressure switch -F1- .

Remove oil pressure switch -2-.
Remove oil supply pipe on retainer -3-.

Note
The hoses -1- up to -3- remain connected.
Place hoses -1- up to -3- on air duct pipe to side.

Remove air pipe. To do this lift retaining clips -arrow- lightly.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
V157- .
wit
, is n
h re
Remove bolts -1 3- and take intake manifold flap motor -
hole
spec
V157- off.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
Disconnect vacuum hose -3- on exhaust gas recirculation

ion
c
valve -N18- .
in t
or
his
ate
Pull pipe to crankcase breather -4- off air duct pipe.

do
priv
cum
or
Loosen spring-type clip -1- on turbocharger using spring-type

f
en
ng
t.
yi
clip pliers -VAS 5024A- .
Co
Cop py
t. rig
Remove bolts -2- and -5- and take air duct pipe off.
gh ht
pyri by
Vo
o
by c lksw
Free vacuum hoses -arrow-. cted agen
Prote AG.
Separate hose to vacuum unit for charge pressure control on

separating point -arrow-.
Remove bolts -1 3- and remove right-hand sound insula

tion.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Remove bolts -1- and -2-.
es, in part or in w
t to the co
Remove right air duct pipe. To do this lift retaining clips
-arrow- lightly.
Take right-hand drive shaft off gearbox flange Running
rrectness of i
gear, axles, steering; Rep. Gr. 40 ; Servicing drive shaft; Re
l purpos
moving and installing drive shafts .

nform
mercia
at
Note
om
ion
c
in t
or
his
e
Do not remove bolt -1-.

at
do
priv
cum
for
en
ng
Remove bolts -2- and -3- on pendulum support.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Remove air hose from turbocharger. To do this lift retaining

clip -arrow- lightly.

Remove oil return pipe -3- at cylinder block.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
Remove oil supply pipe on exhaust manifold -arrows- and
ce
e
nl
pt
place to side.
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Remove connecting pipe for exhaust gas recirculation

-arrows-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Remove heat shield from exhaust manifold -arrows-.
Remove nuts -arrows-.

Press engine forwards (second mechanic) and take exhaust
manifold/turbocharger between subframe and body out.
2.2.2 Installing
Note
Renew seals, gaskets and self-locking nuts.

Fill turbocharger with engine oil at connection for oil supply
line. agen
AG. Volkswagen AG d
oes
olksw not
Hose connections and hoses for charge air system must d by Vbe gu
ara
free of oil and grease before assembly. horise nte
eo
ut ra
Hoses must be locked with clamps Electronic
ss a
parts cata c
logue ETKA .
ce
le
un
pt
an
d
itte
y li
Install exhaust system and align free of stress page 248 .
rm
ab
pe
ility
When installing air pipes with plug-in connectors, ensure that
ot
wit
, is n
h re
-A-.
hole
spec
es, in part or in w
Torque settings page 175 .
t to the co
Observe installation sequence of the oil supply pipe
page 114 .
rrectness of i
Install pendulum support page 23
l purpos
Check engine oil level page 97 . nform

ercia
Note
m
a
com
tion in

r
te o
thi
idling speed and do not rev up immediately, this ensures that the
s
iva
do
turbocharger is supplied with oil.

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.3 Parts of charge air cooling - Assembly

overview, engine codes BKC, BXE
Note

For assembly use lubricant (water without additive) if neces
sary. Do not use lubricants containing oil.
ends.
All charge air system hose connections are secured by spring-
type clips or by connector couplings.
1 - 8 Nm
Location page 184
2 - Retainer
tion.
3 - Charge air cooler lkswage es n
o ot g
byV ua
4 - Seal ir se
d ran
tee
tho
or
5 - O-ring au ac
ss
Renew if damaged.
ce
le
un
pt
an
d
6 - Connecting hose
itte
y li
erm
ab
7 - 8 Nm
ility
ot p
wit
is n
8 - Connecting pipe
h re
ole,
spec
9 - Silencer
t to the co
10 - From turbocharger
11 - From air filter
rrectne
12 - Connector
13 - Hose clip ss o
cial p
14 - To intake manifold
inform
mer
15 - To turbocharger
atio
om
16 - Vacuum reservoir
n
c
i
or
n thi
e
17 - Sleeve
t
sd
iva
o
pr
cum
18 - Grommet
r
fo
en
ng
t.
yi
19 - 15 Nm
Co
Cop py
t. rig
gh
20 - Oil seal
ht
pyri by
Vo
co lksw
by
Renew if damaged. Prote
cted AG.
agen
21 - Charge air pressure send

er -G31- with intake air temperature sender -G42-
22 - 3 Nm
Securing bolts for charge air cooler

To loosen and tighten the securing bolts -arrow- remove bumper
cover General body repairs, exterior;; Rep. Gr. 63 ; Front
bumper .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
184
cted agen
Prote
Rep. Gr.21 - Turbocharging/supercharging
AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
is Jetta 2005 , Bora 2006 , Golf Variant nte
hor e o2007
ut
4-cylinder
ss a diesel engine with unit injector - Edition 05.2007
ra
c
ce
le
un
pt
an
d
3 Charge air system with turbocharger,
itte
y li
erm
ab
engine codes BLS, BRM
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Hoses with quick release coupling page 200
Turbocharger - Assembly overview, engine codes BLS (without
rrectne
diesel particulate filter), BRM page 185
Removing and installing turbocharger, engine codes BLS (without
ss
diesel particulate filter), BRM page 188
o
cial p
f in
Turbocharger - Assembly overview, engine code BLS (with diesel
form
mer
particulate filter) page 195
atio
om
Removing and installing turbocharger, engine code BLS (with
n
c
i
or
n
diesel particulate filter) page 196
thi
te
sd
iva
o
Parts of charge air cooling - Assembly overview, engine codes
pr
cum
r
fo
BLS, BRM page 198
en
ng
t.
yi Co
op
Removing and installing charge air cooler page 202 C py
t. rig
gh ht
yri
p by
o Vo
by c lksw
cted agen
Prote
AG.
gine codes BLS (without diesel particu

late filter), BRM
Note

Before screwing on oil supply line, fill turbocharger at connec
tion with engine oil.
Observe safety precautions page 173 .

3. Charge air system with turbocharger, engine codes BLS, BRM 185
2 - 10 Nm
3 - Oil supply line
Before installing oil sup
ply line, ensure that it is
not blocked.
connection.
page 114 .
Renew.
Coat threads and bolt
head contact surface AG. Volkswagen AG d
with hot bolt paste -G lksw
agen oes
not
052 112 A3- . d by Vo gu
ara
rise nte
5 - Oil seal utho eo
ra
a
Renew. ss c
ce
le
un
pt
6 - Connector
an
d
itte
y li
For loading shovel posi
rm
ab
pe
tion sender -G500-
ility
ot
wit
Applies only to engine:
, is n
h re
BRM
hole
spec
7 - Heat shield
es, in part or in w
t to the co
With retainer for lambda
probe wiring harness
rrectness of i
8 - Seal
Renew.
l purpos

tion.
nform
ercia
9 - Clamp, 7 Nm
m
a
com
tio

n in
r
te o
thi
11 - 25 Nm
s
iva
do
r
rp
cum
12 - 25 Nm
fo
en
ng
t.
yi
Renew.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co
To exhaust gas recirculation cooler.
by lksw
cted agen
Prote AG.
14 - Seal
Renew.
15 - Seal
Renew.
16 - Turbocharger
Can only be renewed completely with exhaust manifold and loading shovel position sender -G500-
17 - Banjo bolt, 60 Nm
Renew.
18 - O-ring
Renew.

Before installing apply a thin coat of clean engine oil.
19 - Oil return line
To cylinder block. agen
AG. Volkswagen AG d
oes
lksw not
by Vo complete gu
a d ran
ise
20 - O-ring ut
ho
r tee
or
a ac
Separate and
ss renew oil return line only when leaking
ce
e
nl
Before installing apply a thin coat of clean engine oil.
pt
du
an
itte
y li
21 - Air duct
erm
ab
ility
To air filter
ot p
wit
, is n
For hot air intake.
h re
hole
For cold country equipment only
spec
es, in part or in w
Installed instead of the shield Item 22 (page 187)
t to the co
22 - Heat shield
rrectness of i
24 - Hose clip
l purpos
25 - Connecting hose
nform
ercia
26 - 8 Nm
m
at
Renew.
om
ion
c
in t
r
27 - Vacuum hose
o
his
ate
do
riv
28 - 4 Nm
p
cum
for
29 - O-ring
en
ng
t.
yi Co
op
Renew. C py
t. rig
gh ht
yri by
30 - Turbocharger guide vane position sender -G500- cop Vo
by lksw
cted agen
Applies only to engine: BRM Prote AG.
3.2 Removing and installing turbocharger, engine codes BLS (without diesel
particulate filter), BRM

equipment required
Hose clamps to 25 mm
-3094-
Torque wrench -
V.A.G 1331-
Torque wrench -
V.A.G 1410-
5024A-
-VAS 6208 -
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caution

charger. To prevent further damage, carry out the following agen
AG. Volkswagen AG d
repairs:
oes
olksw not
V g y ua
db ran
Check air cleaner housing, air filter insert and intakehhoses
or
ise tee
for dirt. au
t or
ac
ss
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Removing page 189
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Installing page 193
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3.2.1 Removing
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Pull vacuum hoses -1- to -3- off intake hose -4-.

Remove intake hose -4- on turbocharger.
Carefully cut through cable tie -1-.
oil sump.
Remove charge air pipe on turbocharger and pull it forwards
as far as possible.
AG. Volkswagen AG d
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Unscrew bolts -2- and -3- at pendulum support.
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nform
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io
Clamp coolant hoses of gearbox oil cooler with hose clamps

n
c
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to 25 mm -3094- .
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Cop py
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Unscrew bolt -2- of the air duct.
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Release connectors e-1- d byand -2- and pull off. ua
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Remove hose -3-.
auth or
ac
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Detach vacuum hose -4-.
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Release connector -A- and pull off.

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Remove bracket. To do this remove nuts -1-.
c by lksw
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Prote AG.
Remove right-hand drive shaft on gearbox Running gear,
axles, steering; Rep. Gr. 40 ; Servicing drive shafts; Removing
and installing drive shafts .
Disconnect coolant hoses -1- and -3- using hose clamps to

25 mm -3094 - , see -arrows-.
Open shield -4- and remove.
Remove connecting pipe -2-.
Remove nuts -3- and take air duct out
AG. Volkswagen AG d
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Pull pipe/hose line -1- off.

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Unscrew bolts -2- and -3- and take exhaust gas recirculation
cooler off.
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Remove bolts -1-, -2- and -4- and take oil return line -3- off
complete from cylinder block and turbocharger.
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nuts -1- as the oil supply pipe is still connected to the turbo
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spec
vent the turbocharger from falling.
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Remove nuts -1- from turbocharger.
rrectness of i
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Unscrew union nut -arrow- and pull oil supply pipe off turbo
charger.
nf
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Unscrew loosened nuts and take turbocharger off threaded

studs. orm
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A second mechanic is required for the following work step.

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t. rig
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wards.
p by
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3.2.2 Installing
Fit the turbocharger -2- on the threaded studs.
To prevent turbocharger from falling screw on two new nuts
-1- by hand.
Fit oil supply line to the turbocharger and fit union nut
-arrow-.
AG. Volkswagen AG d
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Install oil return line -3- complete. by Vol not
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First screw all bolts -2- and -3- from exhaust gas recirculation
n
c
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cooler in loosely. Then tighten bolts -2- and -3-.
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Fit pipe/hose line -1- off.

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Renew cable ties -1-.

Further installation is carried out in the reverse order.
Check engine oil level page 97 .
Fit pendulum support to gearbox page 23 .


gine code BLS (with diesel particulate
filter)
Note

Before fitting hose to oil supply line connection, fill turbocharg
er with engine oil.

1 - 10 Nm
2 - Retainer
3 - Heat shield
4 - 10 Nm
5 - Oil supply line
With union nut, 22 Nm
From turbocharger to oil n AG. Volkswagen AG do
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connection.
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page 114 .
spec
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6 - Pipe union, 30 Nm t to the co

Renew.
Coat threads and bolt
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head contact surface

with hot bolt paste -G
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052 112 A3- .

7 - Oil seal
nf
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Renew.
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8 - Vacuum hose
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9 - Seal
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10 - Turbocharger p by
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11 - To particulate filter AG. Volkswagen AG d

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12 - Clamp, 7 Nm ed b ara
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For turbocharger/particulate
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13 - Exhaust manifold
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Can only be renewed together with turbocharger
an
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14 - 25 Nm
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15 - 25 Nm
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spec
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16 - Seal
t to the co
Renew.
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For exhaust gas recirculation.
l purpos
Assembly overview - exhaust gas recirculation cooler page 265

18 - 25 Nm
nform
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Renew.
m
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19 - 15 Nm
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20 - O-ring
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21 - Banjo bolt, 60 Nm
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For turbocharger
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With oil return line
AG.
23 - Exhaust gas temperature sender bank 1 -G235 - , 45 Nm

Lubricate thread of sender using hot bolt paste - G 052 112 A3-
24 - Heat shield
25 - Connection
For intake hose for air filter/turbocharger
Assembly overview - air filter page 237 .
26 - 9 Nm
27 - 10 Nm
3.4 Removing and installing turbocharger,

engine code BLS (with diesel particulate
filter)

Caution

charger. To prevent further damage, carry out the following
repairs:
Check air cleaner housing, air filter insert and intake hoses
for dirt.
eign bodies.
necessary.
Removing
wage e
Pull connector off yexhaust
Vol
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no-G450-
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Item 2 (page se252)
d b in engine compartment and unscrew
ara
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securing bolts.
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Disconnect
s connector for bank 1 exhaust gas temperature
ce
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sender 1 -G235- Item 23 (page 196) .

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Separate electrical connectors to particulate filter.
erm
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Remove insulation tray General body repairs, exterior; Rep.

wit
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Gr. 50 . h re
ole,
Remove subframe and the right drive shaft Running gear,

spec
axles, steering; Rep. Gr. 40 .

t to the co
Remove particulate filter page 252 .

Unscrew coolant pipe for auxiliary heating from cylinder block.
rrectne
Unbolt pendulum support -arrows-.

ss
Remove turbocharger support Item 22 (page 196) .

o
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Remove connecting pipe page 262 to exhaust gas recircu

form
mer
lation cooler.
atio
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Loosen charge pressure line from turbocharger.

n
c
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Pull vacuum hose Item 8 (page 195) off turbocharger.

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Loosen oil supply line Item 5 (page 195) on turbocharger.

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Unscrew securing bolts for exhaust manifold. t. Cop py
rig
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Tilt the engine forwards in lower mounting and remove turbo yri
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charger with exhaust manifold downwards.
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Installing
Install in reverse order.
Note
Torque setting of pendulum support page 23 .
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3.5 Parts of charge air cooling - Assembly
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Note
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For assembly use lubricant (water without additive) if neces
t to the co
sary. Do not use lubricants containing oil.
rrectness of i
ends.
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All charge air system hose connections are secured by spring-

type clips or by connector couplings.
nform
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m
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1 - 8 Nm
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Location page 199

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4 - Seal
5 - 3 Nm
6 - Charge air pressure sender
-G31- with intake air tempera
ture sender -G42-
7 - Oil seal
Renew if damaged.
8 - O-ring
Renew if damaged.

9 - Connecting hose
10 - Hose clip
14 - 8 Nm
15 - Sleeve
16 - Grommet
17 - Connector
18 - Turbocharger
19 - To charge air cooler
20 - Silencer
AG. Volkswagen AG d
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23 - Connecting hose Volksw not
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24 - Bonded rubber horis mounting nte
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Securing bolts for charge air cooler

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To loosen and tighten the securing bolts -arrow- remove bumper

wit
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cover General body repairs, exterior;; Rep. Gr. 63 ; Front

h re
hole
bumper .
spec
es, in part or in w
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nform
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c
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4 Hose connections
4.1 Hose connections

Hoses with quick release coupling page 200
Hoses with spring washer page 201 olkswage es n
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4.1.1 Hose connections with connector cou
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plings ss
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WARNING
itte
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The seal of the connector coupling can be damaged if the se
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curing clip is in locking position when installing. Leaks could
h re
occur. Observe installation instructions.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
All hoses of the charge air system are secured with hose clips or
l purpos
with quick release couplings. When using quick release couplings

the following points must be observed:
nform
ercia
Removing
m
at
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ion
Unlock quick release coupling by pulling on the securing clip
c
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or
-arrow-.
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Separate hose and pipe without tools.

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Installing
t.
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Cop py
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When installing, ensure that locking lugs -A- engage securely.
t
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If renewed, place seal in groove of charge air hose. Ensure
by
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the seal is correctly seated in the groove.
AG.
Oil sealing surface and seal.
Bring securing clip to release position -1-.

Push charge air hose into coupling to stop.
Set securing clip to locking position -2- and then push charge
air hose again.
Check if connector coupling seats correctly and is properly
engaged by pulling hose.

olksw
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Jetta
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, Golf Variant 2007
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4-cylinder
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4.1.2 Hoses with spring washer u or
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Note
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After charge air lines with spring-type clips have been removed
wit
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and installed there is a danger of the hose slipping when driving.
h re
hole
For this reason spring washers are installed that may only be
spec
opened if there is a defect in the charge air line. During repairs
es, in part or in w
t to the co
the spring washer must be destroyed using the appropriate tool
and renewed with a part from ETKA (Electronic Parts Cata
logue) .
rrectness of i
l purpos
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mercia
at
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ion
c
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or
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ate
do
priv
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for
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t.
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Cop py
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4. Hose connections 201

5 Removing and installing charge air

cooler
5.1 Removing and installing charge air cool

er
Removing page 202 AG. Volkswagen AG d
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Installing page 202 d b ara
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5.1.1 Removing ut ra
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Remove radiator page 132 .
pt
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Remove front bumper General body repairs; Rep. Gr. 63 ;
erm
ab
Front bumper
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Unscrew air guides on left and right side of charge air cooler.
h re
hole
spec
es, in part or in w
WARNING
t to the co
The air conditioning system refrigerant circuit must not be
opened.
rrectness of i
l purpos
Note
nf
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orm
m
atio
To prevent damage to condenser or to refrigerant lines and ho
om
n in
ses, ensure that lines and hoses are not stretched, kinked or bent.
or c
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Remove securing bolts -2- from the condenser and fit to lock
o
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carrier.
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t.
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Remove bolts -1- on charge air cooler. t. Cop py
rig
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Swivel the charge air cooler slightly back. p by
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by lksw
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Unhook charge air cooler upwards and take off downwards. Prote AG.
5.1.2 Installing
Install in reverse order. During this step, observe the following:
Install front bumper General body repairs; Rep. Gr. 63 ;
Front bumper .
Note
Renew seal.

l wage
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s no unit injector - Edition 05.2007
Vo t gu
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When installing air duct pipesut
hor
with connector, ensure that the eo
retaining clip -arrow- engages
ss a audibly into the retaining lug ra
c
-A-.
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pt
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Install cooler page 132 .
itte
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Torque settings
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Component Nm
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spec
Charge air cooler to lock carrier 8
es, in part or in w
Condenser to charge air cooler 8
t to the co
rrectness of i
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nf
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Prote AG.
5. Removing and installing charge air cooler 203

6 Checking charge air system for leaks

Charge air system tester -V.A.G 1687-
Adapter -V.A.G 1687/1-
Remove intake hose -1- from air filter.
Connect adapter -V.A.G 1687/1- in intake hose -1- and secure
with clip.
Prepare charge air system tester -V.A.G 1687- as follows:
Unscrew pressure regulating valve -2- complete and close

valves -3- and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards. gen AG
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Connect charge air system tester -V.A.G 1687- to adapter -

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ab
V.A.G 1687/1- as shown.

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ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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te o
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Cop py
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204
Prote AG.
Rep. Gr.21 - Turbocharging/supercharging
Connect compressed air hose -1- (compressed air source) to

charge air system tester -V.A.G 1687 - .
Note
If there is water in the sight glass, drain at water drain screw -6-.
Open valve -3-.

Adjust pressure to 0.5 bar with pressure regulating valve -2-.
Caution
The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.
n AG. Volkswagen A
Open valve -4- and wait until
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the
wagetest circuit is filled.
G do
Ifesneces
not
sary readjust pressuredto
by 0.5 bar.
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Check the chargeuthair
o system for leaks by hearing, touching,
or
with commercially
ss available leak detector spray or using ultra
a ac
sonic tester -V.A.G 1842- .
ce
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pt
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ab
Note
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How to use the ultrasonic tester -V.A.G 1842 - operating
h re
hole
instructions
spec
es, in part or in w
If leaks occur, when doing any repair work observe notes for
charge air system page 183 . t to the co
Before removing the adapter, depressurise the test circuit by

rrectness of i
pulling coupling off adapter -V.A.G 1687/1- .

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nf
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Prote AG.
6. Checking charge air system for leaks 205

7 Vacuum hoses for connection dia

gram
Vehicles with engine codes BKC, BXE page 206
Vehicles with engine codes BLS, BRM page 207
7.1 Vehicles with engine codes BKC, BXE
1 - Solenoid valve block

2 - Non-return valve
tion.
3 - To brake servo
4 - Connecting pipe air filter/
turbocharger
5 - Air filter
6 - Intake manifold
block
9 - Bypass flap AG. Volkswagen AG d
agen oes
For exhaust gas recircu olksw not
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lation cooler. sed b ara
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10 - Radiator au
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ac
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For exhaust gas recircu
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valve -N18-
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12 - Turbocharger
h re
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spec
es, in part or in w
t to the co

tion.
rrectness of i
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nf
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m
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t.
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.

7.2 Vehicles with engine codes BLS, BRM
1 - Turbocharger
2 - Connecting pipe air filter/
turbocharger
tion.
4 - To brake servo
5 - Charge pressure control
solenoid valve -N75 -
6 - Air filter
block
8 - Intake manifold
9 - Bypass flap
lation cooler.
10 - Radiator
AG. Volkswagen AG d
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not
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11 - Exhaust gas recirculation ised ara
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valve -N18- ut
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12 - Exhaust gas recirculation s
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cooler change-over valve -

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7. Vacuum hoses for connection diagram 207

23 Mixture preparation - injection

1 Diesel direct injection system
The diesel direct injection system control unit is equipped with a
fault memory. Read fault memory before and after making repairs
or adjustments.
AG. Volkswagen AG d
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mer
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208 Rep. Gr.23 - Mixture preparation - injection


Fitting locations overview page 211
Assembly overview - unit injector page 217
Removing and installing unit injector page 219
Removing and installing O-rings for injector unit page 222
Assembly overview - intake manifold page 224
Removing and installing intake manifold page 226
Removing and installing intake pipe with exhaust gas recirculation
potentiometer -G212- and exhaust gas recirculation valve -N18- ,
engine codes BLS, BRM page 233
Dismantling and assembling intake pipe with exhaust gas recir
culation potentiometer -G212- and exhaust gas recirculation
valve -N18- , engine codes BLS, BRM page 234
Removing and installing intake manifold flap motor -V157 -
page 235
Assembly overview - air filter page 237
Connection diagram for charge pressure control, engine codes
BKC, BXE page 238
Connection diagram for solenoid valve block, engine codes BKC,
BXE page 238
Removing and installing engine speed sender -G28-
page 239
Removing and installing sender wheel for .engine speed sender -
AG Volkswagen AG d
G28- page 240 kswagen oes
n ol ot g
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Removing and installing automatic
ed
b glow period control unit -J179-aran
ris
page 240 ut
ho tee
o
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ss c
1.1 Safety precautions
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nl
pt
du
an
The fuel pump is activated when switching on the ignition and by

itte
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erm
the driver's door contact switch. For safety reasons, the connector
ab
ility
-arrow- must be removed from the fuel delivery unit before open
ot p
wit
ing the fuel system, if the battery is not disconnected.

, is n
h re
hole
spec
Caution
es, in part or in w
t to the co

rrectness of i
tions:
l purpos

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or

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atio
hot components.
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Observe following if test and measuring instruments are required

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during a road test:

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1. Diesel direct injection system 209

WARNING
Test and measuring instruments must be secured to rear

seat and operated by a second person from this location.
If test and measuring instruments are operated from front
passenger seat and the vehicle is involved in an accident,
there is a possibility that the person sitting in this seat may
receive serious injuries when the airbag is triggered.
To prevent injuries to persons and/or damage to the injection and

glow plug system, the following must be noted:
WARNING
The ignition must be switched off before connecting or

disconnecting injection or glow plug system wiring or test
er cables.
If the engine is to be turned at starter speed, without start
ing, e.g. when checking compressions, disconnect unit
injector connector on cylinder head.
AG. Volkswagen
Before disconnecting battery, obtain lradio
wagecode for radios does n
n AG
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fitted with anti-theft coding. db
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Disconnecting and reconnecting tho the battery must only be or
undertaken when the ignition
s au is switched off; otherwise the ac
s
diesel direct injection system control unit may be dam
ce
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nl
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1.2 Rules for cleanliness

h re
hole
spec
When working on fuel supply and injection system, pay careful

es, in part or in w
attention to the following rules for cleanliness:

t to the co
Thoroughly clean all unions and adjacent areas before dis

connecting.
rrectness of i
Place removed parts on a clean surface and cover. Do not use

l purpos
fluffy cloths!
nf
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atio

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tool boxes, etc.).

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Also ensure that no diesel fuel comes into contact with the
co Vo
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coolant hoses. Should this occur, the hoses must be cleaned
agen
Prote AG.
immediately. Damaged hoses must be renewed.

olkswagen AG
g en AG. V
Jetta
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4-cylinder
sed diesel engine with unit injector - Edition
b ara
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05.2007
ri tee
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ut or
1.3 Fitting locations overview
a ac
ss
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pt
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itte
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Note
erm
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Some components are mounted under the engine cover.
, is n
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spec
es, in part or in w
t to the co
1 - Intake manifold flap motor -
V157-
rrectness of i
page 235
l purpos

potentiometer -G212- / ex
haust gas recirculation valve -
nf
ercia
o
N18-
rm
m
atio
om
n in
page 233
or c
thi
te
3 - Engine control unit
sd
iva
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page 245
t.
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4 - Unit injectors
. C rig
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Unit injector solenoid co Vo
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valve, No. 1 cyl. - N240-
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Unit injector solenoid

unit injectors
page 219
5 - Turbocharger guide vane
position sender -G500-
page 177
cooler change-over valve -
N345-
Location page 213
7 - Air mass meter -G70-
8 - Charge pressure control solenoid valve -N75 -
Location page 213
9 - 6-pin connector
For lambda probe -G39-
Location page 213
10 - Clutch position sender -G476-
Location page 216
11 - Clutch position sender -G79- / Clutch position sender 2 -G185-
Location page 216

12 - Brake light switch -F- and brake pedal switch -F47-

Location page 216
13 - Relay carrier
Below electronics box engine compartment
With automatic glow period control unit -J179-
Location page 217
14 - Fuel pump relay -J17-
Location page 217
15 - Relay and fuse holder in electronics box in engine compartment
With terminal 30 voltage supply relay - J317-
With terminal 15 voltage supply relay - J329-
Location page 217
16 - Tandem pump
Checking page 160
17 - Coolant temperature sender -G62-
Location page 214
If necessary, release pressure in cooling system beforenremoving
AG. Volkswagen A ge G do
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18 - Radiator outlet coolant temperature sender -G83- yV
olk ot g
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edb ran
Fitting location, engine codes BKC, BXEhorispage 215 tee
t or
Fitting location, engine codes BLS, BRM au page 215 ac
ss
ce
e
19 - Fuel temperature sender -G81-

nl
pt
du
an
itte
Location page 214
y li
erm
ab
ility
20 - Multi-pin connector
ot p
wit
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For unit injectors
h re
hole
Location page 215
spec
es, in part or in w
21 - Engine speed sender -G28-
t to the co
Location page 214
22 - 3-pin connector rrectness of i
For Hall sender -G40- .
l purpos
Location page 214

23 - Glow plugs
nform
ercia
Glow plug 1 -Q10-

m
at
om
io
Glow plug 2 -Q11-

n
c
in t
or
Glow plug 3 -Q12-

his
ate
do
riv
Glow plug 4 -Q13-

p
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or
Removing, installing and testing page 274

f
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24 - Hall sender -G40-
C py
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For camshaft position p by
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Location page 215
agen
Prote AG.
25 - Charge air pressure sender -G31- with intake air temperature sender -G42-
Location page 213

Fitting location: solenoid valve for charge pressure control -N75-

On left bulkhead -arrow-.
Fitting location: charge air pressure sender - G31- intake air tem
perature sender -G42-
In air duct pipe behind the radiator -arrow-.
n AG. Volkswagen AG age does
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pe
ility
ot
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, is n
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hole
spec
Fitting location: exhaust gas recirculation cooler change-over
es, in part or in w
valve -N345-
t to the co
On rear left cylinder head.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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Fitting location: connector Lambda probe -G39-

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On left bulkhead -arrow-.

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. Volkswagen AG
Fitting location: Coolant temperature -G62-kswagen AG does
not
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On engine left. sedb ara
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ri
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aut ra
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d
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ab
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
Fitting location: Fuel temperature sender -G81-
rrectness of i
The sender -arrow- is fitted on engine front left.
l purpos
nform
mercia
a
com
tion in
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Fitting location: Engine speed sender -G28-
t. rig
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On flywheel side of engine.
c by lksw
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Prote AG.
1- Engine speed sender -G28-
2- Sender wheel
Fitting location of 3-pin connector for Hall sender -G40-

Front on engine below intake manifold.

Fitting location: Hall sender -G40 -

At camshaft sprocket on engine (right-side).
lkswage es n
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ir se tee
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nl
pt
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itte
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Fitting location of multi-pin connector for unit injectors
erm
ab
ility
ot p
To disconnect pull the release pin -arrow 1- and loosen
wit
knurled nut -arrow 2-.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Fitting location of the radiator outlet coolant temperature sender orm

m
atio
-G83- , engine codes BKC, BXE
om
n in
or c
The radiator outlet coolant temperature sender -G83-

thi
te
sd
-item 2- is located above the drain plug -arrow- in the coolant

iva
o
r
hose -1- on the lower left of the radiator.

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Fitting location of the radiator outlet coolant temperature sender

-G83- , engine codes BLS, BRM
The radiator outlet coolant temperature sender -G83- -arrow-
is seated in the pipe union of the thermostat on front right on
engine.

Fitting location: accelerator position sender -G79- with accelera

tor position sender 2 - G185- -1-
In drive side footwell.
AG. Volkswagen AG d
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Note ised b ara
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Diagram shows set-up on lefts drive vehicles.
s a c
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pt
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itte
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erm
ab
ility
ot p
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Fitting location: brake light switch -F- and brake pedal switch -
F47-
l purpos
Removing and installing brake systems; Rep. Gr. 46 ; Re
nf
move, install and mount brake pedal - assembly overview;
ercia
o
brake light switch -F- and brake pedal switch -F47- .
rm
m
atio
om
n in
or c
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Cop py
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by lksw
Fitting location: Clutch position sender -G476- Prote
cted AG.
agen
Removing and installing 5-speed manual gearbox 0A4;

Rep. Gr. 30 .

Fitting location of relay and fuse holder in electronics box in en

gine compartment
Terminal 30 voltage supply relay -J317 - -1-.
Terminal 15 voltage supply relay -J329 - -3-.
Fitting location: Automatic glow period control unit -J179-

Electronics box engine compartment -1-.
AG. Volkswagen AG d
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pt
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itte
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erm
Fitting location: Fuel pump relay -J17-

ab
ility
ot p
Plug position -2.1- in 5-pin relay carrier via the onboard supply
wit
, is n
control unit, below dash panel on driver side. h re

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
1.4 Assembly overview - unit injector

at
om
ion
c
in t
or

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ate
do
riv
Always renew seals and O-rings

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1 - 20 Nm + 90 (1/4 turn) fur

ther
Renew.
2 - Rocker arm shaft
With rocker arms
page 219 .
3 - Lock nut, 30 Nm
4 - Adjuster screw
Renew.
5 - Ball stud n AG. Volkswagen AG do
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Renew. yV
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6 - Unit injector ir se tee
tho
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Removing and installing ss
a ac
page 219 .
ce
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un
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d
7 - O-ring
itte
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ab
Renewing page 222 .
ility
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8 - O-ring
is n
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ole,
Renewing page 222 .
spec
9 - O-ring
t to the co
Renewing page 222 .
10 - Heat shield seal
rrectne
Renew.
s
11 - Circlip
s o
cial p
f i
12 - Cylinder head
nform
mer
13 - Clamping block
atio
om
n
c
14 - 12 Nm +270 (3/4 turn) fur

i
or
n thi
e
ther
t
sd
iva
o
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Renew.
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Prote AG.

1.5 Removing and installing unit injector

equipment required
Universal dial gauge brack
et -VW 387-
Special wrench, long reach
-3410-
Special wrench, long reach
-T10054-
Puller -T10055-
Torque wrench -
V.A.G 1331-
AG. Volkswagen AG d
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is n
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ole,
spec
t to the co
rrectne
Removing page 219

ss o
Installing page 220

cial p
f inform
1.5.1 Removing
mer
atio
om
Remove upper toothed belt guard.

n
c
i
or
n thi
e
Remove cylinder head cover page 61 .

t
sd
iva
o
pr
cum
Turn crankshaft until the cam pair for the unit injector which is
r
fo
en
ng
to be removed point uniformly upwards.

t.
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AG. Volkswagen AG d
agen oes
ksw not
Jetta 2005 , Bora 2006 , Golf Variant 2007 by Vol
gu
ara
d
4-cylinder diesel engine with unit injector - Edition
orise 05.2007 nte
eo
th
au ra
s c
Loosen adjustment screw lock nuts -1- and remove
s adjust
ce
le
ment screws.
un
pt
an
d
itte
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Remove rocker arm securing bolts -2- (from outwards to in
rm
ab
wards) with socket -3410- and take rocker arm shaft off.
pe
ility
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Loosen tensioning block securing bolt -3- using special
h re
wrench, long reach -T10054- and remove tensioning block.
hole
spec
es, in part or in w
Lever connector off unit injector with a screwdriver. To avoid
t to the co
canting, support opposite side of connector with light finger
pressure.
Observe unit injector cylinder allocation.
rrectness of i
l purpos
Insert puller -T10055- in place of the clamping block in the slot

on the side of the unit injector.
nform
ercia
Pull the unit injector off by knocking it outwards the cylinder

m
a
com
head seat.
tion in
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te o
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1.5.2 Installing
Note
Each time work is performed which requires adjustment of the

unit injector, the adjustment screw in the rocker arm and also
the unit injector ball stud must be renewed.
New unit injectors are supplied with O-rings and insulating
seals.
Heat insulating seal and O-rings must be renewed if old unit

injector is reused page 222 .
Check that the three O-rings and the heat insulating seal along
with circlip are seated correctly before installing unit injector.
Note
The seals must not be twisted.
Oil seals and insert the injector unit with greatest care in the
cylinder head seat.
Push the injector unit evenly into the cylinder head onto its
stop.
Insert the clamping block in the slot on the side of the unit
injector.

Note
AG. Volkswagen A
If the unit injector is not at right angles to the
olks
tensioning
wagen block theG does no
securing bolt may loosen and this canddamage by
V the unit injector or t gu
ara
the cylinder head. or
ise nte
e th or
au ac
ss
Therefore align the unit injector as follows.
ce
e
nl
pt
du
an
Screw the new securing bolt into the tensioning block only so
itte
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far that the unit injector can still be turned easily.
erm
ab
ility
ot p
Now align unit injector at right angles to camshaft mounting
wit
, is n
brackets.
h re
hole
spec
Check dimension -a- from outer edge of cylinder head to roun
es, in part or in w
ded edge of unit injector using a vernier gauge (measuring
t to the co
range of at least 400 mm).
Cylinder Dimension a
rrectness of i
1 333.0 0.8 mm
l purpos
2 245.0 0.8 mm
3 153.6 0.8 mm
nf
ercia
or
4 65.6 0.8 mm
m
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atio
om
Align unit injector and tighten securing bolt as follows: 12 Nm
n in
or c
and 270 (3/4 turn) further. Turning further can be done in sev
thi
te
sd
a
eral stages.
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Fit rocker arm shaft and tighten new securing bolts as follows:
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First evenly tighten inner bolts -2- and then outer bolts -1- gh ht
yri by
hand-tight. Then tighten to 20 Nm and turn 90 (1/4 turn) further
cop Vo
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evenly in the same sequence.
Prote AG.
Fit the dial gauge onto the adjustment screw of the unit injector
as shown.
Turn the crankshaft in engine direction of rotation until the roll
er of the rocker arm is positioned on the peak of the drive cam.
Roller side -arrow A- positioned at highest point on dial gauge
-arrow B- positioned at lowest point.
Remove dial gauge.
Now turn the adjuster screw into rocker arm until significant
resistance can be felt (unit injector is at limit stop).
Turn adjuster screw 180 back from stop.
Hold adjuster screw in this position and tighten lock nut to 30
Nm.
Connect unit injector connector.
Install cylinder head cover page 61 .
Install toothed belt guard.

1.6 Removing and installing unit injector O-

rings
Assembly sleeves -T10056-
Removing page 222

Installing page 222
1.6.1 Removing
Remove unit injector page 219 . AG. Volkswagen AG d
agen oes
ksw
Lever old O-rings very carefully out ofbunit
y V injector.
ol not
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ara
ed
is nte
Above all ensure that burrs are nothor caused on O-ring seating. eo
aut ra
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1.6.2 Installing s
ce
e
nl
pt
du
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itte
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erm
ab
Note
ility
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Always use the assembly sleeves to fit the O-rings. There is a

h re
hole
danger of damaging the O-rings if the sleeves are not used.

spec
es, in part or in w
Gradual introduction of O-rings without different coloured

t to the co
markings. Note the correct allocation of O-rings to grooves:

the thickness of the rings reduces towards injector nozzle.
rrectness of i
Avoid rolling when sliding onto the O-rings. The O-rings must
not be twisted in their seats in unit injector.
l purpos
Remove the insulating seal together with the retaining ring.

nform
ercia
Clean seating surfaces for O-rings on unit injector very care

m
at
fully.
om
ion
c
in t
r
Fit assembly sleeve -T10056/1- onto unit injector, pushing it

o
his
te
to the limit stop.

a
do
priv
cum
or
Push the upper, thicker O-ring carefully onto the assembly

f
en
g
sleeve and into the seat on the unit injector.

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Remove the assembly sleeve. ht. rig
rig ht
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Prote AG.


to the limit stop.
Slide the middle, thinner O-ring carefully onto assembly sleeve
and into seat on unit injector.
Remove the assembly sleeve.

to the limit stop.
Push the lower O-ring carefully onto the assembly sleeve and
into the seat of the unit injector.
Remove the assembly sleeve.
Push on a new insulating seal together with the retaining ring.
lkswage es n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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en
ng
t.
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1.7 Assembly overview - intake manifold

Intake manifold - Assembly goverview,
n AG. Volksengine codes
wagen AG BKC, BXE
page 224 lkswa e does
not
Vo g y ua
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Intake manifoldo-risAssembly
e
overview, engine codes BLS,anBRM
tee
page 225 au th or
a
ss c
1.7.1 Intake manifold - Assembly overview, engine codes BKC, BXE
ce
le
un
pt
an
d
itte
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rm
ab
pe
1 - Intake manifold
ility
ot
wit
Tighten securing bolts
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h re
to 22 Nm.
hole
spec
2 - O-ring
es, in part or in w
t to the co
Renew.
3 - Intake connecting pipe
rrectness of i
With exhaust gas recir
culation valve.
l purpos
4 - 10 Nm
nform
ercia

m
V157-
a
com
The intake manifold flap tion in

r
te o
is closed for approx.

thi
s
iva
3 seconds when the en

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gine stands and then

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opens again. When do

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ing this the stop stroke is
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6 - 10 Nm
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Prote AG.
7 - Connecting pipe
To exhaust gas recircu
lation cooler.
8 - 22 Nm
9 - Seal
Renew.

1.7.2 Intake manifold - Assembly overview, engine codes BLS, BRM
1 - Seal
replace
2 - Intake manifold
to 22 Nm
3 - Oil seal
Renew.
4 - Intake connecting pipe
V157-
The intake manifold flap
is closed for approx.
3 seconds when the en
gine stands and then
opens again. When do
ing this the stop stroke is
reduced.
6 - From charge air cooler
7 - 10 Nm
valve -N18- with exhaust gas
recirculation potentiometer -
G212-
Assembly overview - ex
haust gas recirculation
page 263
9 - Seal
Renew. lkswage es n
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yV ua
10 - Connecting pipe ir se
d b ran
tee
o
To exhaust gas recircu auth or
ac
lation cooler. ss
ce
e
nl
Assembly overview -
pt
du
an
parts for exhaust gas recirculation page 262

itte
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erm
ab
11 - 22 Nm
ility
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12 - Retainer
h re
hole
For connector
spec
es, in part or in w
13 - 22 Nm
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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t.
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Cop py
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by
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Prote AG.

1.8 Removing and installing intake manifold

Removing and installing intake manifold, engine codes BKC, BXE
page 226
Removing and installing intake manifold, engine codes BLS, BRM
page 231
1.8.1 Removing and installing intake manifold, engine codes BKC, BXE

equipment required
-3094-
Torque wrench -
V.A.G 1331-
Torque wrench -
V.A.G 1410-
5024A- AG. Volkswagen AG d
agen oes
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y V gu
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au ra
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un
pt
an
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rm
ab
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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t.
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Cop py
t. rig
Removing page 227
gh ht
pyri by
Vo
co lksw
by
Installing page 230 cted agen
Prote AG.

Removing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
The hoses -2- remain connected.
es, in part or in w
t to the co
Place lines -2- on air duct pipe to side.
Remove air pipe. To do this lift retaining clips -1- lightly.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
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t.
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Cop py
t. rig
gh ht
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Disconnect connector -2- on air mass meter -G70- . cop Vo
by lksw
cted agen
Prote
Pull breather hose -1- and air duct hose -3- off.
AG.

V157- .
V157- off.
Remove intake pipe with exhaust gas recirculation potentiom
eter -G212- and exhaust gas recirculation valve -N18-
page 233 .

en AG. V
05.2007
olkswagen AG
ag does
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Vol gu
Pull off or disconnect coolant hosesed-1-
b and -2- on exhaust gas
y ara
nte
recirculation cooler using hosethclamps
or
is to 25 mm -3094- . eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Pull off or disconnect coolant hoses -1- and -2- using hose
clamps to 25 mm -3094- .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
vo.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise Jetta
nte 2005 , Bora 2006 , Golf Variant 2007
h eo
aut 4-cylinder diesel
ra
c
engine with unit injector - Edition 05.2007
ss
ce
le
Remove engine lifting eye on rear of cylinder head -arrow-.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f
Remove lower connecting pipe on change-over flap for ex
inform
haust gas recirculation -arrows-.
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Remove exhaust gas recirculation cooler and change-over

flap from intake manifold -arrows- and take out.

Unbolt intake manifold -arrows-.

Installing
Note

Observe installation position of seal for intake manifold.
logue ETKA .

-A-.
Torque settings
Component Nm
Intake manifold to cylinder head 22
Engine lifting eye on cylinder head 22
Retainer to intake manifold 10
Connecting pipe for exhaust gas recirculation 22
to change-over flap
Exhaust gas recirculation cooler to intake mani 10
fold
Intake manifold flap motor -V157- to intake 10
manifold
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.8.2 Removing and installing intake manifold, engine codes BLS, BRM

equipment required
-3094-
Torque wrench -
V.A.G 1331-
Torque wrench -
AG. Volkswagen AG d
V.A.G 1410- ksw
agen oes
not
Vol
by gu
Spring-type clip pliers -VAS ised ara
nte
5024A- ut
hor eo
a ra
ss c
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing page 231

Installing page 232
Removing

Note

V157- .
V157- off.
eter -G212- and exhaust gas recirculation valve -N18-
page 233 .
Remove turbocharger page 188 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
Unbolt intake
ss manifold -arrows-. c
ce
e
nl
pt
Installing
du
an
itte
y li

erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w

t to the co

rrectness of i
logue ETKA .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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iva
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t.
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Cop py
t. rig
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Vo
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by
cted agen
Prote AG.


-A-.
Torque settings
Component Nm
Intake manifold to cylinder head 22
Engine lifting eye on cylinder head 22
Connecting pipe for exhaust gas recirculation 22
to change-over flap
fold
Intake manifold flap motor -V157- to intake 10
manifold
1.9 Removing and installing intake pipe with

exhaust gas recirculation potentiometer
-G212- and exhaust gas recirculation
valve -N18- , engine codes BLS, BRM
Removing page 233 lkswage es n
o ot g
byV ua
d
Installing page 233 o
ir se
ran
tee
th or
u
1.9.1 Removing
a ac
ss
ce
le
un
pt
Remove intake manifold flap motor - V157- page 235 .
an
d
itte
y li
erm
ab
ility
ot p

wit
is n
h re
Loosen connecting pipe -6- from intake pipe -4-. Remove bolts
ole,
-7- for this.

spec
Release connector -3- from intake pipe -4- and pull off.
t to the co
Unscrew bolts -1- and take intake pipe -4- off.

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.9.2 Installing

Renew sealing ring -2- and seal -5-.

Tighten bolts -1- and -6- to 10 Nm.
Install intake manifold flap motor - V157- page 235 .
1.10 Dismantling and assembling intake pipe

with with exhaust gas recirculation po
tentiometer -G212- and exhaust gas re
circulation valve -N18- , engine codes
BLS, BRM
Wet and dry cleaner -VAS 5128-
Plastic brush agen
AG. Volkswagen AG d
oes
olksw not
V
Dismantling ed by gu
ara
nte
ris
o eo
aut
h
ra
eter -G212- with exhaust gas recirculation valve -N18- ss c
ce
e
page 233 .
nl
pt
du
an
itte
Remove bolts -1- and carefully pull exhaust gas recirculation
y li
erm
ab
potentiometer -G212- with exhaust gas recirculation valve -
ility
ot p
N18- -2- off the intake pipe -4-
wit
, is n
h re
Clean exhaust gas recirculation valve sooted surfaces with a
hole
spec
plastic brush . Afterwards remove loose soot with a cloth.
es, in part or in w
t to the co
For protection against soot particles cover intake manifold in
ner part with a lint-free cloth.
Clean exhaust gas recirculation valve seat in intake manifold
rrectness of i
with a plastic brush and a cloth. Ensure that no soot particles

enter the intake manifold.
l purpos
Take the cloth out of the intake manifold and clean the intake
nf
ercia
manifold with a wet and dry cleaner -VAS 5128- , if necessary.

orm
m
Assembling
atio
om
n in
c
Renew the O-ring -3-.

or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Carefully fit the exhaust gas recirculation potentiometer -

G212- with the exhaust gas recirculation valve -N18- -2- into
the seat of the intake pipe -4- and tighten the bolts -1- to
10 Nm.
1.11 Removing and installing intake manifold

flap motor G-V157-
. Volkswage
nA n AG d
wage oe
Special tools and
yV
olworkshop
ks equipment required
s no
t gu
b ara
ed
Torque
ho wrench -V.A.G 1331-
ris nte
e
t or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing page 235

l purpos
Installing page 236

nf
ercia
1.11.1 Removing
orm
m
atio
m

o
n in
or c

thi
e

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
V157- .
an
d
itte
y li
erm
ab
Remove bolts -13- and take intake manifold flap motor -
ility
ot p
V157- off.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f
1.11.2 Installing
inform
mer
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo

en
ng
t.
yi Co
op
C py
t. rig
logue ETKA .
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
AG.

-A-.
Tighten bolts for intake manifold flap motor -V157- to 10 Nm.

1.12 Assembly overview - air filter
1 - O-ring
Renew if damaged.
2 - Connector
3 - Hose clip
4 - Intake hose
To turbocharger
5 - Connector
For heater element for
crankcase breather -
N79- .
Only fitted in vehicles
with cold country equip
ment
. Volkswagen AG
a gen AG does
6 - Air mass meter
Vol -G70-
ksw not
gu
y
db ara
7 - O-ring orise nte
eo
h
ut
sRenew.
sa
ra
c
ce
le
8 - 8 Nm
un
pt
an
d
itte
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9 - Air filter upper part

erm
ab
ility
ot p
10 - 8 Nm
wit
is n
h re
11 - Vacuum hose
ole,
spec
To solenoid valve block

t to the co
12 - 6 Nm
13 - Filter element
rrectne
14 - Air duct
To lock carrier.
ss o
cial p
15 - Air filter lower part

f inform
mer
16 - Water outlet pipe

atio
m
17 - Flap for warm air intake

o
n
c
i
or
With thermal element.

thi
te
sd
va
Integrated in air cleaner lower section

i
o
pr
cum
r
fo
Can not be renewed individually.

en
ng
t.
yi Co
op
18 - 10 Nm
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.13 Connection diagram for charge pressure control, engine codes BKC, BXE
1 - Mechanical exhaust gas re

circulation valve
3 - To vacuum unit for charge
pressure control
4 - To vacuum unit for exhaust
gas recirculation cooler
change-over
5 - Solenoid valve block
culation valve 1 - N18-
With charge pressure
control solenoid valve -
N75-
culation cooler change-
over valve -N345-
Connection diagram lkswage es n
o ot g
page 238 byV ua
d ran
ir se tee
o
6 - Vacuum supply line auth or
ac
ss
From the tandem pump
ce
le
un
to the solenoid valve
pt
an
d
block
itte
y li
rm
ab
pe
7 - Tandem pump
ility
ot
wit
, is n
8 - Breather hose
h re
hole
To air filter
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
1.14 Connection diagram for solenoid valve

m
a
com
tio
block, engine codes BKC, BXE

n in
r
te o
thi
P1 - Vacuum supply line from the tandem pump

s
iva
do
r
rp
cum
P2 - To mechanical exhaust gas recirculation valve

fo
en
ng
t.
yi Co
P3 - To vacuum unit for exhaust gas recirculation cooler change- . Cop py
over
t rig
gh ht
pyri by
Vo
co
P4 - Breather hose to air filter
by lksw
cted agen
Prote AG.
P5 - To vacuum reservoir
P6 - To vacuum unit for charge pressure control
Note
The vacuum connection marked with an -arrow- is not used and

is closed in the connection cap.

1.15 Removing and installing engine speed

sender -G28-
Puller -T10118-
Removing page 239

Installing page 240
wage
1.15.1 Removing byV
olks es n
ot g
ua
d ran
ir se
Remove oil filter bracket page 107tho . tee
or
au ac
Disconnect connector -arrow- on engine speed sender -G28- ss
ce
e
using assembly tool -T10118- .

nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
To unlock connector without assembly tool -T10118- , press con

hole
spec
nector to engine speed sender with a screwdriver and raise

es, in part or in w
release button with a thin wire hook at the same time.

t to the co
Move wire clear.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
239
cted agen
Prote AG.
1. Diesel direct injection system
Remove the securing bolt -2- of the engine speed sender -

G28- -1-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
1.15.2 Installing
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Tighten securing bolt -2- of the engine speed sender -G28-
hole
spec
-1- to 5 Nm.
es, in part or in w
t to the co
Install oil filter bracket page 107 .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
1.16 Removing and installing engine speed

do
r
rp
cum
sender - G28-
fo
en
ng
t.
yi Co
op
The sender wheel for engine speed sender -G28- is removed and
C py
t. rig
gh
installed together with the crankshaft sealing flange -flywheel
ht
pyri by
Vo
o
end- page 38 .
c by lksw
cted agen
Prote AG.
1.17 Removing and installing automatic glow

period control unit - J179-
Removing page 240
Installing page 242
1.17.1 Removing
pipe.


Volkswa AG. gen AG
agen does
Vehicles with engine codes BLS,
Vol BRM
ksw not
gu
by ara
ed
Remove air cleaner housing
ho
ris with air mass meter. nte
eo
t
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Pull 6-pin relay carrier under electronics box off, engine com
partment in -direction of arrow-.

Unclip 6-pin relay carrier cover -arrows-.
Release retaining clips -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
Take 6-pin relay carrier -arrow-
s aut
out of cover. ra
c
s ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Remove automatic glow period control unit -J179- from plug

position -R2-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.17.2 Installing
Installing battery Electrical system; Rep. Gr. 27 ; Removing
and installing battery; Vehicles with diesel engine .

2 Engine control unit

Reading and erasing engine control unit fault memory
page 243 en AG. V
olkswagen AG
ag does
ksw n
Vol
Removing and installing engine control unit page
ot g 245 .
by ua
ed ran
ris tee
2.1 au
tho Reading and clearing engine control unit or
ac
ss
fault memory
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
5051B-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
Connect vehicle diagnosis, testing and information system -VAS
n
c
in t
or
5051B- as follows:
his
ate
do
riv
Fit the connector of the diagnosis cable -2- to the diagnosis

p
cum
or
connection in the driver footwell.

f
en
ng
t.
yi Co
op
Start engine and run at idling speed. C py
t. rig
gh ht
yri
Only if engine does not start:
p by
co Vo
by lksw
cted agen
Switch on ignition.
Prote AG.
Select operating mode:

Press key on display for Vehicle self-diagnosis.
Select vehicle system:
Press button 01 - Engine electronics on display.
2. Engine control unit 243

The display shows the control unit identification and coding -2- as
well as the chassis number and the identification number of the
immobilizer (centre part).
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Note ised b ara
nte
or eo
h
ut ra
A print-out can be made if required. Press the Print sbutton.
s a c
ce
le
un
pt
an
d
Select diagnostic function:
itte
y li
rm
ab
Press key 02 - Read fault memory on display.
pe
ility
ot
wit
, is n
If no fault is stored in engine control unit 0 fault detected is
h re
displayed. hole
spec
es, in part or in w
If faults are stored in the engine control unit, these are shown
t to the co
one below the other on the display.
Press the button.
rrectness of i
Press key 05 - Erase fault memory on display.
l purpos
Press function 06-End output.
nform
ercia
2.2 Adapting functions and components

m
a
com
tio
n in
r
te o
thi
s
iva
do
5051B-
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Push diagnosis cable connector onto diagnosis connector in

driver footwell.
Switch on ignition.
Select "Guided fault finding" in the Vehicle diagnosis, testing
and information system -VAS 5051-.
After all control units have been read:
Press key Go to .
Select Function/Component selection.
Select Drive train.
Select Engine code.
Select 01 - On Board Diagnostic (OBD).
Select Engine management.
Select Functions
Select Function or component.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
ut
ho Jetta e2005
or , Bora 2006 , Golf Variant 2007
a a
ss 4-cylinder dieselc engine with unit injector - Edition 05.2007
ce
e
nl
pt
du
an
2.3 Removing and installing engine control
itte
y li
erm
ab
unit
ility
ot p
wit
, is n
Removing and installing engine control unit without theft protec
h re
tion page 245
hole
spec
es, in part or in w
Removing and installing engine control unit with theft protection
t to the co
page 245
2.3.1 Removing and installing engine control
rrectness of i
unit without theft protection
l purpos
Note
nf
ercia
orm
m
atio
If you wish to replace the engine control unit, connect the Vehicle
om
n in
diagnosis, testing and information system -VAS 5051B- and carry
or c
out the guided function Renew control unit.
thi
te
sd
iva
o
r
rp
cu
Removing
o
m
f
en
ng
t.
yi Co
Switch off ignition. t. Cop py
rig
gh ht
yri
Remove wiper arms and the plenum chamber cover Elec
p by
o Vo
by c
trical system; Rep. Gr. 92 ; Windscreen wiper system; Re
lksw
cted agen
Prote
moving and installing the windscreen wiper system .
AG.
Remove bulkhead in plenum chamber General body re

pairs, exterior; Rep. Gr. 50 ; Plenum chamber bulkhead;
Plenum chamber bulkhead - Assembly overview .
Release front connector -1- from engine control unit and pull
it off.
Lever up catch -2- slightly.
Then push engine control unit out of retainer -arrow-.
Then release rear connector on engine control unit and pull it
off.
Installing
Fit rear connector to engine control unit and lock it in position.
Push engine control unit onto bracket.
Fit front connector to engine control unit and lock it in position.
Install bulkhead in plenum chamber General body repairs,
exterior; Rep. Gr. 50 ; Plenum chamber bulkhead; Plenum
chamber bulkhead - Assembly overview .
Install wiper arms and the plenum chamber cover Electrical
system; Rep. Gr. 92 ; Windscreen wiper system; Removing
and installing the windscreen wiper system .
2.3.2 Removing and installing anti-theft en

gine control unit

Electric cutter -V.A.G 1561A-

AG. Volkswagen AG d
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es, in part or in w
t to the co
Saw set -V.A.G 1561/14-
Pliers
rrectness of i
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Note
nf
ercia
If you wish to replace the engine control unit, connect the Vehicle
orm
diagnosis, testing and information system -VAS 5051B- and carry
m
atio
m
out the guided function Renew control unit.

o
n in
or c
thi
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sd
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Removing
iv
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Switch off ignition.

f
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t.
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op
Remove wiper arms and the plenum chamber cover Elec C py
t. rig
trical system; Rep. Gr. 92 ; Windscreen wiper system; Re
gh ht
yri by
moving and installing the windscreen wiper system . cop Vo
by lksw
cted agen
Prote AG.
Remove bulkhead in plenum chamber General body re
pairs, exterior; Rep. Gr. 50 ; Plenum chamber bulkhead;
Plenum chamber bulkhead - Assembly overview .
Saw shear head bolts so that two parallel surfaces are created
-arrows-.
Remove bolts with pliers .
Insert a screwdriver between protective housing -A- and

bracket -arrow-.

AG. Volkswagen AG d
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4-cylinder
s s a diesel engine with unit injector - Edition 05.2007
ra
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pt
Lever the protective housing out upwards using the screw
du
an
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driver -A- and pull it off sideways from the retaining plate
y li
erm
ab
-arrow-.
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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Release front connector -1- from engine control unit and pull
orm
it off.
m
atio
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Lever up catch -2- slightly.
n in
or c
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Then push engine control unit out of retainer -arrow-.

t
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Then release rear connector on engine control unit and pull it
o
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off.
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Cop py
Installing
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Fit rear connector to engine control unit and lock it in position. by c lksw
cted agen
Prote AG.
Push engine control unit onto bracket.
Fit front connector to engine control unit and lock it in position.
Push protective housing onto bracket.
Tighten new shear bolts -1- evenly until heads shear off.
Install bulkhead in plenum chamber General body repairs,
exterior; Rep. Gr. 50 ; Plenum chamber bulkhead; Plenum
chamber bulkhead - Assembly overview .
Install wiper arms and the plenum chamber cover Electrical
system; Rep. Gr. 92 ; Windscreen wiper system; Removing
and installing the windscreen wiper system .

26 Exhaust system
1 Exhaust system
Caution

tions:
Route all the various lines (e.g. for fuel, hydraulics, acti
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po
sitions. olks
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Ensure that there
ris
ed is sufficient clearance to all movingraor
nte
hot components.
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Note
ab
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The flexible pipe connection (de-coupling element) on the front

exhaust pipe must not be bent more than 10 - otherwise it can h re
hole
be damaged. spec
es, in part or in w
t to the co
Renew seals, gaskets and self-locking nuts.
After working on the exhaust system, ensure that the system
is not under stress and that there is sufficient clearance to the
rrectness of i
bodywork. If necessary, loosen clamp-type clip and align si

l purpos
lencer and exhaust pipe so that sufficient clearance is main

tained to the body and the support rings are evenly loaded.
nf
ercia
The exhaust manifold and the turbocharger are one compo

orm
nent, removing and installing page 177 .

m
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Prote AG.
248 Rep. Gr.26 - Exhaust system


equipment required
Lambda probe open ring
spanner set -3337 -
1331-
Pneumatic sabre saw -
V.A.G 1523 A-
Hot bolt paste Electronic
parts catalogue ETKA
lkswage es n
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1. Exhaust system 249

Parts of exhaust system - Assembly overview page 250

Removing and installing front exhaust pipe page 254
Separating front and rear silencers page 259
Aligning exhaust system free of stress page 260
1.1 Parts of exhaustlksw

agen system - Assembly
AG. Volkswagen AG d
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Parts of exhaust system
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t - Assembly overview, engine codes BKC, or ac
BXE page 250 ss
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Parts of exhaust system - Assembly overview, engine codes BLS
an
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(with catalytic converter), BRM page 251
erm
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Front exhaust pipe - Assembly overview, engine code BLS (with
wit
diesel particulate filter) page 252
is n
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Silencer - Assembly overview, engine code BLS (with diesel par
spec
ticulate filter) page 253
t to the co
1.1.1 Parts of exhaust system - Assembly overview, engine codes BKC, BXE
rrectne
The exhaust manifold and the turbocharger are one component,
removing and installing page 177 .
ss o
cial p
f
1 - Front exhaust pipe with cat
inform
alytic converter
mer
atio
2 - Mounting
om
n
c
Renew if damaged.
or
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3 - 25 Nm
i
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pr
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fo
4 - Clamp-type clip
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5 - 25 Nm
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6 - Bolt/screw cop Vo
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7 - Mounting
8 - Retaining ring for front si
lencer
Renew if damaged.
9 - Front and rear silencers
For repairs, renew indi
vidually.
10 - Mounting
With support loop
Renew if damaged.
11 - Connection point
For repairs
Marked by three inden
tations on circumfer
ence of exhaust pipe.
During production, front
and rear silencers are
installed as a single
component. For repairs,
front and rear silencers
are supplied separately.
The connection is made
with a clamp-type clip.

Separating front and rear silencers page 259
Fitting location of rear clamp-type clip (repair double clamp) page 260
Evenly tighten threaded connections on clamp-type clip (repair double clamp).
Torque settings for clamp-type clip (repair double clamp): M8 = 25 Nm
12 - 40 Nm
13 - Support
14 - 7 Nm
15 - Seal
Renew.
16 - Clip
G. Volkswage
1.1.2 Parts of exhaust system
olksw
agen - Assembly
A n AG d
overview,
oes
not engine codes BLS (with cat
alytic converter),b BRM
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The exhaust manifold and au the turbocharger are one component, ac
ss
removing and installing page 188 .
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1 - Front exhaust pipe with cat
erm
ab
alytic converter
ility
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Engine code BLS with
h re
preparation for diesel
ole,
spec
particulate filter
t to the co
2 - Lambda probe -G39-
3 - Clip
rrectne
4 - Seal
Renew.
ss o

cial p
f in
tion.
form
mer
5 - 7 Nm
atio
om
n
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6 - Mounting
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Renew if damaged.
sd
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7 - 25 Nm
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8 - Clamp-type clip t. Cop py
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9 - 25 Nm p by
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10 - Retaining ring for front si Prote AG.
lencer
Renew if damaged.
11 - Front and rear silencers
For repairs, renew indi
vidually.
12 - Mounting
With support loop
Renew if damaged.
For repairs

tations on circumference of exhaust pipe.
During production, front and rear silencers are installed as a single component. For repairs, front and
rear silencers are supplied separately.
The connection is made with a clamp-type clip. AG. Volkswagen AG d
agen oes
Separating front and rear silencers Vopage lksw 259 not
gu
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Fitting location of rear clamp-type ris clip (repair double clamp) page 260ante
ed
ho eo
Evenly tighten threaded connections
s au
t
on clamp-type clip (repair double clamp). ra
c
s
Torque settings for clamp-type clip (repair double clamp): M8 = 25 Nm
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14 - Mounting
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15 - 40 Nm
is n
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16 - Support
spec
17 - 40 Nm
t to the co
rrectne
1.1.3 Front exhaust pipe - Assembly overview, engine code BLS (with diesel par
ticulate filter)
ss o
cial p
f inform
1 - 8 Nm
mer
atio
m
2 - Exhaust gas pressure sen

o
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sor 1 -G450-
i
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3 - Retainer
iv
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For control lines

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4 - 10 Nm Cop py
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5 - Control line, 45 Nm p by
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6 - Lambda probe -G39- , 50 Prote AG.
Nm
Grease threads only
with hot bolt paste - G
052 112 A3- , hot bolt
paste - G 052 112 A3-
must not get into the
slots of probe body.
To remove use lambda
probe open ring span
ner set -3337-
7 - Exhaust gas temperature
sender bank 2 -G448 - , 45 Nm
Lubricate thread of
sender using hot bolt
paste - G 052 112 A3-
8 - Particulate filter
page 257 .
10 - Marking
For clamp.

11 - To front silencer
12 - 25 Nm
13 - Mounting
Renew if damaged.
14 - Exhaust gas temperature sender 3 -G527-
Lubricate thread of sender using hot bolt paste - G 052 112 A3-
15 - From turbocharger
16 - Clamp, 7 Nm AG. Volkswagen AG d
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17 - Seal d by V gu
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Renew.
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18 - 25 Nm
pt
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19 - Retainer
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ab
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Bolted to cylinder head
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1.1.4 Silencer - Assembly overview, engine code BLS (with diesel particulate fil
es, in part or in w
t to the co
ter)
rrectness of i
1 - From diesel particulate filter

l purpos
2 - 25 Nm
Renew.
nf
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3 - Clamp-type clip
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4 - 25 Nm
or c
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5 - Retainer
sd
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For retaining rings

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6 - Retaining rings
Co
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Renew if damaged.
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7 - Rear silencer
by
cted agen
Prote AG.
8 - Mounting
Renew if damaged.
For repairs
tations on circumfer
ence of exhaust pipe.
During production, front
and rear silencers are
installed as a single
component. For repairs,
front and rear silencers
are supplied separately.
The connection is made
with a clamp-type clip.
Separating front and
rear silencers
page 259
Fitting location of rear
clamp-type clip (repair
double clamp)

page 260
Evenly tighten threaded connections of clamp (repair double clamp).
Torque settings for clamp (repair double clamp): M8 = 25 Nm gen AG. Volkswagen AG d
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Aligning exhaust system free of stress page 260 by
Vol
not
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10 - Front silencer oris tee
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1.2 Removing and installing front exhaust
an
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pipe
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Removing and installing front exhaust pipe with catalytic convert
h re
er, engine codes BKC, BXE page 254 hole
spec
es, in part or in w
Removing and installing front exhaust pipe with catalytic convert
t to the co
er, engine codes BLS, BRM page 255
Removing and installing front exhaust pipe with diesel particulate
rrectness of i
filter, engine code BLS page 257
l purpos
1.2.1 Removing and installing front exhaust

pipe with catalytic converter, engine co
nform
ercia
des BKC, BXE

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at
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or
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ate
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Cop py
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Removing page 254

Installing page 255
Removing
Disconnect Lambda probe connector on plenum chamber
bulkhead.
Loosen clamp-type clip bolts -1-.
Note

exhaust pipe must not be bent more than 10 - otherwise it can
be damaged.
Remove front cross member -arrows-.

Unscrew strut -arrows-.
AG. Volkswagen AG d
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ab
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Open clamp -arrow- and take exhaust pipe off turbocharger.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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Remove exhaust pipe retainer -arrows-.

p
cum
for
en
Slide clamp-type clip backwards and take exhaust pipe off.
ng
t.
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Installing t. C rig
gh ht
pyri by
co Vo
by lksw
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Prote AG.
Renew seal.
Align exhaust system free of stress page 260 .
Torque settings
Component Nm
Front exhaust pipe to turbocharger 7
Mounting to subframe 25
Strut to gearbox and front exhaust pipe 40
Front cross member to body 25

pipe with catalytic converter, engine co
des BLS, BRM

Jetta 2005 , Bora 2006 , Golf Variant 2007 AG. Volkswagen A
agen
G do
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Vol ot gu
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Torque wrench -V.A.G 1331- oris eo
th
au ra
c
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nl
pt
du
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ab
ility
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wit
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spec
es, in part or in w
t to the co
rrectness of i
Removing page 256
l purpos
Installing page 257
nform
ercia
Removing
m
at
om
Pull connector -A- off and disconnect.
ion
c
in t
or
Pull wiring harness off the bulkhead retainers.
his
ate
do
riv

p
cum
or

f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Open clamp -A-. Loosen bolt -arrow-.
Note

exhaust pipe must not be bent more than 10 - otherwise it can
be damaged.
Unscrew catalytic converter on retainer -arrows-.

axles, steering; Rep. Gr. 40 ; Servicing drive shafts; Removing
and installing drive shafts .

Loosen clamp-type clip bolts -1-.

Slide clamp-type clip backwards and take exhaust pipe off.
Turn the front exhaust pipe approx. 90 to the right. Lower it
to between the subframe, heat shield and coolant hoses.
Installing
n AG. Volkswagen AG
Install in reverse order.
olks
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does the following:
no
V t gu
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Renew
ris seal.
ed nte
tho eo
Align
ss
au exhaust system free of stress page 260 . r ac
ce
le
Torque settings
un
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an
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itte
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Component Nm
rm
ab
pe
ility
Front exhaust pipe to turbocharger 7

ot
wit
, is n
h re
hole
spec

es, in part or in w
t to the co

pipe with diesel particulate filter, engine
rrectness of i
code BLS
l purpos

nform
ercia

m
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com
tion in
r
te o
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s
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t.
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Cop py
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by c lksw
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Prote AG.
Removing page 257

Installing page 259
Removing
Separate all electrical connectors to particulate filter (on bulk
head)
Pull wiring off the bulkhead retainers.


Rep. Gr. 50 .
Unplug connector for exhaust gas temperature sender 3 -
G527- .
axles, steering; Rep. Gr. 40 .
Open clamp -A-. Loosen bolt -arrow-.
Note
The flexible pipe connection (de-coupling element)n on .the

Volksfront
wagen AG
exhaust pipe must not be bent more than 10 -
wa ge AG
otherwise it can does
lks not
be damaged.
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Remove diesel particulate filter on retainer -arrows-.
wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om

c
i
or
n thi
te
Remove subframe Running gear, axles, steering; Rep. Gr.

sd
iva
40 .
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Loosen clamp-type clip -1-.

Slide clamp-type clip backwards and take exhaust pipe with
diesel particulate filter off.
Installing
Renew seal.
Align exhaust system free of stress page 260 .
Torque settings
Component Nm
Diesel particulate filter on turbocharger 7
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gen AG
Diesel particulate filter on cylinder
Vol
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1.3 Connecting and disconnecting front and
eo
au ra
c
ss
rear silencers
ce
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nl
pt
du
an
itte
To renew the front and rear silencers individually there is a
y li
erm
ab
separating point provided in the connecting pipe.
ility
ot p
The cutting location is marked by an indentation on the cir

wit
, is n
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cumference of the exhaust pipe.
hole
spec
es, in part or in w
t to the co
Pneumatic sabre saw -V.A.G 1523 A-

rrectness of i
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nf
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orm
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or chain pipe cutter -VAS 6254- C py
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Eye protection

Separate
WARNING
AG. Volkswagen AG d
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To avoid injury from metal shavings, wear eye protection
d by V
and gu
ara
protective clothing. rise nte
tho eo
au ra
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nl
Cut through exhaust pipe -arrow 2- e.g. with body saw -
pt
du
an
V.A.G 1523 A- at right angles at the separating point.
itte
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ab
Connect
ility
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hole
Note
spec
es, in part or in w
t to the co
A second mechanic is required to tighten the repair clamp-type
clip.
rrectness of i
Secure front silencer in the retainers. The front clamping
l purpos
sleeve remains loosely pushed onto the pipes.

Align rear silencer horizontally and hold in this position.
nf
ercia
o
Position the repair clamp-type clip at the side markings
rm
m
-arrow 1- and -arrow 3-.
atio
om
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or c
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Fitting location of rear clamp-type clip (repair double clamp)
te
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Turn repair clamp-style clip -A- as shown.

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Install repair double clamp so that the bolt ends do not protrude
t.
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beyond bottom of clamp.
C py
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Align exhaust system free of stress when cold page 260 . cop Vo
by lksw
cted agen
Prote
Tighten the repair double clamp.
AG.
Specified torque M8: 25 Nm
1.4 Stress-free alignment of exhaust system

Prerequisite
The exhaust system must be aligned when it is cold.

Procedure agen
AG. Volkswagen AG d
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Loosen bolts on front retaining clip -1-. ed by ara
nte
ris
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Position clamp-type clip -1- so thatauthe
th distance -a- to the ra
marking on the pipe -2- is 5 mm and
ss tighten front bolt by hand. c
ce
le
The -arrow- points in direction of travel.
un
pt
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ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
Move the exhaust system with silencer forwards until the di
mension -a- = 911 mm is reached on the outer hand hold
l purpos
straps of the front silencer. The -arrow- points in direction of

travel.
nform
ercia
In this position, tighten front clamp-type clip evenly to 25 Nm.

m
a
Aligning tailpipes
com
tion in
r
te o
thi
s
iva
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Cop py
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rig ht
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Align rear silencer so that dimension -a- between bumper cut- by c lksw
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out and end pipes on the left and right-hand sides are the Prote AG.
same.
At the same time the distance -b- from bumper cut-out to end
pipes must be parallel.
To align tail pipe, loosen rear silencer mountings if necessary.

2 Exhaust gas recirculation system

Parts of exhaust gas recirculation -G
nA Assembly
. Volkswageoverview
n AG d
page 262 lkswage oes
not
Vo g y ua
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or
ise exhaust gas recirculation cooler tee
th o
au r
Parts of the exhaust
ss gas recirculation cooler - Assembly overview, ac
engine codes BLS, BRM page 265
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un
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an
d
Removing and installing exhaust gas recirculation cooler

itte
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erm
page 266
ab
ility
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Check mechanical exhaust gas recirculation valve, engine codes
wit
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BKC, BXE page 272
h re
ole,
spec
2.1 Parts of exhaust gas recirculation - As
t to the co
sembly overview
Engine codes BKC, BXE page 262
rrectne
Engine codes BLS, BRM page 263
ss
2.1.1 Parts of exhaust gas recirculation - As
o
cial p
f in
sembly overview, engine codes BKC,
form
mer
BXE
atio
om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng
The function/control of the exhaust gas recirculation system is

t.
yi Co
undertaken by diesel direct injection system control unit -J248 Cop py
. rig
- via exhaust gas recirculation valve -N18- (electro-pneumatic)
t
gh ht
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to exhaust gas recirculation valve (mechanical). cop Vo
by lksw
cted agen
Prote
The electro-pneumatic exhaust gas recirculation valve -N18-
AG.
can be found in the solenoid valve block.

The mechanical cone-shaped plunger in the exhaust gas re
circulation valve ensures that various cross sectional openings
are possible at different plunger lifts.
Pulsed control enables every conceivable valve position.
Solenoid valve block schematic diagram page 238

1 - 22 Nm
2 - Intake manifold
culation valve and in
take manifold flap motor
-V157- .
to 22 Nm.
page 224 .
3 - Seal
Renew.
4 - Connecting pipe
cooler
page 266 .
6 - 10 Nm
7 - Exhaust manifold/turbo
charger
AG. Volkswagen AG d
lksw
agen oes
not
page 177d b.y Vo gu
a
e ran
ris tee
8 - Connecting
ut pipe
ho or
sa ac
9 - Bypasss flap
ce
le
un
pt
Lets the exhaust gas

an
d
itte
flow into the exhaust

y li
erm
ab
gas recirculation cooler

ility
ot p
when the electro-pneu

wit
is n
matic exhaust gas recir

h re
ole,
culation valve -N18- is

spec
activated
t to the co
10 - Retainer
For bypass flap.
rrectne
11 - 5 Nm
ss o
cial p
f inform
2.1.2 Parts of the exhaust gas recirculation -

mer
atio
Assembly overview, engine codes BLS,

om
n
c
BRM
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Note
en
ng
t.
yi Co
Cop py
The function/control of the exhaust gas recirculation system is
t. rig
gh ht
yri by
undertaken by diesel direct injection system control unit -J248
op Vo
by c lksw
- via exhaust gas recirculation potentiometer -G212- .
cted agen
Prote AG.
2. Exhaust gas recirculation system 263

1 - Intake manifold
With intake manifold
flap motor -V157-
Exhaust gas recircula
tion potentiometer -
G212- and exhaust gas
recirculation valve -
N18-
bling intake pipe with ex
haust gas recirculation
potentiometer -G212-
and exhaust gas recir
culation valve -N18-
page 234
to 22 Nm.
page 231 .
2 - Seal
Renew.
cooler
page 271 .
4 - 22 Nm
5 - Adjustment unit for bypass
flap AG. Volkswagen AG d
agen oes
Component of exhaust olksw not
y V gu
gas recirculation coolerrised b ara
nt ee
tho or
6 - Connecting pipe s au ac
s
ce
le
7 - 22 Nm
un
pt
an
d
Renew.
itte
y li
erm
ab
8 - Exhaust manifold/turbocharger
ility
ot p
wit

is n
h re
ole,
9 - 10 Nm
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

n AG. Volkswagen AG do Jetta 2005 , Bora 2006 , Golf Variant 2007
lkswage es n
byV
o
4-cylinder
ot g
uara diesel engine with unit injector - Edition 05.2007
ed nte
oris eo
th
2.2 ss
au
Parts of the exhaust gas recirculation cooler - Assembly overview, engine
ra
c
codes BLS, BRM
ce
e
nl
pt
du
an
itte
y li
erm
ab
1 - 22 Nm
ility
ot p
wit
, is n
2 - Connecting pipe
h re
hole
spec
3 - 22 Nm
es, in part or in w
Renew.
t to the co
4 - Seal
Renew.
rrectness of i
l purpos
tion cooler.
nform
ercia

m
at
om
i
cooler
on
c
in t
or
his
te
page 271 .
a
do
priv
cum
or
8 - Pipe/hose line
f
en
ng
t.
yi Co
9 - Heat shield Cop py
t. rig
gh ht
yri
10 - Spring-type clip p by
co Vo
by lksw
cted agen
11 - Coolant hose Prote AG.
To exhaust gas recircu

lation cooler.
12 - Coolant hose
From exhaust gas recir
culation cooler.
13 - 10 Nm

2.3 Removing and installing exhaust gas re

circulation cooler
Engine codes BKC, BXE page 266
Engine codes BLS, BRM page 271 AG. Volkswagen AG d
agen oes
ksw
2.3.1 Removing and installing exhaust gas re ol not
byV gu
ara
ed
circulation cooler, engine codes BKC, ris nte
ho eo
ut ra
BXE s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
To improve exhaust emission values the exhaust gas recircu
h re
lation system has a cooler through which coolant flows.
hole
spec
The engine control unit determines when the recirculated ex
es, in part or in w
t to the co
haust gas is routed via the cooler. The control unit actuates a
vacuum unit via the exhaust gas cooler change-over valve -
N345- , which in turn operates the exhaust gas recirculation
rrectness of i
change-over valve.
l purpos
nf
ercia
equipment required
orm
m
atio
om
n in
-3094-
or c
thi
te
Torque wrench -
sd
iva
o
r
V.A.G 1331-
rp
cu
o
m
f
en
ng

t.
yi Co
op
5024A- C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing page 267

Installing page 270
Removing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
The hoses -1- up to -3- remain connected.
spec
es, in part or in w
t to the co
Place hoses -1- up to -3- on air duct pipe to side.
Remove air pipe. To do this lift retaining clips -1- lightly.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


V157- .
Remove bolts -1- to -3- and take intake manifold flap motor -
V157- off.
Pull off or disconnect coolant hoses -1- and -2- on exhaust gas
recirculation cooler using hose clamps to 25 mm -3094- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Pull off or disconnect coolant hoses -1- and -2- using hose
ce
e
nl
clamps to 25 mm -3094- .
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nf
ercia
rm
vo.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Remove engine lifting eye on rear of cylinder head -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Remove lower connecting pipe on change-over flap for ex
spec
haust gas recirculation -arrows-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Remove exhaust gas recirculation cooler and change-over

flap from intake manifold -arrows- and take out.
Installing
Note
Renew gaskets, seals and self-locking nuts.

logue ETKA .

-A-.
Torque settings
Component Nm
fold
Connecting pipe for exhaust gas recirculation to 22
change-over flap
Intake manifold flap motor - V157- to intake 10
manifold en AG. Volkswagen AG
ag does
ksw not
Engine lifting eye on cylinder head
by
Vol 22 gu
a
ed ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

lkswage es n
o ot
byV Jetta 2005 , Bora 2006 g ua , Golf Variant 2007
d ran
ir se
tho 4-cylinder diesel engine with unit injector tee
o-r Edition 05.2007
au ac
ss
2.3.2 Removing and installing exhaust gas recirculation cooler, engine codes
ce
e
nl
pt
du
an
BLS, BRM
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
equipment required
hole
spec
Hose clamps to 25 mm es, in part or in w
t to the co
-3094-
Torque wrench -
V.A.G 1331-
rrectness of i
Torque wrench -
l purpos
V.A.G 1410-
nform
ercia
5024A-
m
at
om
i
on
c
in t
-VAS 6208 -
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing page 271

Installing page 272
Removing
Disconnect coolant hoses -1- and -3- using hose clamps to
25 mm -3094 - , see -arrows-.
Open shield -4- and remove.
Remove connecting pipe -2-.

Remove bolts -1-, -2- and -4- and take oil return line -3- off
complete from cylinder block and turbocharger.
lkswage es n
o ot g
Pull pipe/hose line -1- off. d byV ua
ran
ir se tee
Unscrew bolts -2- and -3- and uthtake exhaust gas recirculation
o
or
cooler off. ss
a ac
ce
e
nl
Installing
pt
du
an
itte
y li
erm
ab
ility
ot p
Install exhaust gas recirculation cooler with new seals.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Install oil return line -3- complete.

rrectness of i
Renew bolts -4-.

l purpos

nform
ercia
Install exhaust pipe with catalytic converter page 255 .

m
at
om

ion
c
in t
or
Check engine oil level page 97 .

his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.4 Check mechanical exhaust gas recircu

lation valve, engine codes BKC, BXE
Diesel extractor -VAS 5226- or

Hand-operated vacuum pump with accessories -V.A.G 1390

-
Test procedure
Final control diagnosis performed.
Lift engine cover sideways -arrows 1- and pull off forwards
-arrow 2-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
Detach vacuum hose at mechanical exhaust gas recirculation
du
an
itte
valve.
y li
erm
ab
ility
ot p
wit
uum pump -V.A.G 1390- to the valve.
, is n
h re
hole
Produce vacuum with the diesel extractor -VAS 5226- or the
spec
hand-operated vacuum pump.
es, in part or in w
t to the co
Pull diesel extractor -VAS 5226- or hand-operated vacuum
pump hose off exhaust gas recirculation valve.
rrectness of i
The closing of the valve should be clearly audible. The mem
brane rod moves in direction of intake manifold
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
4-cylinder diesel engine with unit injector - Edition l05.2007
ksw
agen oes
n o ot g
yV ua
edb ran
ris tee
28 Glow plug system
tho or
au ac
ss
ce
le
un
pt
an
d
1 Checking glow plug system
itte
y li
rm
ab
pe
ility
Checking, removing and installing glow plugs page 274
ot
wit
, is n
h re
1.1 Checking, removing and installing glow plugs
hole
spec
es, in part or in w
t to the co
equipment required
rrectness of i
U/J extension and socket,
10 mm -3220-
l purpos

1331-
nform
ercia
Hand multimeter -V.A.G

m
a
1526 C- or hand multimeter
com
tion in
-V.A.G 1526 A-
r
te o
thi
s
Auxiliary measuring set -
iva
do
r
V.A.G 1594 C-
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
WARNING
Ceramic glow plugs page 275 are sensitive against

bumps and bend.
For this reason dropped down glow plugs must never be
used, even if no damage can be seen obviously (and even
if the height was about 2 cm).
It is absolutely necessary to follow the installation instruc
tions, otherwise there is risk of a pin crack which may
result in an engine damage.
274 Rep. Gr.28 - Glow plug system

Optical characteristics of ceramic glow plugs

A - Ceramic glow plug
Step at the point (see magnifying glass)
Color code -arrow-: white
B - Metal glow plug
Color code -arrow-: green
Removing and installing ceramic glow plug, check page 275 .
Removing and installing metal glow plugs, check page 275 .
1.1.1 Removing and installing metal glow

plugs, checking
Test requirements
Fuse box/battery glow plug strip fuse OK
Battery charge at least 11.5 V
Ignition switched off
Test procedure
Detach glow plug connectors from glow plugs.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Connect cable of voltage tester -V.A.G 1527 B- with clamps

h re
from adapter set -V.A.G 1594 C- to battery positive (+).

hole
spec
es, in part or in w
Place test probe of voltage tester -V.A.G 1527 B- on each glow

t to the co
plug one after the other. Diode lights up: glow plug OK., diode
does not light up: renew glow plug.
rrectness of i
Removing
Remove glow plugs with jointed spanner -3220- .
l purpos
Installing
nform
ercia
The rest of the assembly is basically a reverse of the dismantling

m
sequence.
at
om
ion
c
Install glow plugs with jointed wrench -3220- and tighten to 15

in t
or
his
Nm.
ate
do
priv
cum
or
1.1.2 Removing and installing ceramic glow

f
en
ng
t.
yi Co
plugs, checking Cop py
ht. rig
rig ht
py by
Test prerequisites
co Vo
by lksw
cted agen
Prote AG.
Engine is cold
Ignition switched off
1. Checking glow plug system 275

Removing
WARNING
wage
Ceramic glow plugs page 275 are sensitive toybumps Volks es n
ot g
and bending. ir se
d b ua
ran
o tee
h
For this reason dropped down glow plugs au must never be
t or
ac
used, even if no damage can be seen obviously (and even
ss
ce
le
if the height was about 2 cm).
un
pt
an
d
itte
y li
It is absolutely necessary to follow the installation instruc
rm
ab
tions, otherwise there is risk of a pin crack which may
pe
ility
result in an engine damage.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
Do not tilt when removing and installing ceramic glow plugs. Re
rrectness of i
move components hindering the installation.
l purpos

nform
ercia

m
a
com
t
Detach glow plug connectors from glow plugs.
ion in
r
te o
Remove ceramic glow plugs with jointed spanner -3220- .
thi
s
iva
do
r
Installing
rp
cum
fo
en
g

n
t.
yi Co
Cop py
.
Before installing, all deposits must be removed completely
t rig
gh ht
yri by
from cylinder head bore and thread. cop Vo
by lksw
cted agen
Prote AG.
Note
The thread of the hole in the cylinder head or the ceramic glow
plugs must never be greased or oiled.
Fit the ceramic glow plugs into the cylinder head by hand using
the jointed wrench -3220- .
Install glow plugs with jointed wrench -3220- and tighten to 15
Nm.
WARNING
After installing and before the first engine start on the cold
engine, always check resistance of all ceramic glow plugs.
If a defective ceramic glow plug is broken remove all frag
ments from the engine, otherwise these can cause dam
age to the engine.
Specification: max. 1
If the specification is exceeded, renew defective ceramic glow
plugs.
276 Rep. Gr.28 - Glow plug system

4-Cylinder Diesel Engine With Unit Injector

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Service

Service Department. Technical Information

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Copyright 2010 Volkswagen AG, Wolfsburg MEX5R006420

1.5 Assembly mounting - Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.3 Assembly overview - poly-V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.4 Assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.8 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1.6 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1.10 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h re 136

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 142

2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

3.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

3.2 Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

3.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

3.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

3.5 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

3.6 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

6 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

7 Vacuum hoses for connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

7.2 Vehicles with engine codes BLS, BRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

1 Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

1.3 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

1.5 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

1.6 Removing and installing unit injector O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

1.7 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

1.8 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

1.15 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

1.4 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

1.1 Engine number

1.2 Engine data olksw

Emissions fulfil EU4 standard EU4 standard Tier 2 EU4 standard

Capacity l 1.9 1.9 1.9 1.9

Power output kW at rpm 77/4000 77/4000 74/4000 77/4000

Torque Nm at rpm 250/1900 250/1900 250/1900 250/1900

Bore in mm 79.5 79.5 79.5 79.5

Stroke mm 95.5 95.5 95.5 95.5

Valves per cylinder 2 2 2 2

Catalytic converter yes yes yes yes

Diesel particulate filter no depending on no no

Lambda control no yes no no

Turbocharging/supercharging yes yes yes yes

Charge air cooler yes yes yes yes

10 Removing and installing engine

1.1 Removing engine

Special tools and workshop

Drip tray -V.A.G 1306- or

2 Rep. Gr.10 - Removing and installing engine

Torque wrench -V.A.G

Guide rods -T10093-

1. Removing and installing engine 3

Before carrying out further work, disconnect battery earth

ment, pay attention to the following due to the cramped condi

frigerant liquid, brake liquid, vacuum) and electrical wir

With ignition switched off, disconnect earth strap from battery.

abruptly at front -arrows A- and then pull forwards out of rear

fastening -arrow B-.