4-Cylinder Diesel Engine 1.9 L Engine PDF

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Service Department. Technical Information

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Repair GroupsList of Workshop Manual Repair Groups
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00 - Technical data
10 - Removing and installing engine
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13 - Crankshaft group
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15 - Cylinder head, valve gear
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17 - Lubrication
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28 - Glow plug system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg K0059000420

Golf 2004 ➤ , Golf Plus 2005 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 01.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1 Assembly overview - sealingn flanges AG. Volksw and
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2.2 Renewing crankshaft ooil
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2.3 Removing and iinstalling
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2.4 Renewing crankshaft
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2.5 Removingssand installing engine speed sender G28 . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . 31
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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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4.3 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5 Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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1.3 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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2.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.3 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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2.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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2.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.1 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Contents i
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2 Parts of lubrication system . . . . . . . . . . . . . .a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o87
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2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s
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2.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line . . . . . . . . . . . . . . . . . . 92
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3.1 Assembly overview - oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 92
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3.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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3.3 Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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3.4 Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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1.1 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.3 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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1.4 Draining and filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

1.5 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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1.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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1.7 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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1.8 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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1.9 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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3 Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

3.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.5 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.6 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4 Fuel tank, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.4 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.5 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.6 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5 Repairing fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.2 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.3 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.4 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.5 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.3 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.5 Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.6 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.7 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.8 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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AG. Volkswagen AG d
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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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1 Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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1.4 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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1.5 Adjusting non-contact gap of unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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1.6 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.7 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.8 Cleaning the intake manifold flap support, Engine code BLS and BXJ . . . . . . . . . . . . . . . . 176
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1.9 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

2.1 Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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2.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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2.3 Removing and installing engine control unit, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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2.4 Removing and installing anti-theft engine control unit, Golf . . . . . . . . . . . . . . . . . . . . . . . . 180
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2.5 Removing and installing engine control unit, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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2.6 Removing and installing anti-theft engine control unit, Golf Plus . . . . . . . . . . . . . . . . . . . . 183
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
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Cop py
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1 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
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1.1 Assembly overview - front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . . .
by c
186
lksw
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1.2 Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . 187
AG.
1.3 Assembly overview - silencer with mountings (vehicles with front wheel drive) . . . . . . . . . . 189
1.4 Assembly overview - silencer with mountings (vehicles with four-wheel drive) . . . . . . . . . . 191
1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.1 Assembly overview - parts of exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.1 Removing, installing and checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.2 Characteristics of ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1.3 Removing, installing and checking ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Contents iii
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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 (“code letters” and “serial number”) can be
found at the joint between engine and gearbox.
Additionally there is a sticker on the toothed belt guard with “en‐
gine code” and “serial number”.
The engine code is also included on the vehicle data sticker.
AG. Volkswagen AG d
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1.2 Engine data yV
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Engine code BJB
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BKC BRU BLS e o BXE BXF BXJ
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Manufactured s10.03 ▸ 10.03 ▸ 04.04 ▸ 02.06 ▸ 03.06 03.06 11.07
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Emissions fulfil EU3 EU4 EU4 EU4 EU4 pt EU4 EU4

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standard standard standard standard standard y li standard standard

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Capacity l 1.9 1.9 1.9 1.9 1.9 ility
1.9 1.9
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Output kW at 77/ 77/ 66/ 77/ 77/ 66/ 66/
is n
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rpm 4000 4000 4000 4000 4000 4000 4000

ole,
spec
Torque Nm at 250/ 250/ 210/ 250/ 250/ 210/ 210/

rpm 1900 1900 1800...250 1900 1900 1800 1800...250

t to the co
0 0
Bore ∅ mm 79.5 79.5 79.5 79.5 79.5 79.5 79.5
rrectne
Stroke mm 95.5 95.5 95.5 95.5 95.5 95.5 95.5

Valves per cylinder 2 2 2 2 2 2 2
ss
Compression ratio 19.0 19.0 19.0 18.5 18.5 19.0 19.0

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Fuel accord‐ DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN

form
mer
ing to 590 590 590 590 590 590 590

atio
m
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

o
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c
i
or
Catalytic converter yes yes yes yes yes yes yes

thi
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Exhaust gas recircu‐ yes yes yes yes yes yes yes
i
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Turbocharging/super‐ yes yes yes yes yes yes yes
Co
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Charge air cooler yes yes yes yes yes yes yes
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Particulate filter no
Prote
no no yes no no no
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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 7
Notes on installing ⇒ page 7 .
Assembly mountings ⇒ page 10 .
1.1 Removing engine
Special tools and workshop

equipment required
♦ Lifting tackle -2024 A-
♦ Engine bracket -T10012-
♦ Support clamp -VW 313-
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♦ Engine and gearbox sup‐ olksw not
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port -VW 540- d by ara
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♦ Workshop crane -V.A.G s aut ra
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1202 A- s
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♦ Drip tray -V.A.G 1306-
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2 Rep. Gr.10 - Removing and installing engine

♦ Torque wrench -V.A.G

1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Spring-type clip pliers -VAS
5024-
♦ Stepladder -VAS 5085-
♦ Guide rods -T10093-
♦ Cable ties
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Note
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♦ Before carrying out further work, disconnect battery earth

nf
ercia
strap. First check whether a coded radio is fitted. Obtain anti-

o
theft coding first if necessary.

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♦ The engine is removed downwards together with the gearbox.

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♦ All cable ties which are opened or cut through when engine is
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removed must be replaced in the same position when engine

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1. Removing and installing engine 3

WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
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.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
Procedure
– With ignition switched off, disconnect earth strap from battery.
One-piece engine cover
For one-piece engine cover, pull engine cover abruptly upwards
at front and right -arrows A-, then pull forwards out of rear fas‐
tening -arrow B-.
Two-piece engine cover

For two-piece engine cover, first pull outer engine cover n Aabruptly
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– Remove plenum chamber bulkhead. au ⇒ General body repairs,
th ra
exterior; Rep. Gr. 50 ; Body - front,
ss plenum chamber bulk‐ c
ce
head .
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– Remove air filter housing with air mass meter and connecting
y li
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ab
pipe.
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– Remove bolt -arrow A- and pull air filter housing upwards out
of mounting.
– Remove battery and battery tray.
– Disconnect fuel supply and return lines as well as coolant line
on cylinder head.
WARNING
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger ofAscalding)!
G. Volkswagen
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♦ The fuel ysystem
Vol
ks is also under pressure!
s no
Before
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the system,
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place cloths around the connections.
ara
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carefully
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♦ s Wear eye and hand protection when performing any type
ce
le
of repair work on the fuel system!

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– Remove insulation tray ⇒ General body repairs, exterior; Rep.
wit
Gr. 50 ; Body - front; Assembly overview
is n
h re
ole,
– Bring lock carrier into service position ⇒ General body repairs,
spec
exterior; Rep. Gr. 50 ; Body - front; Lock carrier - service po‐
t to the co
sition .
– Drain coolant ⇒ page 102 . rrectne
Vehicles with air conditioner
ss o
Note
cial p
f inform
mer
To prevent damage to condenser or to refrigerant lines/hoses,

atio
m
ensure that the lines and hoses are not stretched, kinked or bent.
o
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To facilitate removing and installing engine without opening re‐

iva
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frigerant circuit:
p
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– Remove poly V-belt ⇒ page 13 .

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– Remove air conditioner compressor ⇒ Heating, air condition‐
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ing; Rep. Gr. 87 ; Removing and installing compressor brack‐
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– Secure air conditioner compressor to lock carrier so that re‐

frigerant lines are free of stress.
– Remove alternator ⇒ Electrical system; Rep. Gr. 27 ; Re‐
moving and installing alternator and poly V-belt .
Continuation for all vehicles
– Remove connecting pipes between charge air cooler and en‐
gine.
– Unbolt left and right-hand drive shafts from gearbox ⇒ Run‐
ning gear, axles, steering; Rep. Gr. 40 ; Removing and
installing drive shaft .
– Remove front exhaust pipe ⇒ page 186 .
– Release connectors on engine control unit and pull them off.

AG. Volkswagen AG d
– Open all cable guide fasteners -arrows-. agen oes
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– Remove wiring harness from cable guide on longitudinal mem‐rised
nte
ber and lay to side on engine. aut
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– Pull off or disconnect all other electrical connections from en‐
ce
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gine and gearbox as necessary and lay to side.
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– Separate all connecting, coolant, vacuum and intake hoses
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from engine.
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Vehicles with manual gearbox
h re
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spec
– Remove slave cylinder for hydraulic clutch. ⇒ 6-speed manual
gearbox 02S; Rep. Gr. 30 ; Repairing clutch mechanism; As‐
t to the co
sembly overview - hydraulics .
– Unbolt gear selector mechanism from gearbox. ⇒ 6-speed
rrectne
manual gearbox 02S; Rep. Gr. 34 ; Repairing selector mech‐
anism .
ss
Vehicles with four-wheel drive:
o
cial p
f in
– Remove selector mechanism from gearbox ⇒ 6-speed man‐
form
mer
ual gearbox 02Q, four-wheel drive; Rep. Gr. 34 ; Repairing
atio
selector mechanism .
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– Separate pressure line for hydraulic clutch control.
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– Remove front propshaft ⇒ Final drive 02D, 0AV; Rep. Gr. 39 ;

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Assembly overview - repairing propshaft .

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– Unbolt pendulum support -arrows-. by c lksw
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Vehicles with particulate filter
– Remove subframe ⇒ Running gear, axles, steering; Rep. Gr.
40 ; Removing and installing subframe .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. Gr. 40 ; Removing and installing drive shafts .
– Remove steering box ⇒ Running gear, axles, steering; Rep.
Gr. 48 ; Removing and installing steering box .
Continuation for all vehicles:
– Insert engine bracket -T10012- in engine and gearbox jack -

V.A.G 1383 A- .
Note
Support pins must be secured to engine bracket -T10012- as

shown.
– Fit engine bracket -T10012- to cylinder block with M10 x 25/

8.8 bolt and tighten to approx. 40 Nm.
– Raise engine and gearbox slightly using engine and gearbox
jack -V.A.G 1383 A- .

– Unbolt assembly mounting on engine side from engine bracket

-arrows-.
Note
olkswagen AG
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To remove securingVbolts,
olks
waguse stepladder -VAS 5085-
does
not .
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– Unbolt assembly mounting on gearbox side from gearbox
ot
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bracket -arrows-.
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spec
– Carefully lower engine with gearbox.
es, in part or in w
t to the co
Note
rrectness of i
Engine with gearbox must be guided carefully when lowered to
prevent damage to bodywork.
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1.2 Securing engine to assembly stand
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When working on the engine, secure it to support clamp -VW 313-

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of the assembly stand using engine and gearbox support -VW

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– Disconnect gearbox.
co lksw
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– Attach lifting tackle -2024 A- as shown and raise engine out of
engine and gearbox jack -V.A.G 1383 A- using workshop hoist
-V.A.G 1202 A- .
Pulley end: 2nd hole in hook rail at position 1
Flywheel end: 4th hole in hook at position 8
WARNING
The hooks and locating pins must be secured with locking pins.
Note
♦ The positions marked 1...4 on the bar must be towards the

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

gearbox jack -VW 540- .
1.3 Notes on installing

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

– Check clutch release bearing for wear and renew if necessary.

– Lubricate splines of input shaft lightly with G 000 100.
– Check whether dowel sleeves for centring engine and gearbox
are in cylinder block and install if necessary.
When installing engine, ensure correct position of assembly
mountings:
– On belt pulley side, ensure that there is a distance -a- of at
least 10 mm between engine support and right longitudinal
member.
– The side surface of the engine support -2- should be located
parallel to the support arm -1-. Dimension -x- must be identical
at top and bottom.
Note
Distance -a- = 10 mm can also be checked with a metal rod of

suitable size, or similar.
AG. Volkswagen AG d
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– 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.
Note
♦ Torque specifications for assembly mounting ⇒ page 10 .

♦ Electrical connections and routing. ⇒ Electrical system; Rep.
Gr. 97
– Install pendulum support. swage

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– Install drive shafts ⇒ Running gear, axles, esteering;
d b Rep. Gr. ua
ran
ir s
40 ; Removing and installing drive shafts tho . tee
or
au ac
– Install front exhaust pipe ⇒ page 186 .
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Vehicles with manual gearbox
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– Install slave cylinder for hydraulic clutch ⇒ 6-speed manual
ab
pe
ility
gearbox 02S; Rep. Gr. 30 ; Repairing clutch mechanism; As‐
ot
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sembly overview - hydraulics .
, is n
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hole
– Remove selector mechanism from gearbox ⇒ 6-speed man‐
spec
ual gearbox 02S; Rep. Gr. 34 ; Repairing selector mecha‐
es, in part or in w
t to the co
nism .
Vehicles with four-wheel drive:
rrectness of i
– Install selector mechanism on gearbox ⇒ 6-speed manual
gearbox 02Q, four-wheel drive; Rep. Gr. 34 ; Repairing se‐
l purpos
lector mechanism .
– Install pressure line for hydraulic clutch control.
nform
ercia
– Install front propshaft ⇒ Final drive 02D, 0AV; Rep. Gr. 39 ;

m
a
com
t
Assembly overview - repairing propshaft .
ion in
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– On vehicles with particulate filter install subframe ⇒ Running

rp
cum
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gear, axles, steering; Rep. Gr. 40

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ng
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– Install alternator ⇒ Electrical system; Rep. Gr. 27 ; Removing C py
t. rig
and installing alternator and poly V- belt .
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pyri by
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– Install air conditioner compressor ⇒ Heating, air conditioning; cted agen
Prote AG.
Rep. Gr. 87 ; Removing and installing compressor bracket.
– Install poly V-belt ⇒ page 13 .
– Install insulation tray ⇒ General body repairs, exterior; Rep.
Gr. 50 ; Body - front; Assembly overview.
– Install engine control unit ⇒ page 178 .
– Install plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body - front; Plenum chamber bulk‐
head .
– Fill cooling system with coolant ⇒ page 102 .
– Carry out road test and then read fault memory ⇒ page 178 .

Specified torques
Threaded connection Specified torque
Bolts, nuts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
1.4 Assembly mountings

Engine assembly mounting
A = 20 Nm + 90° (1/4 turn) further 1)
B = 40 Nm + 90° (1/4 turn) further 1)
C = 60 Nm + 90° (1/4 turn) further 1)
1) Renew
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Gearbox assembly mounting ss
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A = 40 Nm + 90° (1/4 turn) further 1)
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B = 60 Nm + 90° (1/4 turn) further 1)
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spec
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rrectness of i
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Prote AG.

Pendulum support
Always note the size and strength class of bolt. Different specified
torques are valid.
Caution
From model year 08, in manual gearboxes 02Q Heli Coil in‐
serts are installed in the threaded connections to pendulum
support. Difference ⇒ Rep. Gr. 34
For these and all other gearboxes bolts with strength class 10.9
must be used.
If Heli Coil inserts are not fitted in manual gearboxes 02Q, use
bolts with strength class 8.8 and the specified torques.
Bolt -A-
M10 x 35 strength class 8.8: turn 40 Nm + 90° further
M10 x 35 strength class 10.9: turn 50 Nm + 90° further
Always renew after removing
Bolt -B-
olkswagen AG
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M10 x 75 strength class 8.8:oturn
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M10 x 75 strength class
or
ise 10.9: turn 50 Nm + 90° further nte
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Always renew after
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Bolt -C-
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M14 x 1.5 x 70
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100 Nm + turn 90° further

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Tighten only if pendulum support is bolted to gearbox

hole
spec
Always renew after removing

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13 – Crankshaft group
1 Dismantling and assembling engine
Assembly overview - poly V-belt drive ⇒ page 12
Removing and installing poly V-belt ⇒ page 13
Assembly overview - toothed belt drive ⇒ page 15
AG. Volkswagen AG d
Assembly overview - crankcase ⇒ page 19 lksw
agen oes
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If large quantities of metal particles or other deposits (caused, for
nl
pt
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an
example, by partial seizure of the crankshaft or conrod bearings)
itte
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are found in the engine oil when making repairs, clean the oil
erm
ab
ility
passages thoroughly and renew the engine oil cooler in order to
ot p
prevent further damage from occurring later.
wit
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hole
spec
1.1 Assembly overview - poly V-belt drive
es, in part or in w
t to the co
1 - Belt pulley and vibration
rrectness of i
damper
❑ Can only be installed in
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one position, holes are

offset.
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2 - 25 Nm
rm
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3 - Alternator
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or c
4 - Bracket
thi
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sd
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❑ For alternator and air
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conditioner compressor.
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5 - Poly V-belt tensioning ele‐ . Cop py
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❑ Swing with ring spanner
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to slacken poly V-belt. Prote AG.
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.
❑ Removing and installing
⇒ page 13 .
12 Rep. Gr.13 - Crankshaft group

1.2 Removing and installing poly V-belt

Special tools and workshop equipment required
♦ Locking pin -T10060 A-
♦ 16 mm open-end spanner -T 10241-
lkswage es n
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1.2.1 Removing poly V-belt autho tee
or
ac
ss
– Remove insulation tray. ⇒ General body repairs, exterior;
ce
le
un
Rep. Gr. 50 ; Body - front; Assembly overview .
pt
an
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– Pull fuel filter out of bracket and lay it with hoses to side.
rm
ab
pe
ility
– Mark direction of rotation of poly V-belt.
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– Swing tensioning element in direction of arrow to remove ten‐
hole
spec
sion from poly V-belt.
es, in part or in w
t to the co
The open-end spanner 16 mm -T 10241- is particularly well suited
to relieve tension.
rrectness of i
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Prote AG.
1. Dismantling and assembling engine 13

– Lock tensioning element in position with locking pin -T10060

A- .
– Remove poly V-belt.
1.2.2 Installing poly V-belt

– Installation is carried out in the reverse sequence of removal.
Note
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
♦ When fitting poly V-belt, check direction of belt rotation and
ensure proper seating of belt in pulleys.
♦ Lastly, place poly V-belt over alternator.
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After completing repairs always: byV
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– Start engine and check belt running. tho tee
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Belt drive without air conditioner compressor ss
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Belt drive with air conditioner compressor

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1.3 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
❑ Use counterhold tool -
T10051- to loosen and
tighten. agen
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❑ To remove,byuse Vo puller - gu
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⇒ spage 80 , removing
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and installing camshaft.

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6 - 10 Nm
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❑ Renew
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7 - Stud
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spec
❑ 15 Nm
es, in part or in w
t to the co
8 - Rear toothed belt guard
9 - 25 Nm
rrectness of i
10 - Sealing grommet
l purpos
❑ Renew if damaged.
11 - 20 Nm + 1/8 turn (45°) fur‐
nform
ercia
ther
m
12 - Tensioning roller
com
tion in
❑ Remove engine support

r
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in order to remove and

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install ⇒ page 16 .
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13 - 20 Nm
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14 - Idler roller
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15 - Coolant pump
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Prote AG.
❑ Removing and installing ⇒ page 106 .
16 - Crankshaft toothed belt pulley
17 - 120 Nm + 1/4 turn (90°) further
❑ Renew
❑ Use counterhold tool -3099- to loosen and tighten.
❑ Do not additionally oil or grease thread and shoulder.
❑ Turning further can be done in several stages.
18 - 15 Nm
19 - Toothed belt guard lower part
20 - Belt pulley and vibration damper
❑ Can only be installed in one position, holes are offset.
21 - 10 Nm + 1/4 turn (90°) further
❑ Renew

22 - Cover
23 - Toothed belt
❑ Mark direction of rotation before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing and tensioning ⇒ page 50 .
24 - 40 Nm + 1/2 turn (180°) further
❑ Renew
25 - Toothed belt guard centre part
26 - Engine bracket
1.3.1 Removing and installing engine

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support
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Special tools and workshop equipment
ed
required
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♦ Support bracket -10 - 222 A- auth eo
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ss c
♦ Torque wrench -V.A.G 1331-
ce
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– Remove engine cover.

itte
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ab
– To do this, pull engine cover upwards abruptly at front and right
pe
ility
ot
-arrows A- and then pull forwards out of rear fastening
wit
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-arrow B-.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia

m
a
com
For two-piece engine cover, first pull outer engine cover abruptly
ion in
upwards at -arrows-, then pull inner engine cover abruptly up‐

r
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thi
wards at -arrows-.
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Cop py
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rig ht
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Prote AG.

– Separate push-on connectors of fuel lines -arrows-.
Note
♦ Do this by pressing in catch of push-on connectors.

♦ Ensure that no fuel escapes (use a cloth).
– Lay fuel filter with hoses to side.

– Disconnect coolant hose from top of expansion tank.
– Remove expansion tank and lay it to side.
– Remove charge air pipe between charge air cooler and turbo‐
charger.
– Carefully cover or seal open ends.
Golf, Golf Plus and Touran:
– Fit engine support bracket -10-222A- with adapters -10-222A/

13- and take up weight of engine in installation position.
– Remove securing bolts from assembly mounting/engine sup‐

port -arrows- and remove complete assembly mounting.
AG. Volkswagen AG d
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♦ The assembly mounting may only be removed if the engine is ss c
ce
supported with support bracket 10-222A!

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♦ The engine support must only be loosened when the assembly

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erm
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mounting has been removed.

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WARNING
spec
es, in part or in w
t to the co
When raising and lowering engine using support bracket

-10-222A- , ensure that no components or hoses are damaged
or torn off.
rrectness of i
l purpos
– Remove noise insulation tray ⇒ General body repairs, exteri‐

or; Rep. Gr. 50 ; Body - front; Assembly overview - noise
nf
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insulation .
orm
m
– Remove front right wheel housing liner.

atio
om
n in
or c
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sd
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17
Prote AG.
1. Dismantling and assembling engine
AG. Volkswagen A
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– Raise engine with support bracket -10-222A- ed until both upper
by ua
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bolts of engine support can be loosenedhandoris removed. tee
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– Lower engine with support bracket -10-222A-
ss until lower bolt
can be loosened and removed.
ce
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pt
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itte
– Remove engine support upwards.
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Installing
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– Position engine support from above on cylinder block. , is n
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hole
spec
– Insert new bolts and tighten hand-tight.
es, in part or in w
t to the co
Caution
rrectness of i
The tightening sequence and specified torques for the engine
support securing bolts must always be followed. Otherwise the
l purpos
engine support can be stressed and it can break.
nf
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atio
– Tighten bolts for engine support in the sequence shown
om
n in
-1…3- to 40 Nm + 1/2 turn (180 °) further. To do this, raise or
or c
thi
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lower engine using support bracket -10 - 222 A- .

t
sd
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I : Engine support with less clearance to engine
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II: Engine support with greater clearance to engine
Co
Cop py
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Note
by lksw
cted agen
Prote AG.
Before installing assembly mounting, tighten all engine support

bolts to prescribed torque.
– Install assembly mounting between engine and body, renew

securing bolts ⇒ page 10 .
– Bolt engine assembly mounting to engine support -arrows- by

bringing contact surfaces together using support bracket
-10-222A- . Specified torque: 60 Nm + 90° (1/4 turn) further.
Further assembly is basically the reverse of the dismantling se‐
quence. In the process, note the following:
♦ Ensure that fuel hose connections are tight.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
♦ When installing charge air pipes, ensure that locking lugs en‐
gage correctly.
– Install wheel housing liner.
– Install noise insulation tray ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Body - front; Assembly overview - noise insula‐
tion

1.4 Assembly overview - crankcase
1 - Cylinder block
sealing flange and fly‐
wheel ⇒ page 20 .
crankshaft ⇒ page 33
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 33
2 - Gasket
❑ Renew
3 - Oil filter bracket
bling ⇒ page 92 .
4 - 15 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
❑ First fit upper left and
lower right bolts and
then tighten all four bolts
diagonally.
5 - Bracket
6 - 20 Nm
7 - Connection
❑ For thermostat.
AG. Volkswagen AG d
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8 - 15 Nm olksw not
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9 - O-ring horis nte
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❑ Renew ss a c
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10 - Thermostat
un
pt
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⇒ page 108 .
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❑ Observe installation position ⇒ page 108 , removing and installing thermostat.

wit
is n
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❑ Check: Heat thermostat in water

ole,
spec
❑ Opening begins at approx. 85 °C

t to the co
❑ Ends at approx. 105 °C

❑ Opening lift at least 7 mm.
rrectne
11 - Hexagon bolt
❑ Tightening sequence and torque specifications ⇒ Heating, air conditioning; Rep. Gr. 87 ; Removing and
s
installing compressor bracket .

s o
cial p
f in
12 - Bracket
form
mer
❑ For alternator, if air conditioner compressor is fitted

atio
om
13 - Poly V-belt tensioning element

c
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or
n thi
te
14 - 25 Nm
sd
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pr
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15 - Sump
fo
en
ng
t.
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❑ Clean sealing surface before fitting.
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❑ Install with silicone sealant -D 176 404 A2- . gh ht
pyri by
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by c lksw
16 - 15 Nm Prote
cted AG.
agen

2 Removing and installing sealing

flange and flywheel
Assembly overview - sealing flange and flywheel ⇒ page 20
Removing and installing engine speed sender ⇒ page 31
Renewing crankshaft oil seal - pulley end ⇒ page 21 .
Removing and installing sealing flange - pulley end
⇒ page 21 .
Renewing crankshaft sealing flange - flywheel end ⇒ page 25 .
2.1 Assembly overview - sealing flanges and flywheel
Note AG. Volkswagen AG d

agen oes
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Repairing clutch ⇒ 6-speed manual gearbox 02S; Rep. Gr. ed by30
V
; Repairing clutch. gu
ara
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1 - Seal
ce
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nl
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du
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❑ Do not additionally oil or
itte
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grease the oil seal seal‐
erm
ab
ility
ing lip.
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❑ Before installing, re‐
h re
move oil residue from
hole
spec
crankshaft journal using
es, in part or in w
a clean cloth.
t to the co
❑ Renewing crankshaft oil
seal - pulley end
⇒ page 21 .
rrectness of i
2 - Sealing flange
l purpos
❑ Must be positioned on
dowel sleeves.
nform
ercia

m
at
⇒ page 23 .
om
ion
c
❑ Install with silicone seal‐

in t
or
his
e
ant -D 176 404 A2-

at
do
riv
⇒ page 23 .
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3 - Cylinder block
en
ng
t.
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❑ Removing and installing C py
ht. rig
crankshaft ⇒ page 33 rig ht
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by lksw
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bling pistons and con‐
AG.
rods ⇒ page 33
4 - 60 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew
5 - Flywheel
❑ To remove and install
flywheel, counterhold
with 3067.
6 - Intermediate plate
❑ Must be positioned 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 - Removing and installing engine speed sender -G28- ⇒ page 31 .,
❑ Loosen and tighten using commercially available ball-ended hexagon key socket
❑ Specified torque: 5 Nm.
2.2 Renewing crankshaft oil seal - pulley end

equipment required
♦ Counterhold tool -3099-
♦ Oil seal extractor -3203-
♦ Assembly tool -T10053-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
AG. Volkswagen AG d
agen oes
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
2.2.1 Removing
a
com
tion in
r
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– Remove toothed belt. ⇒ page 50

thi
s
iva
do
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cum
fo
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t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.
2. Removing and installing sealing flange and flywheel 21

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

ed belt pulley using counterhold tool -3099- .
Note
When bolting on counterhold tool, place two washers between

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

into crankshaft to stop.
AG. Volkswagen
– Unscrew inner part oflkoil
swaseal extractor two turns
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mm) out of outerd bpart
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– Oil threaded
ut head of oil seal extractor.
ho or
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ss
ce
e
– Using great pressure, screw oil seal extractor as far as possi‐

nl
pt
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ble into seal.
an
itte
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erm
ab
– Loosen knurled screw and turn inner part against crankshaft
ility
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until oil seal is pulled out.
wit
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spec
es, in part or in w
t to the co
rrectness of i
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2.2.2 Installing
nf
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Note
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The oil seal sealing lip must not be additionally oiled or greased.
iv
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f
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ng
t.
– Remove oil residue from crankshaft journal using clean cloth.
yi Co
Cop py
t. rig
– Place guide sleeve -T10053/1- onto crankshaft journal. gh ht
pyri by
Vo
co lksw
by
– Slide oil seal over guide sleeve onto crankshaft journal. Prote
cted AG.
agen

– Press oil seal in to stop using assembly tool -T10053- and

centre bolt.
– Install and tighten toothed belt ⇒ page 50 .
2.3 Removing and installing sealing flange - pulley end

equipment required
♦ Counterhold tool -3099-
♦ Assembly tool -T10053-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Hand drill with plastic brush
attachment
♦ Silicone sealant -D 176 404
A- agen
AG. Volkswagen AG d
o w es n
olks ot g
♦ Flat scraper ed
byV ua
ran
ris tee
tho or
au ac
ss
ce
e
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
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
2.3.1 Removing
for
en
ng
t.
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op
– Remove toothed belt. ⇒ page 50 C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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

ed belt pulley using counterhold tool -3099- .
Note
When bolting on counterhold tool, place two washers between

toothed belt pulley and counterhold tool.
– Drain engine oil.

– Remove sump ⇒ page 88 .
– Pull off front sealing flange.
– Remove sealing flange; if necessary, loosen by applying light
blows with a rubber-headed hammer.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove residual sealant from sealing flange using a plastic

rotary brush (wear eye protection).
– Clean sealing surfaces. They must be free of oil and grease.
AG. Volkswagen AG d
agen oes
olksw not
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ed
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nl
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itte
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2.3.2 Installing
wit
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spec
es, in part or in w
Note
t to the co
♦ Observe expiry date of sealing compound.

rrectness of i
♦ Install sealing flange within 5 minutes of applying the silicone

sealant.
l purpos
– Cut off tube nozzle at forward marking (approx. 3 mm nozzle

nf
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∅).
orm
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n in
c
Note
or
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sd
iva
♦ Sealant bead must not be wider than 2...3 mm, because oth‐
r
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cu
o
erwise excess sealant can enter sump and clog strainer in oil
f
en
ng
t.
pump suction pipe as well as drip onto crankshaft oil seal.
yi Co
Cop py
ht. rig
♦ Before applying sealant bead, cover sealing surface of oil seal rig ht
py by
with a clean cloth.
co Vo
by lksw
cted agen
Prote AG.

– Apply silicone sealant bead as shown to the clean sealing sur‐

face of 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 sump ⇒ page 88 .
Note
After fitting, allow sealant to dry for approx. 30 minutes. Only then
fill with engine oil.
Installing toothed belt and adjusting valve timing. ⇒ page 50
2.4 Renewing crankshaft sealing flange -

flywheel end agen
AG. Volkswagen AG d
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olks ot g
Special tools and workshop equipment required ed
byV ua
ran
ris tee
♦ Assembly tool -T10134- tho or
au ac
ss
ce
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nl
pt
du
an
♦ Socket -V.A.G 1332/11-
itte
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erm
ab
♦ Vernier gauge
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♦ Three hexagon bolts M6 x 35 mm
h re
hole
♦ Two hexagon bolts M7 x 35 mm
spec
es, in part or in w
t to the co
2.4.1 Pressing out sealing flange with sender
wheel
rrectness of i
l purpos
Note
♦ For the sake of clarity, the work is performed with the engine
nf
ercia
removed.
rm
m
atio
m
♦ The procedure is identical whether the engine is installed or

o
n in
c
removed.
or
thi
te
sd
iva
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– Remove flywheel.
o
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f
en
ng
t.
– Remove intermediate plate.
yi Co
Cop py
ht. rig
– Set engine to TDC No. 1 cylinder ⇒ page 50 , Removing and rig ht
py by
installing toothed belt.
co Vo
by lksw
cted agen
Prote AG.
– Remove sump ⇒ page 88 .

– Remove engine speed sender -G28- -arrow- using a commer‐

cially available ball-ended hex key socket ⇒ page 31 .
– Unscrew sealing flange securing bolts.
Note
Sealing flange and sender wheel are pressed off the crankshaft
together using three M6 x 35 mm bolts.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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– Screw three M6 x 35 mm bolts into threaded holes -arrows- of s
ce
e
sealing flange.
nl
pt
du
an
itte
y li
– Screw bolts alternately (max. 1/2 turn 180° for each bolt) into
erm
ab
sealing flange and press sealing flange together with sender
ility
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wheel off crankshaft.
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hole
spec
es, in part or in w
t to the co
rrectness of i
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2.4.2 Pressing in sealing flange with sender nform

ercia
wheel
m
at
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ion
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Note
o
his
ate
do
priv
♦ The sealing flange with a PTFE seal is equipped with a sealing

um
for
lip support ring. This support ring serves as a fitting sleeve and
en
ng
t.
yi
must not be removed prior to installation.
Co
Cop py
ht. rig
♦ Sealing flange and sender wheel must not be separated or
rig ht
py by
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turned after removal from packaging. by c lksw
cted agen
Prote AG.
♦ The sender wheel is held in its installation position on the as‐
sembly device -T10134- by a locating pin.
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
♦ The assembly device -T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.
Assembly tool -T10134-

A - Clamping surface
B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
G - Guide pin for petrol engines (red knob)

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gen AG
2.4.3 A - Assembling seal olkwith
swa sender wheeloes no d
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on assembly tool
ise -T10134-
d b ara
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ut or
– Screw in hexagon nut -B-
ss to just before clamping surface -A-
a ac
of threaded spindle.
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Clamp assembly device -T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
nform
ercia
– Press assembly housing -C- downwards so that it lies on hex‐

m
agon nut -B- -arrow-.
a
com
tion in
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Note
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en
Inner part of assembly tool and assembly housing must be at
ng
t.
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same height. ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
twisted.
– 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.

– Push sealing lip support ring -A- downwards in direction of ar‐

row until it lies on flat surface.
– Upper edge of sender wheel and front edge of sealing flange

must align -arrows-.
lkswage es n
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– Place sealing flange with front side on assemblyistooled -T10134-
b ua
ran
so that locating pin -A- can be inserted in sender
thor
wheel hole tee
or
-A-. ss
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nl
pt
du
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Note
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ility
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Ensure sealing flange lies flat on assembly device.
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly device -T10134- whilst tightening the
l purpos
three knurled screws -A- so that locating pin cannot slide out
of sender wheel hole.
nform
mercia
at
Note
om
ion
c
in t
or
When installing sealing flange, ensure that sender wheel remains

his
ate
fixed in assembly device.

do
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for
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Cop py
t. rig
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co
2.4.4 B - Attaching assembling tool -T10134-
by lksw
cted agen
Prote AG.
with sealing flange on crankshaft flange
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder

– Screw hexagon nut -B- to end of threaded spindle.

– Press threaded spindle of assembly tool -T10134- in direction
of arrow, until hexagon nut -B- lies against assembly housing
-A-.
– Align flat side of assembly housing on sump side of crankcase
sealing surface.
– Secure assembly tool -T10134- to crankshaft flange using

hexagon socket head bolts -A-.
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
– To guide sealing flange, screw two M7 × 35 mm bolts -A- into

cylinder block. wage
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spec
es, in part or in w
t to the co
2.4.5 C - Bolting assembly tool -T10134- onto

crankshaft flange
rrectness of i
– Push assembly housing -C- by hand in direction of arrow until

l purpos
sealing lip support ring -B- contacts crankshaft flange -A-.

– Push guide pin for diesel engines (black knob) -D- into hole in
nform
ercia
crankshaft. This ensures that the sender wheel reaches its fi‐
nal installation position.
m
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tion in
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Note
s
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fo
The guide pin for petrol engines (red knob) -F- must not be inser‐
en
ng
t.
ted in threaded hole of crankshaft.
yi Co
Cop py
t. rig
gh ht
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– Hand-tighten both hexagon socket head bolts of assembly cop Vo
by lksw
tool. cted agen
Prote AG.
– Screw hexagon nut -E- onto threaded spindle by hand until it

lies on assembly housing -C-.

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Golf 2004 ➤ , Golf Plus 2005 ➤ ed b ara
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4-cylinder diesel engine (1.9 l engine)uth- Edition 01.2009
o eo
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2.4.6 D - Pressing sender wheel onto crank‐
ce
e
nl
pt
du
an
shaft flange using assembly tool -
itte
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erm
ab
T10134-
ility
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wit
, is n
– Tighten hexagon nut of assembly tool -T10134- to 35 Nm us‐
h re
hole
ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G
spec
1332/11- .
es, in part or in w
t to the co
Note
rrectness of i
After hexagon nut is tightened to 35 Nm, a small air gap must be
l purpos
present between cylinder block and sealing flange.
nf
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orm
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2.4.7 E - Checking sender wheel installation

t
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position on crankshaft
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– Screw hexagon nut -E- to end of threaded spindle. . Cop py
rig
ht ht
rig
– Remove the two bolts -A- from cylinder block. py by
co Vo
by lksw
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– Screw the three knurled screws -B- out of sealing flange. Prote AG.
– Remove assembly tool -T10134- .

– Remove sealing lip support ring.
– The sender wheel is in the correct installation position on the

crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.
– Set vernier gauge on crankshaft flange.

– Measure distance -a- between crankshaft flange and sender
wheel.
If measurement -a- is too small:
– Press sender wheel further. ⇒ page 31
If dimension -a- is attained:
– Tighten new securing bolts for sealing flange to 15 Nm using
alternate and diagonal sequence.

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

ing bolt to 5 Nm.
– Install sump ⇒ page 88 .
– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to 60
Nm +1/4 turn (90°).
2.4.8 F - Re-pressing sender wheel

– Secure assembly tool -T10134- to crankshaft flange using
hexagon socket head bolts -A-.
– Hand tighten both hexagon socket head bolts.
– Push assembly tool -T10134- by hand to sealing flange.
AG. Volkswagen AG d
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– Screw hexagon nut -E- onto threaded spindle by hand until it
ce
e
nl
pt
lies on assembly housing -C-.
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
– Tighten hexagon nut of assembly tool -T10134- to 40 Nm us‐

nf
ercia
ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G

or
1332/11- .
m
m
atio
m
– Check installation position of sender wheel on crankshaft

o
n in
or c
again. ⇒ page 30
thi
te
sd
iva
If dimension -a- is too small again:

o
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rp
cu
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m
f
– Tighten hexagon nut for assembly tool -T10134- to 45 Nm.

en
ng
t.
yi Co
op py
– Check installation position of sender wheel on crankshaft t. C rig
gh ht
again. ⇒ page 30 yri
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by c lksw
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Prote AG.
2.5 Removing and installing engine speed

sender -G28-

♦ Hexagon key extension, 4 mm -T10370-
♦ Or commercially available ball-ended hexagon key socket, 5

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mm swa
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Two different bolts are installed, check which tool is to be used.

un
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an
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insulation .
is n
h re
ole,
– Clamp off coolant hoses at engine oil cooler using hose clip
spec
and pull off hoses.
t to the co
– Remove oil filter bracket.
– Remove securing bolt -arrow- and pull out engine speed send‐
rrectne
er -G28- .
Installation is performed in the reverse order, observing the fol‐
ss
lowing: specified torque for engine speed sender -G28- securing
o
cial p
f i
bolt: 5 Nm.
nform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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.

3 Crankshaft
Assembly overview - crankshaft ⇒ page 33
Crankshaft dimensions ⇒ page 38 .
3.1 Assembly overview - crankshaft
1 - Bearing shells 1, 2, 4 and 5

❑ For bearing cap without
oil groove. n AG. Volkswagen AG do
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❑ For cylinder block with d byV ua
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oil groove. ir se tee
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❑ Do not interchange ss
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used bearing shells
ce
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nl
(mark).
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2 - 65 Nm + 1/4 turn (90°) fur‐
erm
ab
ility
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ther
wit
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❑ Renew
h re
hole
spec
❑ To measure radial clear‐
es, in part or in w
ance, tighten to 65 Nm
t to the co
but not further.
3 - Bearing cap
rrectness of i
❑ Bearing cap 1: pulley
end.
l purpos
❑ Bearing cap 3 with re‐

cesses for thrust wash‐
nf
ercia
ers.
orm
m
❑ Bearing shell retaining
atio
m
lugs in cylinder block

o
n in
or c
and bearing caps must
thi
te
align.
sd
iva
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4 - Bearing shell 3
o
m
f
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ng
t.
yi
❑ For bearing cap without
Co
op py
oil groove. t. C rig
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❑ For cylinder block with cop Vo
by lksw
oil groove. cted agen
Prote AG.
5 - Thrust washer
❑ For bearing cap 3.
❑ Note fixing arrange‐
ment.
6 - Crankshaft
❑ Axial clearance new: 0.07…0.17 mm, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage new: 0.03...0.08 mm, wear limit: 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 38 .
7 - Thrust washer
❑ For cylinder block, bearing 3
3. Crankshaft 33
3.1.1 Renewing needle bearing in crankshaft

- vehicles with dual clutch gearbox
6-speed dual clutch gearbox: If the engine or gearbox has to be
removed during repairs, check needle bearing in crankshaft. If it
is damaged or tarnished blue, it must be renewed.
– If it is not damaged, lightly grease with high-temperature
grease -G052133A2- .
7-speed dual clutch gearbox: Always renew needle bearing when

removing engine or gearbox.
6-speed dual clutch gearbox
AG. Volkswagen AG d
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ab
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This gearbox can be identified by the gearbox oil cooler
hole
spec
es, in part or in w
Special tools, testers, measuring instruments and auxiliary items
t to the co
required
rrectness of i
l purpos
nf
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orm
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Cop py
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pyri by
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1 - -1- Kukko 21/2

2 - Centring mandrel -3176-
3 - Drift -VW 207 C-
AG. Volkswagen AG d
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wit
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spec
es, in part or in w
t to the co
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mercia
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s
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Puller -T10055- with adapter -T10055/3-

um
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t.
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Procedure
Co
Cop py
t. rig
• Gearbox is unscrewed from engine.
gh ht
pyri by
Vo
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by
Pulling needle bearing out: cted agen
Prote AG.
3. Crankshaft 35
– Pull out needle roller bearing using Kukko 21/2, adapter -

T10055/3- and puller -T10055- .
7-speed dual clutch gearbox

No gearbox oil cooler is installed.
AG. Volkswagen AG d
Always renew needle bearing when removingolkengine
swa
gen or gearbox. oes
not
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by
Special tools, testers, measuring instruments
ris
ed and auxiliary items ara
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required utho eo
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
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c
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Cop py
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rig ht
py by
co Vo
by lksw
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1 - -1- Kukko 21/2 and -4- Kuk‐

ko 22/1
AG. Volkswagen AG d
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2 - Centring mandrel -3176- Volksw not
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3 - Drift -VW 207 C- horis nte
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aut ra
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d
itte
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erm
ab
ility
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wit
is n
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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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o
pr
cum
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Procedure
• Gearbox is unscrewed from engine.
Pulling needle bearing out:
– Pull out using commercially available puller -A-, e.g. Kukko
21/2 and Kukko 22/1.
Installing
3. Crankshaft 37
– Drive needle bearing in with drift -VW 207 C- or with centring

mandrel -3176- .
– Carefully drive needle bearing in.
– Always measure the driving depth when driving in.
Renew bearing, if driving depth is too deep.
AG. Volkswagen AG d
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• Driving depth: Dimension -a- = 1.5 to 1.8 mm.
itte
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erm
ab
ility
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
3.2 Crankshaft dimensions
mer
atio
m
(Dimensions in mm)
o
n
c
i
or
n thi
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Honing dimen‐ Crankshaft bearing Conrod

t
sd
va
sion journal ∅ journal ∅

i
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pr
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fo
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Basic dimension 54.00 -0.022 47.80 -0.022

t.
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-0.042 -0.042 Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.

4 Pistons and conrods

Assembly overview - pistons and conrods ⇒ page 39 .
Separating new conrod ⇒ page 40 .
Checking piston projection at TDC ⇒ page 41
Piston and cylinder dimensions ⇒ page 42 .
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Piston rings, cylinder bore and piston installation position lksw
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⇒ page 42 d by
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4.1 Assembly overview - pistons and conrods ho eo
aut ra
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nl
pt
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1 - Piston rings
an
itte
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erm
❑ Offset gaps by 120°.
ab
ility
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❑ Use piston ring pliers to
wit
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remove and install.
h re
hole
❑ “TOP” faces towards
spec
piston crown.
es, in part or in w
t to the co
❑ Checking piston ring
gap ⇒ page 42 .
❑ Checking ring-to-groove
rrectness of i
clearance ⇒ page 42 .
l purpos
2 - Piston
❑ With combustion cham‐
nform
ercia
ber.
m
at
❑ Mark installation posi‐
om
io
tion and cylinder num‐
n
c
in t
or
ber.
his
ate
do
riv
❑ Installation position and

p
cum
allocation of piston to
for
en
g
cylinder ⇒ page 43 .
n
t.
yi Co
op py
❑ Arrow on piston crown t. C rig
gh ht
points to belt pulley end. yri
p by
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by c lksw
❑ Install using piston ring cted agen
Prote AG.
clamp.
❑ Cracks on piston skirt,
renew piston.
❑ Checking piston projec‐
tion at TDC
⇒ page 41
3 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C.
❑ Remove and install us‐
ing drift -VW 222- .
4 - Circlip
5 - Conrod
❑ Mark cylinder allocation -A- with coloured pen.
❑ Installation position: Marking -B- faces towards pulley end.
❑ With industrially cracked conrod cap.
6 - Bearing shell
❑ Note installation position.
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
cation: Black line on bearing surface in area of joint.
4. Pistons and conrods 39

❑ 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 bore ⇒ page 43 .
❑ Piston and cylinder dimensions ⇒ page 42 .
8 - Conrod bearing cap
❑ The cap only fits in one position and only on the appropriate conrod due to the breaking procedure
(cracking), separating the cap from conrod.
9 - Oil spray jet
❑ For piston cooling
Note
10 - 25 Nm
❑ Insert without sealant.
11 - Conrod bolt, 30 Nm + 1/4 turn (90°) further
❑ Renew
❑ Oil threads and contact surface.
❑ Use old bolt for measuring radial clearance.
lkswage es n
Vo ot g
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4.2 Separating new conrod ss
ce
le
un
pt
an
d
– Mark cylinder allocation of conrod ⇒ Item 5 (page 39)

itte
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erm
ab
– Lightly clamp the conrod in a vice using aluminium vice

ility
ot p
clamps, as shown in the illustration.

wit
is n
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ole,
spec
Note
t to the co
♦ To prevent damage to the conrod, only clamp conrod in lightly.

♦ Clamp conrod in below the marked line.
rrectne
– Unscrew the two bolts -arrows- approx. 5 turns.

ss o
cial p
f inform
mer
atio
m
– Using a plastic hammer, carefully knock against conrod bear‐

o
n
c
ing cap -arrow- until it is loose.

i
or
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te
sd
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cum
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fo
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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.

4.3 Checking piston projection at TDC

♦ Measuring bridge -VW 382/7-
♦ End dimension plate -VW 385/17-
lkswage es n
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ir se tee
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un
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♦ Dial gauge
, is n
h re
hole
Test procedure
spec
es, in part or in w
t to the co
Note
rrectness of i
If different values are determined during the projection measure‐

ment, use the largest dimension for selecting the gasket.
l purpos
Piston projection at TDC must be measured when installing new

nform
ercia
pistons or a short engine. Install the appropriate cylinder head

gasket depending upon piston projection, according to following
m
a
com
table:
ion in
r
te o
thi
s
iva
do
Note
r
rp
cum
fo
en
ng
t.
Turn engine clockwise to measure piston projection at TDC.
yi Co
Cop py
t. rig
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yri by
Piston projection Identification
cop Vo
by lksw
Holes/notches
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Prote AG.
0.91 mm ... 1.00 mm 1

1.01 mm ... 1.10 mm 2
1.11 mm ... 1.20 mm 3

Golf 2004 ➤ , Golf Plus 2005 ➤ olkswagen AG
4-cylinder diesel engine (1.9 l engine) en AG. V01.2009
-agEdition does
lksw
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Cylinder head gasket identification horis tee
t or
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♦ Part number = arrow 1 ss
ce
le
un
♦ Production control code = arrow 2 (can be disregarded)
pt
an
d
itte
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♦ Holes = arrow 3
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
4.4 Piston and cylinder dimensions
l purpos
Honing dimension Piston ∅ Cylinder bore ∅
nform
ercia
Basic dimen‐ mm 79.47 79.51

sion
m
a
com
tio
Stage I mm 79.72 79.76
n in
r
te o
thi
Stage II mm 79.97 80.01
s
iva
do
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rp
cum
4.5 Piston rings, cylinder bore and piston in‐
fo
en
ng
t.
yi
stallation position
Co
Cop py
t. rig
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yri
Checking piston ring gap
p by
o Vo
by c lksw
cted agen
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
dimensions in mm
1. compression ring 0.20...0.40 1.0
Oil scraper ring 0.25...0.50 1.0
Checking ring-to-groove clearance

♦ Feeler gauges

– Clean ring groove before checking.

Piston ring New Wear limit
dimensions in mm
Oil scraper ring 0.03...0.06 0.15
Checking cylinder bores

♦ 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 max. 0.10 mm.
Note
Cylinder bores must not be measured swa

gewhen cylinder
n AG. Vo block
lkswagen AG
doesis
mounted on a repair stand with y engine
Vo lk support bracket -VW 540-
not ,
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as measurements may then ris
ed be
b
incorrect. ara
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Piston installation position
ss and allocation of piston to cylinder
ce
le
un
pt
Piston in cylinders 1 and 2:

an
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itte
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rm
Larger inlet valve chamber towards flywheel -arrows-.

ab
pe
ility
ot
Piston in cylinders 3 and 4:

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h re
Larger inlet valve chamber towards belt pulley side -arrows-.

hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ New piston allocation to cylinders is shown by a coloured

marking on piston crown.
l purpos
♦ Piston for cylinders 1 and 2: marked 1/2

nform
ercia
♦ Piston for cylinders 3 and 4: marked 3/4

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tion in
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ When installing an exchange cylinder head with fitted cam‐

shaft, the contact surfaces between the bucket tappets and
the cam must be oiled before installing the cylinder head cov‐
er.
♦ The plastic protectors fitted to protect the open valves must be
removed only immediately before the cylinder head is fitted.
♦ If the cylinder head is replaced, all the coolant in the system
must also be renewed.
AG. Volkswagen AG d
agen oes
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d by ara
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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
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
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
44 Rep. Gr.15 - Cylinder head, valve gear

Removing and installing cylinder head cover ⇒ page 48 .

Removing, installing and tensioning toothed belt ⇒ page 50
Removing and installing cylinder head ⇒ page 67
Checking compression ⇒ page 71 .
1.1 Assembly overview - cylinder head
1 - Toothed belt guard upper

part
2 - Toothed belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning
⇒ page 50 .
3 - 10 Nm
❑ Renew
4 - 25 Nm
5 - 100 Nm
6 - Camshaft pulley agen
AG. Volkswagen AG d
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7 - Hub d by gu
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❑ With sender wheel
utho eo
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a
❑ Use counterhold
ss tool - c
ce
le
T10051- to loosen and

un
pt
tighten.
an
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rm
❑ To remove, use puller -

ab
pe
ility
T10052-
ot
wit
, is n

h re
hole
spec
8 - Rear toothed belt guard

es, in part or in w
t to the co
9 - Sealing grommet
rrectness of i
10 - Hall sender -G40-

❑ For camshaft position
l purpos
❑ To remove, unbutton
sealing grommet
nform
ercia
⇒ Item 9 (page 45) from rear toothed belt guard.

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com
11 - Stud
ion in
r
❑ 15 Nm
te o
thi
s
iva
do
12 - Cylinder head bolt

r
rp
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fo
❑ Observe sequence when loosening and tightening ⇒ page 67 .

en
ng
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❑ Before installing, place washers in cylinder head ⇒ Item 4 (page 74) .
t. Cop py
rig
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13 - Fuel return line p by
co Vo
by lksw
cted agen
14 - Fuel supply line Prote AG.
15 - Coolant line
16 - Cylinder head cover
❑ Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth.
1. Cylinder head 45
17 - Pressure regulating valve

❑ For crankcase ventilation.
18 - To turbocharger.
19 - Sealing cap
❑ Renew seal if damaged
20 - Seal
21 - 10 Nm
❑ Observe tightening sequence ⇒ page 48 .
22 - Gasket for cylinder head cover
❑ Renew together with cylinder head cover only.
❑ Before fitting, seal transitions with “AMV 174 004 01” ⇒ page 48
Volkswa AG. gen AG
agen does
23 - 20 Nm olksw not
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24 - Lifting eye rise nte
tho eo
au ra
25 - Unit injector ss c
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nl
pt
du
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itte
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26 - 10 Nm
erm
ab
ility
ot p
27 - Central connector
wit
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❑ For unit injector
h re
hole
spec
28 - From brake servo
es, in part or in w
t to the co
29 - Tandem pump
❑ For fuel and vacuum supply
❑ Checking ⇒ page 147 . rrectness of i
l purpos
❑ Must not be dismantled.

nf
ercia
30 - Supply hose
orm
m
❑ From fuel filter.

atio
om
❑ White or with white marking.

n in
or c
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e

t
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❑ Secure with spring-type clips.

rp
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31 - Return hose
t.
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op py
❑ To fuel filter
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❑ Blue or with blue marking. cop Vo
by lksw
cted agen
❑ Check for secure seating. Prote AG.
❑ Secure with spring-type clips.

32 - Gasket
❑ Renew
33 - Bracket
34 - 20 Nm
35 - Cylinder head
❑ After renewing, renew entire coolant
36 - Cylinder head gasket
❑ Renew
❑ Note marking ⇒ page 47
❑ After renewing, renew entire coolant

37 - Glow plug
❑ 15 Nm
❑ Checking ⇒ page 198 .
38 - Tensioning roller
❑ Remove engine support in order to remove and install ⇒ page 16 .
39 - 20 Nm + 1/8 turn (45°) further
Checking cylinder head for distortion
AG. Volkswagen AG d
agen oes
olksw not
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Special tools and workshop equipment required orise nte
eo
h
ut ra
♦ Straight edge ss a c
ce
e
nl
♦ Feeler gauges
pt
du
an
itte
y li
Max. permissible distortion: 0.1 mm.
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Reworking diesel cylinder heads is not permissible.
t to the co
Cylinder head gasket identification
rrectness of i
♦ Part number = arrow 1
l purpos
♦ Production control code = arrow 2 (can be disregarded)

♦ Holes = arrow 3
nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
te
♦ Different thicknesses of cylinder head gasket are fitted de‐

sd
iva
o
r
pending on the piston projection. When renewing gasket,

rp
cu
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install new gasket with same identification.

f
en
ng
t.
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op
♦ Piston projection at TDC must be determined when installing
C py
ht. rig
new pistons or a short engine. ⇒ page 41 rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 47
1.2 Removing and installing cylinder head

cover

♦ Sealant -AMV 174 004 01-
⇒ page 4 Removing
– Remove engine cover. To do this, pull engine cover upwards
abruptly at front -arrows A- and then pull forwards out of rear
fastening -arrow B-.

AG. Volkswagen AG d
agen oes
For two-piece engine cover, first pull outer engine cover abruptlyy Volksw not
gu
upwards at -arrows-, then pull inner engine cover abruptly up‐ ed
b ara
nte
wards at -arrows-. oris eo
th
au ra
c
– Remove upper toothed belt guard. ss
ce
e
nl
pt
du
– Disconnect crankcase breather hose at union of rear of charge an

itte
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air pipe.
erm
ab
ility
ot p
– Unbolt bracket from exhaust gas recirculation valve.

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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Engine codes BLS, BXJ: to remove cylinder head cover, addi‐

tionally remove:
♦ -1- upper toothed belt guard
♦ -2- intake hose
♦ -3- intake manifold flap Renew seal.
♦ -4- bolt, 8 Nm
gen AG
. Volkswagen AG
d wa oes
olks not
– Remove cylinder
d b head cover.
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ara
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ris
utho eo
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ss
Cylinder head cover, engine codes: BJB, BKC, BRU, BXE, BXF
ce
le
un
pt
an
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itte
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erm
ab
ility
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wit
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spec
t to the co
Cylinder head cover, engine codes: BLS, BXJ rrectness o
cial p
f inform
Installing for all engine codes

mer
atio
m
Installation is carried out in the reverse sequence of removal. In

o
n
c
the process, note the following:

or
n thi
te
sd
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fo
Note
en
ng
t.
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op py
♦ Renew cylinder head cover gasket and seal for bolts if dam‐
t. C rig
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aged. p by
co Vo
by lksw
cted agen
♦ Renew seal for intake manifold flap. Engine codes BLS, BXJ Prote AG.
– Place a drop of sealant -AMV 174 004 01- (∅ approx. 5 mm)

-arrows- on edges of both sealing surfaces of bearing cap and
cylinder head at front of engine.
1. Cylinder head 49
Cylinder head cover, engine codes: BJB, BKC, BRU, BXE, BXF
– Screw on cylinder head cover hand-tight in the sequence -1 to
13.-
– Tighten bolts to 10 Nm in the sequence -1...13-.
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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un
pt
an
d
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rm
Cylinder head cover, engine codes: BLS, BXJ
ab
pe
ility
ot
– Screw on cylinder head cover hand-tight in the sequence -1 ...
wit
, is n
13-.
h re
hole
spec
– Tighten bolts to 10 Nm in the sequence -1...13-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
1.3 Removing, installing and tensioning
com
tion in
toothed belts
r
te o
thi
s
iva
do
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cum
fo
Note
en
ng
t.
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Cop py
t. rig
♦ From 05.05 a modified engine support has been introduced, it yri
gh by
ht
is no longer necessary to remove the engine support and sup‐
op Vo
by c lksw
porting the engine for the procedure “removing, installing and cted agen
Prote AG.
tensioning toothed belt”.
♦ To change the tensioning roller, for both versions the engine
support must be removed.
– Determine which type of engine support is installed in the ve‐

hicle.
-1-: Engine support bolted close to engine (removal necessary)
⇒ page 51 .

-2-: Engine support bolted further away from engine ▸ (removal

not necessary) ⇒ page 60 .
AG. Volkswagen AG d
agen oes
olksw not
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tho eo
au ra
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un
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an
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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
1.3.1 Removing and installing toothed belt (vehicles with engine support bolted
rrectness of i
close to engine)
l purpos
nform
ercia
equipment required
m
a
com
t
♦ Locking pin -3359-
ion in
r
te o
♦ Pin wrench -T10020- or

thi
s
iva
hexagon wrench
do
r
rp
cum
fo
♦ Locking pin -T10115-

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ng
t.
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op
♦ Crankshaft stop -T10050- C py
t. rig
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yri by
♦ Torque wrench - cop Vo
by lksw
V.A.G 1331- cted agen
Prote AG.
♦ Torque wrench -
V.A.G 1332-
1. Cylinder head 51
♦ Support bracket -10-222A-

with adapters -10-222A/1-
♦ Counterhold tool -T10172-
with pins -T10172/4-
♦ Crankshaft stop -T10100-
(on vehicles with oval
crankshaft belt pulley)
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
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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
Removing
rrectness of i
Note
l purpos
Adjustment work on toothed belts must be performed only on cold

nform
ercia
engines, as the indicator position on the tensioning element varies

depending on the engine temperature.
m
at
om
ion
c
in t
or
– Remove engine cover. ⇒ page 4

his
ate
do
riv

p
cum
for
en
g
– Remove tensioning element for poly V-belt.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
– Remove belt pulley with vibration damper.
c by lksw
cted agen
Prote AG.
– Remove lower and centre parts of toothed belt guard.

– Set up support bracket -10-222A- with adapters -10-222A/22-

and support engine in installation position.
Note
If toothed belt is to be removed in order to remove cylinder head,

set up support bracket -10-222A- with higher adapters -10-222A/
13- . This will provide the space necessary for removing the cyl‐
inder head.
– Pull fuel filter out of bracket.

– Unscrew filler neck for window wash system.
– Unbolt fuel filter bracket from engine mounting -arrows-.

– Unbolt coolant expansion tank and lay to side (hoses remain
AG. Volkswagen AG d
connected). lksw
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ris tee
tho or
au ac
ss
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Remove securing bolts between assembly mounting and en‐
es, in part or in w
t to the co
gine bracket and between assembly mounting and body
-arrows- and remove complete assembly mountings.
rrectness of i
Note
l purpos
♦ The assembly mounting may only be removed if the engine is
nform
ercia
supported with support bracket -10-222A- !

m
♦ The engine bracket must be loosened only when the assembly

at
om
mounting has been removed. ion

c
in t
or
his
ate
do
priv
cum
or
– Raise engine with support bracket -10-222A- until both upper

f
en
g
bolts of engine bracket can be loosened.

n
t.
yi Co
Cop py
– Lower engine with support bracket -10-222A- until both lower
t. rig
gh ht
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bolts of engine bracket can be loosened. op Vo
by c lksw
cted agen
Prote
– Remove refrigerant line securing clamp from longitudinal
AG.
member.
– Remove engine bracket rearwards.
– Turn crankshaft to TDC No. 1 cylinder.
Note
Gradual introduction of oval crankshaft toothed belt pulleys.

When installing this toothed belt pulley, the crankshaft stop -
T10100- must be installed to determine the TDC position instead
of crankshaft stop -T10050- . Observe identification characteris‐
tics -arrows-.
1. Cylinder head 53
Characteristics of crankshaft toothed 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
marking at 1 o'clock
Vehicles with round crankshaft belt pulley
Note
Turn crankshaft until marking on crankshaft pulley and tooth seg‐

ment of camshaft pulley is on top. The markingaon nthe
AG.rear
Volkstoothed
wagen AG
w ge does
belt guard must line up with the markingy Von
olksthe camshaft sender not
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wheel -arrow-. ised b ara
n r tee
ho
aut or
ac
– Lock hub using locking . To do this, slide locking pinss-3359-
pin through the free elongated hole on left into hole in cylinder
ce
e
nl
pt
du
head.
an
itte
y li
erm
ab
– Lock crankshaft toothed belt pulley with crankshaft stop -

ility
ot p
T10050- . To do this, push crankshaft stop into teeth of belt

wit
pulley from face side.

, is n
h re
hole
spec
es, in part or in w
Note
t to the co
The marks on the crankshaft toothed belt pulley and the crank‐
shaft stop must align. When doing this, the pin of the crankshaft
rrectness of i
stop must insert in the drilling of the sealing flange.

l purpos
Vehicles with oval crankshaft belt pulley

nform
ercia

m
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.

Note

ment of camshaft pulley is on top. The marking on the rear toothed
belt guard must align with the marking on the camshaft sender
wheel -arrow-.
– Lock hub using locking pin -3359- . To do this, slide locking

head.
T10100- . To do this, push crankshaft stop into teeth of toothed
. Volkswagen AG
belt pulley from its face side. swa
gen AG does
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Note tho eo
au ra
c
ss
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le
un
pt
shaft stop must align. At the same time, the crankshaft stop pin
an
d
itte
y li
must engage in the drilling in the sealing flange.
erm
ab
ility
ot p
wit
is n
h re
ole,
– Mark direction of rotation of toothed belt.
spec
t to the co
– Loosen securing bolts -1- of camshaft toothed belt pulley until
camshaft pulley can be moved within the elongated holes.
rrectne
– Loosen tensioning roller securing nut.
ss 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
– Turn pin wrench -T10020- anti-clockwise until toothed belt
Co
op py
tensioning roller can be locked with locking pin -T10115- .
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
A hexagon key can be used to tension or relieve tension on the

tensioner.
1. Cylinder head 55
– Now turn pin wrench -T10020- clockwise to stop and tighten

securing nut -1- hand tight.
– Remove toothed belt first from coolant pump and then from
remaining pulleys.
Installing
• Camshaft locked with locking pin -3359- .
ks wage es n
• The crankshaft is locked with crankshaft stopVol -T10050- or ot g
by ua
crankshaft stop -T10100- . ris
ed ran
tee
tho or
• Tensioning roller locked with locking
au pin -T10115- and se‐ ac
ss
cured to right stop.
ce
le
un
pt
an
d
itte
y li
rm
Note
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Turn camshaft pulley in its elongated holes to centre position
-arrows-.
rrectness of i
– Fit toothed belt onto crankshaft toothed belt pulley, tensioning
l purpos
roller, camshaft toothed belt pulley and idler roller.

– Then fit toothed belt on coolant pump toothed belt pulley.
nform
mercia
a
com
tion 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
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pyri by
Vo
Note
co lksw
by
cted agen
Prote AG.
Ensure that tensioning roller seats correctly in rear toothed belt

guard -arrow-.
– Loosen tensioning roller securing nut and pull out locking pin
-T10115- .
– Now carefully turn tensioning roller clockwise using pin wrench

-T10020- until indicator is in middle of gap in the base plate
-arrow-.
Ensure that securing nut does not turn as well.
– Hold tensioning roller in this position and tighten tensioning
roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.

– Fit counterhold tool -T10172- with pins -T10172/4- as shown.

Press counterhold tool -T10172- in direction of arrow, keeping
camshaft toothed belt pulley under tension.
– In this position, tighten camshaft toothed belt pulley securing
bolts -1- to 25 Nm.
– Remove locking pin -3359- and crankshaft stop -T10050- .
– Turn crankshaft two rotations in engine direction
agen
AG.of
Vorotation
lkswagen AG
does
until crankshaft is just before TDC No.olksw
1 cylinder. not
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ed
Vehicles with round crankshaft belt
ho pulley
ris nte
e
t or
au ac
ss
ce
e
nl
pt
du
an
– Lock hub with locking pin -3359- whilst turning engine in di‐
itte
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erm
rection of rotation.
ab
ility
ot p
– Check whether crankshaft can be locked with crankshaft stop
wit
, is n
-T10050- .
h re
hole
spec
If crankshaft cannot be locked
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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op
– Loosen securing bolts -1- for camshaft toothed belt pulley.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
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.
Vehicles with oval crankshaft belt pulley
1. Cylinder head 57
– Lock hub with locking pin -3359- whilst turning engine in di‐
rection of rotation.
– Check whether the crankshaft can be locked with crankshaft
stop -T10100- .
If crankshaft cannot be locked:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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– Loosen securing bolts -1- for camshaft toothed belt
oris pulley.
e nte
h eo
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
– Turn crankshaft against engine direction of rotation slightly
until pin of crankshaft stop is located just before hole in sealing
l purpos
flange -arrow-.
nform
– Now turn crankshaft in engine direction of rotation until crank‐
ercia
shaft stop pin engages in sealing flange from rotational move‐

m
a
ment.
com
tion in

r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
– Fit counterhold tool -T10172- with pins -T10172/4- as shown. cted agen
Prote AG.
bolts -1- to 25 Nm.
– Turn crankshaft two rotations in engine direction of rotation
until crankshaft is just before TDC No. 1 cylinder.
– Repeat check.

– Set engine bracket against cylinder block and tighten securing

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

bolts to prescribed torque.
– Install assembly mounting between engine and body (renew

securing bolts).
Specified torque, M8 bolts: 20 Nm + 90° (1/4 turn)
Specified torque, M10 bolts: 40 Nm + 90° (1/4 turn)
olkswagen AG
en AG. V
– Bolt engine assembly mounting to engine bracket by bringingolkswag does
not
contact surfaces together using support bracket -10-222A-
ed
by.
V gu
ara
ris nte
Specified torque: 60 Nm + 90° (1/4 turn) utho eo
ra
a c
ss
– Install centre and lower parts of toothed belt guard.
ce
e
nl
pt
du
an
– Install belt pulley vibration damper (renew securing bolts).
itte
y li
erm
ab
Specified torque: 10 Nm + 90° (1/4 turn)
ility
ot p
wit
, is n
h re
hole
spec
– Install toothed belt guard upper part.
es, in part or in w
t to the co
– Install front right wheel housing liner.
– Install coolant expansion tank.
rrectness of i
– Bolt fuel filter bracket to engine mounting to 8 Nm torque
l purpos
-arrows-.
– Engage fuel filter in bracket.
nform
ercia
– Bolt on filler neck for window wash system.

m
at
om
io
– Fit engine cover.
n
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
cted agen
Prote AG.
1. Cylinder head 59
1.3.2 Removing and installing toothed belt (vehicles with engine support bolted
further away from engine)
Note
♦ A revised engine support has been introduced gradually and it is no longer necessary to remove the engine
support and to support the engine for the procedure “removing, installing and tensioning toothed belt”.
♦ To change the tensioning roller, for both versions the engine support must be removed.

equipment required
♦ Diesel injection pump lock‐
ing pin -3359-
♦ Locking pin -T10060 A-
♦ Crankshaft stop -T10100-
♦ Special wrench, long reach
-T10264-
♦ Locking tool -T10265-
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
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Removing
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– Remove engine cover. ⇒ page 4 To do this, pull engine cover

om
upwards abruptly at front -arrows A- and then pull forwards out

n
c
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or
of rear fastening -arrow B-.

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– Remove two-piece engine cover ⇒ page 4
WARNING
♦ In extreme cases the fuel lines and the fuel can reach a
temperature of 100 °C on vehicles with unit injector en‐
gine. Allow the fuel to cool down before disconnecting the
lines - danger of scalding.
♦ Wear protective gloves.
♦ Wear eye protection.
– Pull fuel supply hose -1- and fuel return hose -2- off fuel lines.
– Pull off coolant line -3-.
– Remove bolt -1-.
AG. Volkswagen AG d
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– Remove connecting pipe between charge air cooler and intake

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connecting pipe, to do this, lightly lift retaining clips -arrows-.
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– Disconnect fuel supply line -3- and return line -2- by pulling
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1. Cylinder head 61
– Pull fuel filter out of bracket -arrow-.

– Unscrew bolt at filler neck -2- for windscreen washer system
reservoir.
– Unscrew bracket -3- for fuel filter.
– Disconnect 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 retaining

clips -arrows-.
– Remove belt pulley with vibration damper.
– Remove lower and centre parts of toothed belt guard.
– Turn crankshaft to TDC No. 1 cylinder. AG. Volkswagen AG d
agen oes
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62
AG.
Rep. Gr.15 - Cylinder head, valve gear
Note

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
wheel -arrow-.
– Lock hub using locking pin -3359- . To do this, slide locking

head.
T10100- . To do this, push crankshaft stop into teeth of belt
pulley from face side.
Note
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.

wage es n
– Loosen securing bolts -1- of camshaft toothed belt pulley y Vuntil
olks ot g
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camshaft pulley can be moved within the elongatedisholes.
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– Loosen tensioning roller securing nut -1-.
rrectne
– Turn eccentric of tensioning roller anti-clockwise -arrow- using
socket -T10264- , until the tensioning roller can be locked with
ss
locking tool -T10265- .
o
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mer
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1. Cylinder head 63
– Now turn tensioning roller eccentric clockwise -arrow- onto

stop and tighten securing nut -1- hand-tight.
– Remove toothed belt first from coolant pump and then from
remaining toothed belt pulleys.
Installing
• Camshaft locked with locking pin -3359- .
• Crankshaft locked with crankshaft stop -T10100- .
• Tensioning roller locked with locking pin -T10265- and se‐ wagen AG. Volkswagen AG does
cured to right stop with securing nut. olks not
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– Turn camshaft pulley in its elongated holes to centre position
spec
-arrows-.
es, in part or in w
t to the co
– Guide toothed belt through gap between engine support and
engine.
rrectness of i
– Fit toothed belt onto crankshaft toothed belt pulley, tensioning
roller, camshaft toothed belt pulley and idler roller.
l purpos
– Then fit toothed belt on coolant pump toothed belt pulley.
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guard -arrow-.
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– Remove locking pin -T10265- from tensioning roller.
– Loosen tensioning roller securing nut -1-.
– Turn eccentric of tensioning roller clockwise -arrow- using

special wrench, long reach -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

roller nut to 20 Nm + 45° (1/8 turn).

– Fit counterhold tool -T10172- with pin -T10172/4- as shown in

illustration, and keep the toothed belt under tension on pulling
side, by pressing in -direction of arrow-.
– Tighten bolts -1- of camshaft toothed belt pulley to 25 Nm.
until the crankshaft is just before TDC again.
– Lock hub of camshaft with locking pin -3359- whilst turning

engine in direction of rotation.
– Check whether crankshaft can be locked with crankshaft stop

-T10100- .
If crankshaft cannot be locked
lkswage es n
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– Loosen securing bolts -1- for camshaft toothed belt pulley.

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1. Cylinder head 65
AG. Volkswagen AG d
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– Turn crankshaft slightly against engine direction oof rotation
lksw not
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until the pin of the crankshaft stop is positioned
ed just before the
b ara
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hole in the sealing flange -arrow-. ris
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– Now turn crankshaft in engine direction
ss of rotation until crank‐
ce
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shaft stop pin engages in sealing flange whilst turning.
nl
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– Fit counterhold tool -T10172- with pins -T10172/4- as shown.
rrectness of i
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bolts -1- to 25 Nm.
nform
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until crankshaft is just before TDC No. 1 cylinder.
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– Repeat check and adjustment if necessary.

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– Install centre and lower parts of toothed belt guard.

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Specified torque: 10 Nm + 90° (1/4 turn) by c lksw
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– Install toothed belt guard upper part.
– Install connecting pipe between charge air cooler and intake
connecting pipe.
– Install front right wheel housing liner.
– Install coolant expansion tank.
– Bolt fuel filter bracket to engine mounting to 8 Nm torque

-arrows-.
– Engage fuel filter in bracket.
– Bolt on filler neck for window wash system.
– Fit engine cover.

G. Volkswagen AG d
4-cylinderkdiesel
swagen Aengine (1.9 l engine)
oes - Edition 01.2009
n
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1.4 Removing and installing cylinder head
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♦ Drip tray -V.A.G 1306- or
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drip tray -VAS 6208-
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♦ Torque wrench -
hole
spec
V.A.G 1331-
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t to the co
♦ Torque wrench -
V.A.G 1332-
rrectness of i
♦ Hand vacuum pump with
accessories -V.A.G 1390-
l purpos
♦ Water drainage container -

V.A.G 1390/1-
nf
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or
♦ Retainer -T10014- (only ve‐
m
m
atio
hicles ▸ 05.05)
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♦ Support bracket -10-222A- with adapters -10-222A/13- (only
vehicles ▸ 05.05)
1. Cylinder head 67
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. en AG. V
olkswagen AG
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hot components.
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1.4.1 Removing
l purpos
nform
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Note
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at
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Before removing cylinder head, extract fuel using hand-operated n
c
in t
r
vacuum pump with accessories -V.A.G 1390- and water drainage

o
his
e
container -V.A.G 1390/1- ⇒ page 147 .

at
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– Remove engine cover panel ⇒ page 4 . To do this, pull engine

n
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cover upwards abruptly at front -arrows A- and then pull for‐ t. Cop py
wards out of rear fastening -arrow B-.
rig
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– Remove two-piece engine cover ⇒ page 4
by lksw
cted agen
Prote AG.
– Remove plenum chamber bulkhead. ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body - front, plenum chamber bulk‐
head .
pipe.

of mounting.
– Drain coolant. ⇒ page 102
– Disconnect fuel supply and return lines as well as coolant line
on cylinder head.
– Before removing cylinder head, extract fuel from tandem pump
using hand-operated vacuum pump with accessories -V.A.G
1390- and water drainage container -V.A.G 1390/1-
⇒ page 147 .
– Pull fuel filter module upwards out of bracket and lay it with
hoses to side.
– Remove front exhaust pipe ⇒ page 186 .
– Remove turbocharger support and oil return from turbocharg‐
er.
– Remove oil supply line and lay it to side ⇒ page 95 .
lkswage Note es n
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byV ua
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From 05.05 a modified
tho engine support has been introduced, itoris
tee
no longer necessary
ss
au
to remove the engine support and supporting ac
the engine for the procedure “removing, installing and tensioning
ce
le
un
toothed belt” ⇒ page 50

pt
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– Remove toothed belt tensioning roller.

h re
hole
– Install hub for camshaft pulley ⇒ page 80 , Removing and

spec
es, in part or in w
installing camshaft.
t to the co
– Remove rear toothed belt guard securing bolts -2- and -4-.
rrectness of i
– Unscrew Hall sender -G40- -3-.

l purpos
– Remove exhaust gas recirculation connecting pipe.

– Pull off or disconnect all other electrical connections as nec‐
nform
ercia
essary from cylinder head and lay to one side.

m
– Separate all connection, coolant, vacuum and intake hoses

com
tio
from cylinder head.

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Both lifting eyes for the support are located on the cylinder head,
p by
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so an additional bracket for supporting the engine must be se‐ Prote
cted AG.
agen
cured on the cylinder block.
1. Cylinder head 69
– Screw retainer -T10014- into threaded hole above coolant

pump and tighten to 20 Nm.
– Lift engine slightly using spindle -A- until spindle -B- is relieved.
– Unhook spindle -B- and push it to side.
– Remove cylinder head cover. ⇒ page 48
AG. Volkswagen AG d
agen oes
olksw not
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– Maintain sequence when loosening cylinder head bolts.

un
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– Lift cylinder head slightly and remove from engine laterally
erm
ab
past toothed belt guard.
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The cylinder head must be guided carefully to prevent damage.
rrectness o
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1.4.2 Installing f inform

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Note
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♦ Always renew cylinder head bolts.

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♦ In cases of repair carefully remove gasket remains from cyl‐

ng
t.
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inder head and cylinder block. Ensure that no long scores or t. Cop py
scratches are created. When using abrasive paper do not use
rig
gh ht
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a grade less than 100. cop Vo
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♦ Carefully remove remains of emery and abrasives.
AG.
♦ 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.
– Turn crankshaft to TDC marking 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
Note identification on cylinder head gasket ⇒ page 47 .

– Fit cylinder head and tighten all cylinder head bolts hand-tight.
– Tighten cylinder head in four stages in sequence as shown as
follows:
AG. Volkswagen AG d
agen oes
1- Tighten initially with torque wrench: olksw not
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Stage I = 35 Nm horis nte
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Stage II = 60 Nm ss c
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2- Turn further with rigid spanner:
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Stage III = 1/4 turn (90°)
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Stage IV = 1/4 turn (90°)
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Note
t to the co
After repair work it is not necessary to retighten the cylinder head
bolts.
rrectness of i
l purpos
Further installation is carried out in the reverse order. In the proc‐

ess, note the following:
nform
ercia
– After tightening cylinder head, turn camshaft so that cams for

m
at
om
No. 1 cylinder equally point upwards. Before fitting toothed
ion
c
belt, turn crankshaft in engine direction of rotation
in t
or
⇒ page 50 , removing, installing and tightening toothed belt.
his
ate
do
priv
c
– Install hub for camshaft toothed belt pulley ⇒ page 147 , Re‐
um
for
moving and installing camshaft.
en
ng
t.
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– Install toothed belt ⇒ page 50 .
C py
ht. rig
rig ht
py by
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by lksw
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Prote AG.
– Install oil supply line ⇒ page 95 .
– Install insulation tray ⇒ General body repairs, exterior; Rep.
Gr. 50 ; Body - front; Assembly overview.
– Install plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body - front; Plenum chamber bulk‐
head .
– Carry out road test and then read fault memory ⇒ page 178 .
1.5 Checking compression
Note
If ceramic glow plugs are fitted, before removing check idling

speed smooth running control using vehicle diagnostic, testing
and information system -VAS 5051B- . The compression test is
warranted only if one or more cylinders are conspicuous in this
idling speed check.
1. Cylinder head 71
Special tools and workshop AG. Volkswagen AG d

agen
equipment required Volksw
oes
not
gu
d by ara
♦ Jointed spanner -3220- orise nte
eo
h
ut ra
♦ Torque wrench - ss a c
V.A.G 1331-
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♦ Adapter -V.A.G 1381/12-
itte
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♦ Compression tester -
ility
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wit
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Test prerequisite
• Engine oil temperature min. 30 °C.
Test procedure
– Pull off central connector for unit injectors.
Note
If ceramic glow plugs are fitted, always observe notes on remov‐

ing and installing ceramic glow plugs ⇒ page 198 .
– Remove all glow plugs or ceramic glow plugs using jointed

extension and socket -3220- .

AG. Volkswagen
agen(1.9 l engine) -AG
4-cylinder diesel oengine Edition
does 01.2009
lksw V
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– Screw in adapter -V.A.G 1381/12- in place of glowthplugs
or
is
or eo
ceramic glow plugs. au ra
c
ss
ce
e
– Check compression using compression tester -V.A.G 1763- .
nl
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Note
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Using compression tester ⇒ Operating instructions.
hole
spec
es, in part or in w
– Operate starter until tester shows no further pressure in‐
t to the co
crease.
Compression pressures:
rrectness of i
New: 25...31 bar, wear limit: 19 bar
l purpos
Maximum permissible difference between all cylinders: 5 bar
nform
ercia
Note
m
at
om
ion
c
in t
r
If ceramic glow plugs are fitted, always observe notes on remov‐

o
his
te
ing and installing ceramic glow plugs ⇒ page 198 .

a
do
priv
cum
for
en
g
– Remove glow plugs or ceramic glow plugs using jointed ex‐

n
t.
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tension and socket -3220- . t. Cop py
rig
gh ht
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Specified torque: 15 Nm. p by
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by lksw
cted agen
– Read fault memory of engine control unit. ⇒ page 178 Prote AG.
Note
Disconnecting the central connector for unit injectors causes

faults to be stored. Therefore, read fault memory and clear if nec‐
essary.
1. Cylinder head 73
AG. Volkswagen AG d
ksw
agen oes
n ol ot g
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ris tee
2 Valve gear au
tho or
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Cylinder heads with cracks between the valve seats may be used
wit
is n
without reducing engine life, provided the cracks are small and
h re
not more than 0.5 mm wide.
ole,
spec
t to the co
Assembly overview - valve gear ⇒ page 74 .
Checking valve guides ⇒ page 76 .
rrectne
Renewing valve stem seals ⇒ page 78 .
Removing and installing camshaft ⇒ page 80
ss o
cial p
f
Removing and installing camshaft seal ⇒ page 84
inform
mer
2.1 Assembly overview - valve gear
atio
om
n
c
i
or
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1 - 20 Nm + 1/4 turn (90°) fur‐

t
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ther
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❑ Renew
t.
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❑ Note sequence when
C py
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loosening and tighten‐
rig ht
py by
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ing ⇒ page 80 , Re‐ by c lksw
cted agen
moving and installing Prote AG.
camshaft.
2 - Rocker arm shaft
❑ Do not interchange.
3 - Cylinder head bolt
❑ Renew
❑ Note sequence when
loosening and tighten‐
ing ⇒ page 67 , Remov‐
ing and installing cylin‐
der head.
❑ Before installing, insert
washers
⇒ Item 4 (page 74) 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.
❑ Store with cam contact
surface downwards
❑ Before installing, check camshaft axial clearance ⇒ page 76 .
❑ Oil contact surfaces.
❑ Before removing, remove camshaft bearing caps

6 - Valve cotter
7 - Valve spring plate
8 - Outer valve spring
❑ Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder
head installed ⇒ page 78 , Renewing valve stem seals.
9 - Inner valve spring
❑ Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder
head installed ⇒ page 78 , Renewing valve stem seals. Volkswa
AG. gen AG
agen does
10 - Valve stem seal olksw not
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❑ Renewing ⇒ page 78 rise nte
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11 - Valve guide au ra
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12 - Unit injector
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13 - Cylinder head
h re
hole
❑ See note ⇒ page 74 .
spec
es, in part or in w
14 - Seal
t to the co
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove residual oil from camshaft journal using a clean cloth.
rrectness of i
❑ To install, tape over groove in taper of camshaft (e.g. using Sellotape).
l purpos

15 - Valves
nform
ercia
❑ Valve dimensions ⇒ page 76

m
at
om
io
16 - Bearing shell
n
c
in t
or
❑ Do not interchange used bearing shells (mark).
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ate
do
riv
❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head
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17 - Camshaft
n
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❑ Checking axial clearance ⇒ page 76 .
C py
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rig ht
❑ Removing and installing ⇒ page 80 . py by
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by lksw
cted
❑ Check radial clearance with Plastigage, wear limit: 0.11 mm.
agen
Prote AG.
❑ Runout: max. 0.01 mm.

18 - Bearing cap
❑ Installation sequence ⇒ page 80 , removing and installing camshaft
❑ To install, seal parting surfaces of bearing caps 1 and 5 with sealant -AMV 174 004 01- ⇒ page 76
19 - 8 Nm + 1/4 turn (90°) further
❑ Renew
2. Valve gear 75
Checking camshaft axial clearance

♦ Universal dial gauge bracket -VW 387-
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Seal parting surfaces of bearing caps 1 and 5 with sealant -AMV
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Note
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Be careful that no sealant gets into grooves -arrows-.
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Valve dimensions nform

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Note
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Valves must not be reworked. Only grinding-in is permissible.

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α ∠° 45 45
2.2 Checking valve guides


♦ Universal dial gauge bracket -VW 387-
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♦ Dial gauge
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Test procedure
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– Insert new valve into guide. The end of the valve stem must
be flush with the guide. Due to slight differences in stem di‐
rrectne
ameters, use only an inlet valve in inlet guide and an exhaust
valve in exhaust guide.
s
– Determine rock. Wear limit: max. 1.3 mm
s o
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– Cylinder head must be renewed if the rock is greater than the
form
mer
wear limit.
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2. Valve gear 77
2.3 Renewing valve stem seals
Special tools and workshop agen

AG. Volkswagen AG d
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♦ Fitting tool -3129-
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♦ Thrust piece -VW 541/5-
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2.3.1 Removing
(With cylinder head installed)
– Remove camshaft. ⇒ page 80
– Remove bucket tappets and place them with the contact sur‐
face downwards. When doing this, ensure that tappets are not
interchanged.
– Set piston of respective cylinder to top dead centre (TDC).

– Insert valve assembly device -2036- and adjust mounting to

height of studs.
– Remove valve springs using valve lever -VW 541/1A- and
press tool -VW 541/5- .
Note
The valves are supported by the piston crown.
– Pull off valve stem seals using puller -3047 A- .
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2.3.2 Installing
spec
es, in part or in w
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– Place the plastic sleeve -A- supplied on the respective valve
stem. This will prevent the new valve stem seal -B- being
damaged.
rrectness of i
– Insert new valve stem seal in fitting tool -3129- .
l purpos
– Lubricate sealing lip of valve stem seal and carefully push on

valve guide.
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2. Valve gear 79
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2.4 Removing and installing camshaft aut
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equipment required
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♦ Puller -T10052-
h re
hole
spec
♦ Torque wrench (5…50 Nm)
es, in part or in w
-V.A.G 1331-
t to the co
♦ Torque wrench (40…200
Nm) -V.A.G 1332-
rrectness of i
♦ Sealant -AMV 174 004 01-
l purpos
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Prote AG.
2.4.1 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 counterhold tool -T10051- .
– Loosen hub securing boltwaabout
gen AG2 turns. n AG doe
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– Apply puller -T10052- and screw securing bolts -1- into hub.
spec
es, in part or in w
– Apply tension to hub by evenly tightening puller until hub sep‐
t to the co
arates from taper of camshaft.
rrectness of i
Note
l purpos
When doing this, hold puller with 30 mm spanner.
nform
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– Remove hub from taper of camshaft.

m
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io
– Remove cylinder head cover.
n
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or
his
ate
– Mark rocker arm shafts using a permanent felt tip marker to

do
priv
prevent interchanging. This will prevent having to perform ba‐

um
for
en
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sic settings of unit injectors -arrows-.

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– Remove rocker arm shafts.
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Note
First loosen both outer and then inner securing bolts respectively.
– Remove tandem pump ⇒ page 147 .
– First remove bearing caps 5, 1 and 3. Then loosen bearing

caps 2 and 4 alternately and diagonally.
– Remove camshaft.
2. Valve gear 81
2.4.2 Installing
Note
♦ When camshaft is installed, No. 1 cylinder cams must point

upwards. n AG. Volkswagen AG do
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♦ Do not interchange used bearing dshellsby
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♦ When installing the camshaft,uthensure proper seating of retain‐
o
or
ing lugs in bearing caps and
ss cylinder head.
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♦ Before installing bearing caps, ensure that cylinder head bolt

un
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washers are inserted in the cylinder head.

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– Oil bearing shell running surfaces.
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– Install bearing caps 2 and 4 using new bolts.
hole
spec
– Tighten bearing caps 2 and 4 diagonally and alternately to
es, in part or in w
t to the co
8 Nm + 1/4 turn (90°).
– Install bearing caps 5, 1 and 3 using new bolts.
rrectness of i
l purpos
Note
nform
ercia
♦ Seal parting surfaces of bearing caps 1 and 5 with sealant -

AMV 174 004 01- ⇒ page 76 .
m
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♦ Bearing cap 5 must align flush with outer edge of cylinder
n in
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head, because otherwise leaks can develop at tandem pump.

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– Tighten bearing caps 5, 1 and 3 likewise to 8 Nm +1/4 turn

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– Install camshaft oil seal. ⇒ page 84
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– Install rocker arm shafts and tighten securing bolts, first the Prote AG.
inner -2- and then the outer -1-, evenly and diagonally to 20 Nm
+ 1/4 turn (90°).
– Fit hub onto camshaft.
– Tighten hub securing bolt -1- to 100 Nm.

– To do this, use counterhold tool -T10051- .

– Push camshaft toothed belt pulley onto hub.
Note
The toothed segment -arrow- of the camshaft toothed 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.
– Lock hub using locking pin -3359- .
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– Install and tighten toothed
by
Vol belt ⇒ page 50 .
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– Screw new adjustment oris screws into rocker arms hand-tight andtee o
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fit lock nut. ss au ra
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– Fit the dial gauge onto the adjustment screw of the unit injector
an
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as shown.
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– Turn crankshaft in direction of engine rotation until roller of
wit
rocker arm is located at tip of drive cam. Roller side
is n
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-arrow A- is positioned at highest point and dial gauge
ole,
spec
-arrow B- is positioned at lowest point.
t to the co
– Remove dial gauge.
– Now turn the adjuster screw into rocker arm until significant
resistance can be felt (unit injector is at limit stop).
rrectness o
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– Turn adjustment screw 180° back off stop.

form
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atio
– Hold adjuster screw in this position and tighten lock nut to 30

om
Nm.
n
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– Install tandem pump ⇒ page 147 .

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– Install cylinder head cover.

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When new tappets have been installed the engine must not be Prote AG.
started for about 30 minutes, hydraulic compensation elements
must settle (otherwise valves will strike pistons).
2. Valve gear 83
2.5 Removing and installing camshaft oil seal

equipment required
♦ Fitting sleeves -10-203-
♦ Oil seal extractor -3240-
1331-
1332-
♦ Bolt M12×1.5 × 65
AG. Volkswagen AG d
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2.5.1 Removing
spec
es, in part or in w
t to the co

– Remove camshaft toothed belt pulley and hub ⇒ page 80 ,
Removing and installing camshaft.
rrectness of i
– Unscrew inner part of oil seal extractor -3240- two turns (ap‐
l purpos
prox. 3 mm) out of outer part and lock with knurled screw.
– Lubricate threaded head of oil seal extractor -3240- , place it
nf
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in position and exerting firm pressure, screw it as far as pos‐

rm
m
sible into oil seal.

atio
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c
– Loosen knurled screw and turn inner part against camshaft

or
thi
e
until oil seal is pulled out.

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Prote AG.

AG. Volkswagen AG d
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ara Plus 2005 ➤
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thor 4-cylinder diesel engine (1.9 l engine) - Edition
eo 01.2009
au ra
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2.5.2 Installing
ce
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nl
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Note
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The oil seal sealing lip must not be additionally oiled or greased.
hole
spec
es, in part or in w
– Remove oil residue from camshaft journal using a clean cloth.
t to the co
– Tape over groove in taper of camshaft (e.g. with Sellotape).
rrectness of i
– Fit oil seal carefully on camshaft.
l purpos
– Press in oil seal with press piece of fitting tool -10-203- and
bolt M12 5x65 onto stop.
nf
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– Install and tighten toothed belt ⇒ page 50 .
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2. Valve gear 85
AG. Volkswagen AG d
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Golf 2004 ➤ , Golf Plus 2005 ➤ aut
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4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 s
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17 – Lubrication
erm
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1 Engine oil
hole
spec
es, in part or in w
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Note
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The oil level must not be above the max. mark - danger of damage
to catalytic converter! Markings.
l purpos
Engine oil specification ⇒ Maintenance ; Booklet 38
nf
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Oil capacities ⇒ page 86
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Checking engine oil level ⇒ page 86
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1.1 Oil capacities t
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Engine codes BJB, BKC, BRU, BXE and BXF
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With oil filter change: 3.8 l C py
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Engine codes BLS and BXJ
Prote AG.
With oil filter change: 4.3 l

Without oil filter change: 3.8 l
1.2 Checking engine oil level

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched field: Can be topped up with engine
oil.
c - Area from min. mark up to hatched field: Must be topped up,
max. 0.5 l of engine oil!
86 Rep. Gr.17 - Lubrication

AG. Volkswagen AG d
agen 4-cylinder diesel oeengine (1.9 l engine) - Edition 01.2009
olksw s no
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2 Parts of lubrication system t eo
au ra
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Caution
an
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itte
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erm
ab
ility
Finding metal shavings or a large quantity of small metal par‐
ot p
wit
ticles during engine repair could indicate that the crankshaft
is n
h re
bearings or conrod bearings are damaged. To prevent this
ole,
from causing further damage, perform the following repairs:
spec
t to the co
Thoroughly clean oil channels.
Renew oil cooler.
rrectne
Renew oil filter element
ss o
Assembly overview - oil pump, sump ⇒ page 87
cial p
f inform
Removing and installing sump ⇒ page 88
mer
atio
m
2.1 Assembly overview - oil pump, sump

o
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1 - 15 Nm
cum
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t.
2 - Sealing flange
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❑ With seal.
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❑ Must be positioned on
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dowel sleeves.
agen
Prote AG.

⇒ page 23 .
❑ Install with silicone seal‐
ant -D 176 404 A2-
⇒ page 23 .
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing crankshaft oil
seal - pulley end
⇒ page 21 .
3 - Chain tensioner with ten‐
sioning rail, 15 Nm
❑ When installing, preten‐
sion spring and fit
4 - Dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 86
5 - Dipstick guide
6 - Guide tube
7 - Dowel sleeves
8 - O-ring
❑ Renew
2. Parts of lubrication system 87

9 - 15 Nm
10 - Suction line
❑ Clean strainer if soiled
11 - Baffle plate
12 - 15 Nm
13 - 15 Nm
14 - Sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant -D176404A2-
n AG . Volkswagen AG
15 - Oil drain plug, 30 Nm wage does
Volks not
❑ Renew ed by gu
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16 - 10 Nmauth eo
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17 - Oil level and oil temperature sender -G266-
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❑ Black connector, 3-pin.
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18 - Seal
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❑ Renew
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19 - Oil pump spec

❑ With 12 bar pressure relief valve

t to the co
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
❑ Renew if running surfaces and gears are scored
rrectne
20 - Chain sprocket for oil pump

21 - Bracket
ss o
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❑ For oil level/temperature sender wiring harness.

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22 - 20 Nm + 1/4 turn (90°) further

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❑ Renew
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23 - Chain
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24 - 25 Nm
um
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❑ Insert without sealant.

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25 - Oil spray jet
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❑ For piston cooling by c lksw
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Note
2.2 Removing and installing sump


AG. Volkswagen AG d
♦ Hexagon key extension, 5 mm -3249- agen oes
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♦ Hand drill with plastic brush attachment
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♦ Silicone sealant -D176404A2-
l purpos
♦ Hand drill with plastic brush attachment
nform
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♦ Eye protection
m
♦ Flat scraper
a
com
tion in
2.2.1 Removing
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– Drain engine oil. C py
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Note Prote AG.
Observe environmental regulations for disposal.
– Pull 3-pin connector off oil level and oil temperature sender -
G266- .
– Remove sump.
– Loosen sump with light blows of a rubber headed hammer if
necessary.
– Remove sealant residue from cylinder block with a flat scraper.

– Remove sealant residue on sump using a rotating brush, e.g.

an electric drill with a plastic brush attachment (wear safety
goggles).
– Clean sealing surfaces. They must be free of oil and grease.
2.2.2 Installing
Note
♦ Observe expiry date of sealing compound.

♦ The oil sump must be installed within 5 minutes of applying
silicone sealing compound.
– Cut off tube nozzle at forward marking (approx. 3 mm nozzle

∅).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealing compound bead must be:
♦ 2…3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealant bead must not be thicker, otherwise excess sealing

compound will enter the oil sump and may block the oil suction
line strainer. olks
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es, in part or in w
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Rep. Gr.17 - Lubrication Prote
cted AG.
agen
AG. Volkswagen AG d
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or eo
h
aut Golf 2004 ➤ , Golf Plus 2005 ➤
ra
c
s
s 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009
ce
e
nl
pt
du
an
itte
– Apply silicone sealing compound bead as shown to the clean
y li
erm
ab
sealing surface of the sump. (The figure shows the position of
ility
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the sealant bead on the cylinder block.)
wit
, is n
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– Install sump immediately and tighten all sump bolts lightly.
hole
Ensure that sump is flush against intermediate plate and gear‐
spec
box flange.
es, in part or in w
t to the co
Note
rrectness of i
When installing sump with engine out of vehicle, ensure that sump
l purpos
is flush with cylinder block at flywheel end.
nf
ercia
– Tighten sump bolts diagonally to 15 Nm.
orm
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atio
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– Tighten bolts securing sump to gearbox to 45 Nm.

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Note
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Let sealing compound dry for approx. 30 minutes after installing

t.
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sump. Only then fill with engine oil.
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Further assembly is basically the reverse of the dismantling se‐ Prote
cted AG.
agen
quence.

3 Oil filter bracket, oil pressure, engine

oil cooler and oil supply line
Assembly overview - oil filter bracket and oil cooler ⇒ page 92
Checking oil pressure and oil pressure switch ⇒ page 93
Assembly overview - oil supply line to turbocharger ⇒ page 94
Removing and installing oil supply line to turbocharger
⇒ page 95
3.1 Assembly overview - oil filter bracket and engine oil cooler
1 - Oil filter bracket

2 - 15 Nm + 1/4 turn (90°) fur‐
ther lkswage es n
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❑ Renew d b ua
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❑ First fit upper left and utho
or
lower right bolts and ss
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then tighten all four bolts
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diagonally.
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3 - Gasket
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❑ Renew
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4 - Seal
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spec
❑ Renew
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5 - Connection, 35 Nm
6 - Oil supply line, 22 Nm
rrectness of i
❑ To turbocharger.
l purpos

⇒ page 95 .
nform
ercia
7 - Sealing cap, 25 Nm
m
at
8 - Seal
om
ion
c
❑ Renew
in t
or
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ate
9 - Oil filter element

do
priv
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or
❑ Ensure "Top" is upper‐

f
en
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most when fitting

t.
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Cop py
. rig
10 - Plug, 10 Nm
t
gh ht
pyri by
Vo
o
❑ If seal is leaking, nip
c by lksw
cted agen
open and renew. Prote AG.
11 - Oil pressure switch -F1-

❑ 0.7 bar switch: brown.
❑ Tighten to 20 Nm.
❑ If seal is leaking, nip open and renew.
12 - Plug, 25 Nm
13 - Seal
❑ Renew.
14 - Engine oil cooler
❑ Ensure clearance to adjacent components.
❑ See note ⇒ page 87 .

❑ Checking engine oil cooler for leaks ⇒ page 112
15 - Gasket
❑ Renew.
16 - Bracket AG. Volkswagen AG d
agen oes
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17 - 10 Nm by
Vol not
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3.2 Checking oil pressure and oil pressure switch
s
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un
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rm
ab
pe
ility
equipment required
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wit
, is n
h re
♦ Oil pressure tester -
hole
spec
V.A.G 1342-
es, in part or in w
t to the co
♦ Voltage tester -
V.A.G 1527 B-
♦ Auxiliary measuring set -
rrectness of i
V.A.G 1594 A-
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
o
by c lksw
cted agen
Prote AG.
3.2.1 Test procedure
Note
Functional check and repair of optical and acoustic oil pressure

warning: ⇒ Current flow diagrams, Electrical fault finding and Fit‐
ting locations Guided fault finding with VAS 5051.
3. Oil filter bracket, oil pressure, engine oil cooler and oil supply line 93
– Remove oil pressure switch -F1- and screw into tester.

– Screw tester into oil filter bracket in place of oil pressure
AG. Volkswagen AG d
switch. lksw
agen oes
n o ot g
yV ua
– Connect brown
ris
ed wire of tester to earth (-).
b ran
tee
tho o
– Connects avoltage
u tester -V.A.G 1527 B- to battery positive r(+)ac
and oil pressure
s
switch using cables from auxiliary measuring
ce
le
set -V.A.G 1594 A- . LED must not light up.

un
pt
an
d
itte
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– Start engine and increase speed slowly.
erm
ab
ility
ot p
– At 0.55…0.85 bar the LED must light up; otherwise renew oil
wit
is n
pressure switch.
h re
ole,
spec
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be at least 2.0 bar.
t to the co
At higher engine speed, oil pressure must not exceed 7.0 bar. If
necessary renew oil filter bracket.
rrectne
3.3 Assembly overview - oil supply line to turbocharger
ss o
cial p
f inform
1 - Retaining clamp
mer
atio
2 - 25 Nm
om
n
c
i
or
n
3 - Oil supply line
thi
te
sd
a
iv
o
pr
cum
r
fo
4 - 10 Nm
en
ng
t.
yi Co
op
5 - Bracket
C py
ht. rig
rig ht
py by
6 - Union nut, 22 Nm co Vo
by lksw
cted agen
Prote
7 - 10 Nm
AG.
8 - Union nut, 22 Nm

3.4 Removing and installing oil supply line

to turbocharger
3.4.1 Removing AG. Volkswagen AG d

agen oes
ksw
– Remove engine cover. ⇒ page 4 To do this, pull by
V engine cover
ol not
gu
upwards abruptly at front -arrows A- and thenrised pull forwards out ara
nte
of rear fastening -arrow B-. ut
ho eo
ra
s a c
s
ce
le
pipe.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
of mounting.
ss
o
cial p
f inform
– Loosen securing bolts for retaining clips.
mer
atio
– Loosen oil supply line union nuts on oil filter bracket and tur‐
om
bocharger.
c
i
or
n thi
te
– Remove oil supply line.

sd
iva
o
pr
cum
r
fo
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ng
t.
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Cop py
t. rig
gh ht
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3.4.2 Installing
p by
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by c lksw
cted agen
Prote AG.
Note
The procedure must be followed to ensure that oil supply line is

installed tension-free.
3. Oil filter bracket, oil pressure, engine oil cooler and oil supply line 95
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
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
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rp
cu
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m
f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Loosen securing nut -2- from 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 Nm.
– 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 cooling system
WARNING

tions:
sitions.
hot components.
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning
agen repair
AG. Volkswagen AG d
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work. yV
olksw not
gu b ara
ed
♦ Hoses are secured with spring-type clips.
ho
ris In case of repair, nte
e
only use spring-type clips. au
t or
ac
ss
♦ Spring-type clip pliers -VAS 5024- or hose clip pliers -
ce
le
un
pt
V.A.G 1921- are recommended for fitting spring-type clips.
an
d
itte
y li
rm
ab
♦ When installing coolant hoses, route stress-free so that they
pe
ility
do not come into contact with other components (observe
ot
wit
markings on coolant connection and hose).
, 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
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
1. Parts of cooling system 97

Perform leakage test of cooling system using cooling system test‐

er -V.A.G 1274- and adapters adapter -V.A.G 1274/8- and adapt‐
er -V.A.G 1274/9- . n AG. Volkswagen A ge G do
swa es n
Parts of cooling system - body side ⇒ pageby98
Vol .
k ot g
ua
d ran
se
Parts of cooling system - engine sideth⇒
or page 99
i tee
or
au ac
Coolant hose schematic diagram ⇒
ss page 101
ce
le
un
pt
Draining and filling with coolant ⇒ page 102
an
d
itte
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rm
ab
Removing and installing radiator ⇒ page 105 .
pe
ility
ot
Removing and installing coolant pump ⇒ page 106 .
wit
, is n
h re
hole
Removing and installing thermostat ⇒ page 108
spec
es, in part or in w
Checking cooling system for leaks ⇒ page 110
t to the co
Checking engine oil cooler for leaks ⇒ page 112
rrectness of i
1.1 Parts of cooling system, body side
l purpos
1 - Upper coolant hose
nform
ercia
❑ Coolant hose schematic

diagram ⇒ page 101
m
a
com
tio
2 - O-ring
n in
r
te o
thi
s
iva
do
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rp
c
3 - Cooler
um
fo
en
g

n
t.
yi Co
op
⇒ page 105 . C py
t. rig
gh ht
yri
❑ After renewing, renew p by
co Vo
entire coolant
by lksw
cted agen
Prote AG.
4 - Sealing cap
❑ Check using cooling
system tester -
V.A.G 1274- and adapt‐
er -V.A.G 1274/9- .
❑ Test pressure: 1.4...1.6
bar.
5 - Connector
6 - 5 Nm
7 - Expansion tank
❑ Check using cooling
system tester -
V.A.G 1274- and adapt‐
er -V.A.G 1274/8- .
8 - 5 Nm
9 - 10 Nm
10 - Fan support
11 - Additional fan
❑ Vehicles with optional
equipment only.
12 - Radiator fan
13 - Connector
14 - Lower coolant hose
❑ Coolant hose schematic diagram ⇒ page 101
98 Rep. Gr.19 - Cooling

15 - Retaining clip
16 - Radiator outlet coolant temperature sender -G83-
1.2 Parts of cooling system, engine side
1 - To top of expansion tank

2 - Upper coolant pipe
❑ Bolted to cylinder head
cover agen
AG. Volkswagen AG d
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3 - To bypass flap d by ara
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❑ Coolant hose schematic utho eo
ra
diagram ⇒ page 101 ss a c
ce
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nl
4 - O-ring
pt
du
an
itte
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❑ Renew.
erm
ab
ility
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5 - Retaining clip
wit
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❑ Check for secure seat‐
h re
hole
ing.
spec
es, in part or in w
6 - Coolant temperature send‐
t to the co
er -G62-
❑ With coolant tempera‐
ture display sender -G2-
rrectness of i
7 - To exhaust gas recircula‐
l purpos
tion cooler
nform
ercia

m
at
om
8 - Connection
ion
c
in t
or
9 - 10 Nm
his
ate
do
riv
10 - To heat exchanger
p
cum
for

en
ng
t.
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diagram ⇒ page 101 t. Cop py
rig
gh ht
11 - 40 Nm yri
p by
co Vo
by lksw
cted
12 - T-piece
agen
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13 - To bypass flap
14 - T-piece
15 - To top of radiator
16 - 15 Nm
17 - To bottom of expansion tank
18 - Coolant pipe
19 - To bottom of radiator

AG. Volkswagen AG d
agen oes
olksw not
byV gu
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Golf 2004 ➤ , Golf Plus 2005 ➤uth o eo
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a
4-cylinder diesel engine (1.9 l sengine) - Edition 01.2009
s c
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nl
pt
du
20 - Connection
an
itte
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erm
❑ For thermostat.
ab
ility
ot p
21 - Thermostat
wit
, is n
h re
hole
spec
❑ Observe installation position ⇒ page 108 , removing and installing thermostat.
es, in part or in w
t to the co
❑ Check: Heat thermostat in water
❑ Opening begins at approx. 85 °C
rrectness of i
❑ Ends at approx. 105 °C
❑ Opening lift at least 7 mm.
l purpos
22 - To heat exchanger
nform
ercia
❑ Coolant hose schematic diagram ⇒ page 101 .

m
23 - Rear coolant pipe
at
om
ion
c
24 - 10 Nm
in t
or
his
ate
25 - To auxiliary heater
do
priv
cum
or

f
en
ng
t.
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26 - Coolant pipe Cop py
ht. rig
rig ht
27 - To exhaust gas recirculation cooler py by
co Vo
by lksw
cted
agen
Prote AG.

29 - Coolant pump
❑ Check for ease of movement.

1.3 Coolant hose schematic diagram
1 - Expansion tank
2 - Bypass flap AG. Volkswagen AG d
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lksw not
3 - Exhaust gas recirculation byV
o gu
ara
cooler rised
nte
ho eo
ut
4 - Heat exchanger for heater ss a ra
c
unit
ce
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nl
pt
du
an
5 - Cylinder head/cylinder
itte
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block
erm
ab
ility
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6 - Gearbox oil cooler
wit
, is n
h re
❑ For gear oil
hole
spec
❑ Only on vehicles with
es, in part or in w
automatic gearbox
t to the co
7 - Upper coolant hose
rrectness of i
8 - Cooler
l purpos
9 - Lower coolant hose

nform
ercia
11 - Coolant pump and ther‐

m
mostat
at
om
ion
c
12 - Auxiliary heater
in t
or
his
te
❑ Vehicles with optional

a
do
riv
equipment only.
p
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.
Note
Coolant hose schematic diagram for vehicles with optional equip‐

ment ⇒ Heating, ventilation, air conditioning system; Rep. Gr.
82 ; Connection diagram for coolant hoses in vehicles with auxil‐
iary heater

1.4 Draining and filling with coolant

equipment required
♦ Refractometer -T10007-wagen AG. Volkswagen AG doe
ks s no
Vol t gu
♦ Drip tray -V.A.G e1306-
db
y ara
is nte
or
♦ Spring-typeauclip
th pliers - eo
ra
VAS 5024s A-
s c
ce
e
nl
pt
♦ Cooling system charge unit
du
an
itte
-VAS 6096-
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.
1.4.1 Draining
– Open cap on coolant expansion tank.
WARNING
Steam may be released when cap is removed from expansion

tank. Cover cap with a cloth and open carefully.


– To drain coolant from radiator, open drain plug -arrow-.
– To drain coolant from engine, also remove coolant hose from

engine oil cooler -arrow-.
Note
Observe environmental regulations for disposal.
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
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1.4.2 Filling
Note
♦ In vehicles as of model year 2008, only G 12 plus-plus ac‐

cording to TL VW 774 G may be used as coolant additive.
♦ For vehicles up to and including model year 2007 coolant ad‐
ditive G 12 plus according to TL VW 774 F and G 12 plus-plus
according to TL VW 774 G can be used.
♦ The coolant additive G 12 plus-plus can be mixed with the
previous coolant additive G 12 plus. Identification: Both are
coloured purple.
♦ Coolant additives marked “according to TL VW 774 G” or “ac‐
cording to TL VW 774 F” prevent frost and corrosion damage,
scaling and also raise boiling point of coolant. Therefore, the
cooling system must be filled all year round with coolant ad‐
ditive and corrosion protection additive.
♦ Because of its higher boiling point, the coolant improves en‐
gine reliability under heavy loads, particularly in countries with
tropical climates.
♦ Frost protection is required down to about -25 °C (in countries
with arctic climates: down to about -35 °C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
coolant additive concentration must be at least 40 %.
♦ If for climatic reasons greater frost protection is required, the
amount of coolant additive can be increased, but only up to 60
% (frost protection to about -40 °C). Otherwise frost protection
and cooling effectiveness are reduced again.
♦ The refractometer -T10007- is recommended for determining
the current anti-freeze concentration.
wage
e ks s no
Vol t gu
♦ If radiator, heat exchanger,
ed cylinder head or cylinder head
by ara
gasket is renewed, dothonot
ris reuse old coolant. nte
eo
au ra
c
ss
Recommended mixture ratios:
ce
e
nl
pt
du
an
itte
Frost Anti-freeze G 12 plus1) Water 1)

y li
erm
ab
protection to proportion G 12 plus-

ility
ot p
plus1)
wit
, is n
h re
-25 °C 40 % 3.2 l 4.8 l

hole
spec
-35 °C 50 % 4.0 l 4.0 l

es, in part or in w
t to the co
1)The quantity of coolant can vary depending upon the vehicle

equipment.
rrectness of i
– Close radiator drain plug.

l purpos
– Connect coolant hoses to oil cooler.

– Install noise insulation tray. ⇒ General body repairs, exterior;
nform
ercia

m
at
– Screw adapter -V.A.G 1274/8- onto expansion tank.

om
ion
c
in t
– Fill coolant circuit using cooling system charge unit -

or
his
e
VAS 6096- ⇒ Operating instructions for cooling system charge

at
do
riv
unit VAS 6096

p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.5 Removing and installing radiator

equipment required
♦ Refractometer -T10007-
♦ Torque wrench -
V.A.G 1331-
♦ Spring-type clip pliers -
VAS 5024 A-
wage
e ks s no
Vol t gu
♦ Cooling system d b charge unit
y ara
-VAS 6096- rise nte
ho t 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
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
yri by
1.5.1 Removing
cop Vo
by lksw
cted agen
Prote AG.
– Bring lock carrier into service position. ⇒ General body re‐
pairs, exterior; Rep. Gr. 50 ; Body - front; Lock carrier service
position .
– Pull coolant hoses off radiator.
– Separate connector for radiator fan.
– Remove radiator securing bolts.
– Remove radiator downwards.
1.5.2 Installing
note the following:
– Fill with coolant. ⇒ page 102

AG. Volkswagen AG d
agen
1.6 Removing and installing coolant pump by
Volksw
oes
not
gu
d ara
ise nte
or eo
h
ut
Special tools and workshop ss a ra
c
equipment required
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
♦ Torque wrench -
h re
V.A.G 1331-
hole
spec
es, in part or in w
t to the co
VAS 5024 A-
rrectness of i
-VAS 6096-
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
o
by c lksw
cted agen
Prote AG.
1.6.1 Removing
Note
Always renew seals and gaskets.
– Drain coolant ⇒ page 102 .

– Remove toothed belt ⇒ page 50 .

– Remove securing bolts -1- for coolant pump -2- and carefully
remove coolant pump.
1.6.2 Installing
note the following:
– Moisten new O-ring -3- with coolant.
– Insert coolant pump -2- in cylinder block and tighten securing
bolts -1- to 15 Nm.
Note
The coolant pump plug faces downwards.
– Install toothed belt ⇒ page 50 .

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
cted
107
agen
Prote AG.
1. Parts of cooling system
1.7 Removing and installing thermostat

equipment required
♦ Torque wrench -
V.A.G 1331-
VAS 5024 A-
-VAS 6096-
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
wit
, is n
1.7.1 Removing
h re
hole
spec
es, in part or in w
t to the co
Note
Always renew seals and gaskets.

rrectness of i
l purpos

– Remove alternator. ⇒ Electrical system; Rep. Gr. 27 ; Re‐
nform
ercia
moving and installing alternator with poly V-belt .

m
at
– Pull coolant hose off connection.

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
o
by c lksw
cted agen
Prote AG.

– 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 it from
connection -2-.
1.7.2 Installing
note the following:
– Moisten new O-ring -3- with coolant.
– Insert thermostat -4- into connection -2- and turn 1/4 turn (90
°) to right.
Note
The brace on the thermostat must be almost vertical.

olksw AG. V agen AG
agen does
olksw not
– Insert connection
db
y V -2- with thermostat -4- in cylinder
gu
ara block.
ise nte
r
– Tightenut securing bolts -1- to 15 Nm.
ho eo
ra
s a c
s
– Replenish coolant. ⇒ page 102
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
cted agen
Prote AG.

1.8 Checking cooling system for leaks

equipment required
♦ Cooling system tester -
V.A.G 1274-
♦ Adapter for cooling system
tester -V.A.G 1274/8- AG. Volkswagen AG d
agen oes
lksw not
♦ Adapter for cooling system d by Vo gu
ara
tester -V.A.G 1274/9- orise nte
th eo
au ra
ss c
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Test prerequisite
• Engine at operating temperature.
Test sequence:
WARNING
Hot steam may escape when expansion tank is opened. Place

rag over cap and open with caution.
– Open cap on coolant expansion tank.

– Attach cooling system tester -V.A.G 1274- with cooling system

tester adapter -V.A.G 1274/8- to expansion tank.
– Use hand pump on tester to create a pressure of about 1.0 bar.
If pressure drops:
– Find leaks and rectify.
Checking pressure relief valve in filler cap
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– Attach cooling system y Volk tester -V.A.G 1274- withscooling
not
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tester adapter rised-V.A.G
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– Use hand s aupump on cooling system tester to create a pressure
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of max. 1.6 bar.
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The pressure relief valve must not open.
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If the pressure relief valve opens prematurely:
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– Renew sealing cap.
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– Increase pressure to over 1.6 bar.
spec
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The pressure relief valve must open.
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If the pressure relief valve does not open:
– Renew sealing cap. rrectness of i
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4-cylinder diesel engine (1.9
AG.l Vengine)
olkswagen- A
Edition 01.2009
n G do
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Volks ot g
1.9 Checking engine oil cooler for leaks
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♦ Hose clamps up to
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Ø 25 mm -3094-
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spec
♦ Cooling system tester -
es, in part or in w
V.A.G 1274-
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♦ Adapter for cooling system
tester -V.A.G 1274/8-
rrectness of i
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5024A-
♦ Drip tray -VAS 6208-
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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-
♦ Screw clamp
Test prerequisite:
• Engine cold
Test procedure
insulation .
– Clamp supply line and return line off engine oil cooler using
hose clips to ∅ 25 mm -3094- .
– Loosen spring type clips -arrows- using spring type clip pliers
-VAS 5024A- .
Note
Collect escaping coolant with drip tray -VAS 6208- .
– Pull coolant hoses off oil cooler.
– Push sealing cap -5- to rear connection of oil cooler -4-.

– Secure sealing plug -2- to breather connection of expansion
tank -1-.
– Secure coolant hose -3- to oil cooler and expansion tank.
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– Fill expansion tank up to “Max”
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– Attach cooling system thotester
ris -V.A.G 1274- with cooling system tee
or
tester adapter -V.A.G
au 1274/8- to expansion tank. ac
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Use hand pump on tester to create a pressure of about 1.6 bar.

nl
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Watch pressure drop on pressure gauge. A pressure drop within

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10 minutes is not permitted.

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If pressure drops:
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– Renew oil cooler.

spec
es, in part or in w
Assembly is carried out in the reverse order, note the following:

t to the co
– Check coolant level, if necessary replenish coolant.

rrectness of i
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20 – Fuel supply system AG. Volkswagen AG d

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1 Safety precautions when working on orised b ara
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fuel supply system
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WARNING
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tions:
hole
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sitions.
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hot components.
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very hot (danger of scalding)!
orm
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♦ The fuel system is also under pressure! Before opening
atio
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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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When removing and installing fuel gauge sender or fuel pump
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(fuel delivery unit) from a full or partly full fuel tank, observe the by c lksw
cted agen
following: Prote AG.
♦ Before beginning work, place an extraction hose close to

sender opening in fuel tank to extract escaping fuel fumes and
switch on exhaust extraction system. If no exhaust gas ex‐
traction 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!
114 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. wage
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♦ Place removed parts eon
d b a clean surface and cover. Do not use
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fluffy cloths! horis nte
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♦ Carefully coverss opened components or seal if repairs cannot
be carried out immediately.
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♦ Install clean components only. Do not remove replacement
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parts from packing until immediately before installing. Do not
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use parts that have not been stored in their packing (e.g. in
ot
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tool boxes etc.).
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♦ When system is open: do not work with compressed air if this
spec
es, in part or in w
can be avoided. Do not move vehicle unless absolutely nec‐
t to the co
essary.
♦ Also ensure that no diesel fuel runs on to the coolant hoses.
Should this occur, the hoses must be cleaned immediately.
rrectness of i
Damaged hoses must be renewed.
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2. Rules for cleanliness 115

3 Fuel tank, vehicles with front-wheel

drive
Observe safety precautions ⇒ page 114 .
Observe rules for cleanliness ⇒ page 115 .
Assembly overview - fuel tank ⇒ page 116 .
Emptying fuel tank ⇒ page 117 .
Removing and installing fuel tank ⇒ page 121 .
Removing and installing fuel delivery unit ⇒ page 123 .
Removing and installing fuel gauge sender ⇒ page 124 .
Checking fuel pump ⇒ page 125 .
3.1 Assembly overview - fuel tank
1 - Sealing cap
2 - 1.5 Nm
3 - Earth connection
❑ Check for secure seat‐ agen
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6 - Fuel tank
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❑ When removing, sup‐

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port using engine and

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gearbox jack -V.A.G

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1383/A- .
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spec
⇒ page 121 .
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7 - 25 Nm
❑ To secure the securing
rrectne
straps for the fuel tank,

only bolts with loose
washers must be used.
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If other bolts are used,

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the securing straps

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could be twisted whilst

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tightening. Bolts ⇒ ET‐

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KA (electronic parts
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❑ Renew.
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9 - Securing strap
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10 - Heat shield
❑ For fuel tank.
11 - Seal
❑ Moisten with fuel when installing

AG. Volkswagen
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by
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12 - Fuel delivery unit s aut ra
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s
❑ With fuel gauge sender (G).
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❑ Note installation position of flange on fuel tank ⇒ page 117 .
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❑ Checking fuel pump ⇒ page 125 .
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❑ Removing and installing fuel gauge sender ⇒ page 124 .
hole
spec
❑ Clean strainer if soiled
es, in part or in w
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13 - Locking ring
❑ Remove and install using fuel tank sender unit tool -T10202- .
rrectness of i
❑ Specified torque: 110 Nm.
14 - Supply line l purpos
❑ To fuel filter
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❑ Clipped onto fuel tank

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❑ Black
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❑ To pull off flange, press release button on connecting piece.
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15 - Return line
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❑ From fuel cooler

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❑ Blue or with blue marking.
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❑ Check for secure seating. Prote AG.
❑ To pull off flange, press release button on connecting piece.

16 - Tank flap unit
❑ Removing and installing ⇒ General body repairs, exterior; Rep. Gr. 55 ; Tank flap unit .
Installation position of fuel delivery unit

Marking -3- on the flange must align with marking on the fuel tank.
Return line blue or with blue marking -1-.
Supply line (black) -2-.
Note
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
3.2 Emptying fuel tank

3. Fuel tank, vehicles with front-wheel drive 117

olkswagen AG
wag en AG. V
Golf 2004 ➤ , Golf Plus 2005 ➤ olks
does
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4-cylinder diesel engine (1.9 l engine)
se
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♦ Fuel extractor -VAS 5190- ss
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♦ Fuel tank sender unit tool -T10202-
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♦ Torque wrench (40…200 Nm) -V.A.G 1332-

– Note safety precautions before beginning work ⇒ page 114 .
Emptying fuel tank, bleeding fuel system when fuel pump is intact
⇒ page 118 .
Emptying fuel tank if more than 3/4 full ⇒ page 120
Emptying fuel tank if less than 3/4 full ⇒ page 120
3.2.1 Emptying fuel tank, bleeding fuel system

when fuel pump is intact
♦ Diagnostic tester
♦ Fuel extractor -VAS 5190-
♦ Adapter for fuel extraction -VAS 5190 /3 -
WARNING
Fuel supply line is pressurised. Wear eye protection and pro‐

tective clothing to avoid possible injury and skin contact. Before
loosening hose connections, wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off con‐
nection.
Note
Press in securing ring to release fuel lines.

– Pull off supply line -arrow- and catch escaping fuel with a cloth.
AG. Volkswagen AG d
agen oes
olksw not
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pt
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erm
ab
ility
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wit
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– Connect fuel extractor -VAS 5190- with adapter for fuel ex‐
hole
spec
tractor -VAS 5190 /3 - to fuel supply line.
es, in part or in w
t to the co
rrectness of i
l purpos
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– Connect a diagnostic tester.

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The fuel pump is being activated when engine is not running.
co lksw
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– Switch on ignition.
– Remove filler cap from fuel tank filler neck.
– Perform the function “Emptying fuel system” in “guided func‐
tions”.
If the fuel tank is emptied, “stop” the function to prevent the fuel
pump from running “dry”.
– Operate shut-off tap on fuel extractor -VAS 5190- , until the
fuel tank is emptied.
Bleeding fuel system
1) Low-pressure section
• Fuel tank filled.

– Perform the function “Bleeding fuel system” in “guided func‐
tions”.

3.2.2 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 -1- of fuel extractor -VAS 5190- .
– At distance -a- = 1180 mm from end, mark extraction hose with
insulating tape -arrow-.

– Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel
filler neck. wage
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– Push extraction hose into fuel tank until marking eond b hose
y ara
-arrow- coincides with shaft end. tho
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ility
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Note t to the co
A ball valve -2- is located at the bottom of the filler neck in the fuel
rrectness of i
tank -1-; it must not be damaged by the extraction hose -3-.

Therefore push hose into filler neck only as far as marking
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-arrow-.
nform
ercia
– Empty fuel tank as far as possible.

m
at
– Carefully pull out extraction hose.

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Note
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♦ When no more fuel is extracted, the tank is emptied just

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enough for the sender flange to be opened without danger. C py
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♦ If the fuel tank has to be drained fully, proceed as follows:
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⇒ page 120 Prote
cted AG.
agen
3.2.3 Emptying fuel tank if it is less than 3/4 full

– Remove bench seat ⇒ General body repairs, interior; Rep.
Gr. 72 ; Rear seats; Removing and installing bench seat .

– Remove cover from fuel delivery unit.
WARNING

nection.
– Pull connector and fuel lines off flange.
Note
Press buttons on hose couplings to do this.
– Open locking ring using fuel tank sender wrench -T10202- .

– Lift sender flange.
– Insert extraction hose of fuel extractor -VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, reinstall sender flange.
3.3 Removing and installing fuel tankgen AG. Volkswagen AG

a does
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Special tools and workshop equipment requiredby Vo gu
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♦ Torque wrench -V.A.G 1331- tho eo
au ra
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pe
ility
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es, in part or in w
t to the co
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♦ Engine and gearbox jack -V.A.G 1383/A-

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mercia
a
com
tion in
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Golf 2004 ➤ , Golf Plus 2005 ➤ ir se
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3.3.1 Removing
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spec
Note
es, in part or in w
t to the co
♦ Before carrying out further work, disconnect battery earth
strap. Check whether a coded radio is fitted. Obtain anti-theft
rrectness of i
coding first if necessary.
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♦ When lowering fuel tank, guide it carefully to prevent damage.
nform
ercia
– With the ignition switched off, disconnect battery earth strap.
m
– Empty fuel tank ⇒ page 117 .
at
om
ion
c
– Fold rear seats forwards.
in t
or
his
ate
– Detach carpet under seats and fold it back. ⇒ General body
do
priv
c
repairs, interior; Rep. Gr. 70 ; Load and luggage compartment
um
for
trim; Removing and installing luggage compartment floor
en
ng
t.
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op py
– Remove cover from fuel delivery unit. t. C rig
gh ht
pyri by
– Pull connector off flange.
co Vo
by lksw
cted agen
Prote AG.
– Remove fuel flap unit. ⇒ General body repairs, exterior; Rep.
Gr. 55 ; Fuel flap unit
– Remove rear right wheel housing liner. ⇒ General body re‐
pairs, exterior; Rep. Gr. 66 ; Removing and installing wheel
housing liner .
– Remove bolts from filler neck -arrows-.
– Disconnect fuel lines at front right of fuel tank.
Note
– If vehicle has supplementary heating, separate connector to

metering pump and unclip wire. ⇒ Supplementary heating;
Rep. Gr. 82 ; Removing and installing metering pump -V54
– Support fuel tank using engine and gearbox jack -V.A.G 1383/
A- .
– Remove securing bolts -arrows- for the fuel tank.

– Slowly lower fuel tank.
– Tilt fuel tank to get it past rear axle.
3.3.2 Installing

♦ Install breather and fuel hoses free of kinks.

♦ Clip fuel lines onto fuel tank.
3.4 Removing and installing fuel delivery

unit
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3.4.1 Removing
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hole

spec
es, in part or in w

t to the co
– First check whether a coded radio is fitted. If so, obtain anti-

theft coding.
rrectness of i

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– The fuel tank must not be more than 3/4 full when removing
the suction-jet pump. Drain fuel tank if necessary
nf
ercia
⇒ page 117 .
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Note
WARNING
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
– Remove union nut using fuel tank sender unit tool -T10202- .
– Pull fuel delivery unit with seal out of opening in fuel tank.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
3.4.2 Installing
. Volkswagen AG
– Installing the fuel delivery unit is carried out in reverse korder
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of removal. Vol s not
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Note ss c
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♦ Do not bend fuel gauge sender when installing.

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♦ Insert seal for flange or fuel delivery unit dry into opening of
ility
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fuel tank.
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♦ Moisten seal with fuel only when installing flange or fuel de‐
hole
spec
livery unit.
es, in part or in w
t to the co

♦ After installing fuel delivery unit, check that the supply, return
and breather lines are still clipped onto the fuel tank.
rrectness of i
♦ Note installation position of fuel delivery unit flange: mark on

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flange must align with mark on fuel tank.

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ercia
3.5 Removing and installing fuel gauge

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sender
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Removing
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– Remove fuel delivery unit. ⇒ page 123

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– Release connector tabs of lines -3- and -4- and pull them off.
– Raise retaining tabs -1- and -2- using a screwdriver and pull
fuel sender off downwards -arrow-.
Installing
– Insert fuel gauge sender into guides on fuel delivery unit and
press upwards until it engages.
3.6 Checking fuel pump olkswage

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Checking voltage supply of fuel pump ir se -G6- ⇒ page 125
d ran
tee
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or
Checking current consumption sof
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fuel pump -G6- ⇒ page 126 ac
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3.6.1 Checking function and voltage supply

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♦ Hand multimeter -V.A.G 1526 B- or multimeter -V.A.G 1715-
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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orm
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♦ Auxiliary measuring set -V.A.G 1594 C-

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♦ Diode test lamp -V.A.G 1527 B-

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Test prerequisites
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• Fuses must be OK.
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• The battery voltage must be at least 11.5 V.
c by lksw
cted agen
Prote AG.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
– Switch on ignition. Fuel pump must be heard to run.
– Switch off ignition.
If the fuel pump does not start:
– Pull 4-pin connector off fuel delivery unit flange.

wage e
– Connect diode test lamp -V.A.G
yV
olks 1527 B- to outer contacts
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connector using auxiliary
ised bcables from auxiliary measuring setaran
-V.A.G 1594 C- . uthor tee
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s The LED must light up for about 2 seconds.
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If LED does not light up
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– Check actuation of fuel pump relay and wiring for open circuit
ility
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or short circuit. ⇒ Vehicle diagnosis, testing and information
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system VAS 5051
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If LED lights up (voltage supply OK):
spec
t to the co
– Check that electrical wiring between flange and fuel pump is
connected and has continuity.
rrectne
If no open circuit can be found:
ss
– Renew fuel delivery unit. ⇒ page 123
o
cial p
f inform
mer
3.6.2 Checking current draw of fuel pump
atio
om
n
c
i
or
n thi
te
sd
– Set multimeter to measuring range 20 A and connect in series
iva
o
r
between contacts -1- of connector and fuel pump using auxil‐

p
cum
r
fo
iary cables from auxiliary measuring set -V.A.G 1594 C- .

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
o Vo
by c lksw
cted agen
Prote AG.
The current pick-up clamp of multimeter -V.A.G 1715- can also
be attached to an auxiliary cable between contacts -1- of con‐
nector and fuel pump.
– Connect contacts -4- of connector and fuel pump using an

auxiliary cable from auxiliary measuring set -V.A.G 1594 C- .
– Start engine and run at idling speed.
– Measure current draw of fuel pump: Specification: max. 7.5
Amperes.
– If the measured value is not within specifications:

4 Fuel tank, vehicles with four-wheel

drive
Assembly overview - fuel tank ⇒ page 127 .
Emptying fuel tank ⇒ page 128 .
Removing and installing fuel tank ⇒ page 132 .
Removing and installing fuel gauge sender 2 -G169-
⇒ page 135 .
Removing and installing suction jet pump ⇒ page 137
Checking fuel pump ⇒ page 125 .
4.1 Assembly overview

Volkswa
- fuel tank
AG. gen AG
agen does
olksw not
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1 - Supply linerise
db ara
nte
❑ Black tho eo
s au ra
c
s
ce
le
un
ing.
pt
an
d
itte
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2 - Return line
erm
ab
ility
ot p
❑ Blue
wit
is n

h re
ole,
ing.
spec
3 - Seal
t to the co
❑ When installing, fit dry in
rrectne
fuel tank opening

❑ Moisten with fuel only
s
when installing flange.

s o
cial p
f in
4 - Fuel delivery unit

form
mer

atio
m
⇒ page 123 .
o
n
c
i
or
❑ Checking fuel pump

thi
te
⇒ page 125 .
sd
iva
o
pr

um
r
fo
en
ng
tion on fuel tank yi

t.
Co
⇒ page 128 . t. Cop py
rig
gh
❑ With fuel gauge sender
ht
pyri by
Vo
-G-
co lksw
by
cted agen
Prote
AG.
fuel gauge sender

⇒ page 124 .
5 - Locking ring, 110 Nm
ing.
❑ Remove and install us‐
ing wrench -T10202- .
6 - Tank flap unit
❑ With rubber cup
❑ Removing and installing ⇒ General body repairs, exterior; Rep. Gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit .
4. Fuel tank, vehicles with four-wheel drive 127

7 - Cap
8 - Securing bolt
❑ Tighten to 1.5 Nm.
9 - Earth connection AG. Volkswagen AG d
agen oes
❑ Check for secure seating. olksw not
y V gu
d b ara
10 - 10 Nm rise nte
tho eo
au ra
11 - Suction-jet pump ss c
ce
e
nl
❑ Clipped onto fuel gauge sender 2 -G169-
pt
du
an
itte
y li
erm
ab
ility
ot p
12 - Fuel gauge sender 2 -G169-
wit
, is n
h re
13 - Fuel tank
hole
spec
❑ When removing, support using engine and gearbox jack -V.A.G 1383 A- .
es, in part or in w
t to the co
14 - Securing strap
rrectness of i
l purpos
15 - 25 Nm
❑ To secure the securing straps for the fuel tank, only bolts with loose washers must be used. If other bolts
are used, the securing straps could be twisted whilst tightening. Bolts ⇒ ETKA (electronic parts cata‐
nf
ercia
o
logue) .
rm
m
atio
❑ Renew.
om
n in
or c
16 - Heat shield
thi
te
sd
a
❑ Riveted to exhaust pipe mounting

iv
o
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rp
cu
o
m
f
en
ng
t.
yi Co
op py
Installation position of flange for fuel delivery unit and fuel gauge t. C rig
gh ht
sender 2 -G169- yri
p by
co Vo
by lksw
cted
The marking on the flange must align with the marking on the fuel
agen
Prote AG.
tank -arrow-.
Note
The marking on the fuel tank is not clearly visible.
4.2 Emptying fuel tank

♦ Fuel extractor -VAS 5190-


Emptying fuel tank when fuel pump is intact ⇒ page 129 .
Emptying fuel tank if it is more than 3/4 full ⇒ page 130 .
Emptying fuel tank if it is less than 3/4 full ⇒ page 131 .
4.2.1 Emptying fuel tank, bleeding fuel system

when fuel pump is intact
♦ Diagnostic tester AG. Volkswagen AG d
agen oes
ksw
♦ Fuel extractor -VAS 5190- by Vol not
gu
d ara
ise nte
♦ Adapter for fuel extraction -VAS 5190 thor/3 - eo
au ra
ss c
ce
le
WARNING
un
pt
an
d
itte
Fuel supply line is pressurised. Wear eye protection and pro‐ y li

erm
ab
tective clothing to avoid possible injury and skin contact. Before ility
ot p
loosening hose connections, wrap a cloth around the connec‐ wit

is n
h re
ole,
nection.
spec
t to the co
Note
rrectne
Press in securing ring to release fuel lines.

ss o
cial p
f in
– Pull off supply line -arrow- and catch escaping fuel with a cloth.
form
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.

– Connect fuel extractor -VAS 5190- with adapter for fuel ex‐ AG. Volkswagen AG d
tractor -VAS 5190 /3 - to fuel supply line. lksw
agen oes
n o ot g
yV ua
edb 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
Note
l purpos
The fuel pump is being activated when engine is not running.
nform
ercia
m
at
om
io
n
c
in t
or
his
e
– Perform the function “Emptying fuel system” in “guided func‐

at
do
riv
tions”.
p
cum
for
en
g
If the fuel tank is emptied, “stop” the function to prevent the fuel
n
t.
yi Co
pump from running “dry”. Cop py
t. rig
gh ht
yri
– Operate shut-off tap on fuel extractor -VAS 5190- , until the p by
o Vo
by c
fuel tank is emptied.
lksw
cted agen
Prote AG.
Bleeding fuel system
2) Low-pressure section
• Fuel tank filled.

– Perform the function “Bleeding fuel system” in “guided func‐
tions”.
4.2.2 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.

lkswage diesel engine (1.9
4-cylinder els engine)
no - Edition 01.2009
V o t gu
by ara
ed nte
– Remove cotter -2- from shaft -1- of fuel
ho extractor -VAS 5190- .
ris
eo
aut ra
– At distance -a- = 1180 mm from end,
ss mark extraction hose with c
ce
e
insulating tape -arrow-.
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
– Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel
filler neck.
nf
ercia
or
– Push extraction hose into fuel tank until marking on hose
m
m
atio
-arrow- coincides with shaft end.
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.
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; it must not be damaged by the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
– Empty fuel tank as far as possible.

– Carefully pull out extraction hose.
Note
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
♦ If the fuel tank has to be drained fully, proceed as follows:
⇒ page 131
4.2.3 Emptying fuel tank if it is less than 3/4 full

Gr. 72 ; Rear seats; Removing and installing bench seat .
WARNING

nection.

Note
Press buttons on hose couplings to do this. agen

AG. Volkswagen AG d
oes
olksw not
byV gu
ara
– Open locking ring using fuel tank ris sender wrench -T10202- .
ed
nte
ho eo
ut
– Lift sender flange. ss a ra
c
ce
le
– Insert extraction hose of fuel extractor -VAS 5190- as deeply

un
pt
an
d
as possible into fuel tank and extract fuel.

itte
y li
erm
ab
If fuel tank needed only to be emptied, reinstall sender flange.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
4.3 Removing and installing fuel tank
ss
o
cial p
f in
form
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.
♦ Engine and gearbox jack -V.A.G 1383 A-
Remove fuel tank ⇒ page 132 .
4.3.1 Removing fuel tank


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Note orise nte
eo
h
aut ra
s c
Vehicles up to 06/2007 are fitted with a two-part propshaft. For
s
ce
le
these vehicles it is sufficient to remove the rear propshaft. Vehi‐
un
pt
an
d
cles from 06/2007 are fitted with a single part propshaft. For these
itte
y li
vehicles the complete propshaft must be removed.
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
c
♦ Engine and gearbox jack -V.A.G 1383 A-
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

theft coding.
Before disconnecting battery, open fuel tank flap and if necessary
remove wheel lock adapter from luggage compartment.
⇒ Electrical system; Rep. Gr. 27 ; Disconnecting and con‐
necting batteries .
If necessary, drain fuel tank using fuel extractor -VAS 5190- .
⇒ page 128
– Unbolt rear right wheel.
– Remove rear right wheel housing liner. ⇒ General body re‐
pairs, exterior; Rep. Gr. 66 ; Removing and installing wheel
housing liner; Rear wheel housing liner .
– Unscrew securing bolts and remove tank flap unit. ⇒ General
body repairs, exterior; Rep. Gr. 55 ; Fuel flap unit

– Unscrew filler neck from body -arrows- and unclip electrical

wire from filler neck.
Gr. 72 ; Rear seat; Removing and installing seat bench .
– Remove covers and separate electrical connectors -arrows-. agen

AG. Volkswagen AG d
oes
olksw not
– Remove centre and rear silencers. byV gu
ara
ed
ris nte
ho eo
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
– Secure exhaust system to underbody using wire.
rrectness of i
– Remove rear propshaft ⇒ Manual gearbox; Rep. Gr. 39 ; Final
drive, differential, differential lock
l purpos
Vehicles from 06/2007 (single part propshaft):
nform
ercia
– Remove complete exhaust system ⇒ page 186 .

m
– Remove complete propshaft ⇒ Propshaft and rear final drive;
a
com
tio
Rep. Gr. 39 ; Repairing propshaft - Golf .
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
g
WARNING
n
t.
yi Co
Cop py
ht. rig
Fuel supply line is pressurised. Wear eye protection and pro‐ rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
nection.
– Pull off adapter cable on four-wheel drive control unit -J492- .

– Support fuel tank using engine and gearbox jack -V.A.G 1383
A- and unscrew tensioning straps and securing bolts.
– Slowly lower fuel tank.
Note
AG. Volkswagen AG d
agen oes
ksw
The filler neck must beby“guided
Vol
out” between body andnorear
t gu axle.
To do this, take therisfuel
ed tank off engine and gearbox jack -V.A.G
ara
nte
1383 A- with theutassistance of a 2nd mechanic.
ho eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
4.3.2 Installing fuel tank
ility
ot p
wit
, is n
– Clip in cable for four-wheel drive control unit -J492- on fuel
h re
tank.
hole
spec
es, in part or in w
– With the aid of a 2nd mechanic, guide the filler neck in between
t to the co
rear axle and body. Then place the fuel tank on the engine and
gearbox jack -V.A.G 1383 A- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
– Raise the fuel tank slowly up to the installation position and

te
sd
a
secure -arrows-.
iv
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.
– Fit adapter cable on four-wheel drive control unit -J492- .

The remaining installation steps are carried out in the reverse se‐
quence. In the process, note the following:
♦ Install breather and fuel lines free of kinks.
♦ Ensure that line connections are firmly seated.
♦ Check earth connection on fuel tank and body to filler neck.
4.4 Removing and installing fuel gauge

sender 2 -G169-
• The fuel tank should be no more than half full

Note
♦ Ensure that the fuel gauge sender is not bent.

♦ If necessary, drain fuel tank using fuel extractor -VAS 5190- .
⇒ page 128
♦ Note safety precautions before starting work ⇒ page 114 .
♦ Observe rules for cleanliness ⇒ page 115 .
Removing:
theft coding.
– With the ignition switched off, disconnect nbattery
. Volkearth
swagenstrap.
ge AG
⇒ Electrical system; Rep. Gr. 27 o; lkDisconnecting
AG do
and con‐
swa es n
ot g
necting batteries . d by V ua
r e an
ris tee
– Remove bench seat ⇒ Generaltho body repairs, interior; Rep. or
au
Gr. 72 ; Rear seat; Removing
ss and installing seat bench . ac
ce
le
un
– Remove left cover (as seen facing direction of normal travel)
pt
an
d
from fuel gauge sender 2 -G169- .

itte
y li
rm
ab
pe
– Disconnect electrical connectors.
ility
ot
wit
, is n
– Open locking ring using wrench -T10202- .
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
– Pull fuel gauge sender 2 -G169- upwards slightly and unclip it

s
iva
from the suction-jet pump.

do
r
rp
cum
fo
Installing:
en
ng
t.
yi Co
Cop py
ht. rig
Caution rig ht
py by
co Vo
by lksw
cted agen
When installing do not bend fuel gauge sender 2 -G169- float
Prote AG.
arm.
– Place fuel gauge sender 2 -G169- in fuel tank.

– Fit suction-jet pump on sender on inside of fuel tank. Locating

lugs must engage.
– Place a new flange seal dry into opening in fuel tank and mois‐
ten inside (contact to flange) only with fuel.
– Note installation position of fuel gauge sender 2 -G169-
⇒ page 128
– Check for correct position of seal.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
– Tighten locking ring using wrench -T10202- . Specified torque:

un
pt
an
d
110 Nm.
itte
y li
rm
ab
– Fit connectors.
pe
ility
ot
wit
, is n
– Install cover.
h re
hole
spec
– Install bench seat. ⇒ General body repairs, interior; Rep. Gr.
es, in part or in w
72 ; Rear seat; Removing and installing seat bench .
t to the co
rrectness of i
l purpos
4.5 Removing and installing suction-jet nform

ercia
pump
m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
♦ On vehicles with four-wheel drive, fuel has to be pumped from

en
ng
t.
yi
the area of fuel gauge sender 2 -G169- to the fuel delivery unit
Co
Cop py
by means of a suction jet pump due to the shape of the fuel
t. rig
gh ht
yri
tank.
p by
co Vo
by lksw
cted agen
♦ Checking is only necessary when the engine stops due to lack
Prote AG.
of fuel, even though the fuel gauge shows that the tank is still
1/4 full.
Procedure
– Remove fuel delivery unit ⇒ page 123 .
– Pull return hose of suction-jet pump out of fuel delivery unit
-arrow-.
– Separate quick-release coupling of supply line from suction-
jet pump on Y-piece of fuel delivery unit.
– Remove fuel gauge sender 2 -G169- ⇒ page 135 .
– Now the suction-jet pump can be pulled out from side of fuel
gauge sender 2 -G169- (left side of vehicle).
– Check that the fuel lines on suction-jet pump are fitted securely
and are not damaged.
– Additionally check suction-jet pump for possible soiling.

4.6 Checking fuel pump

Checking voltage supply of fuel pump -G6- ⇒ page 138
Checking current consumption of fuel pump -G6- ⇒ page 139
4.6.1 Test prerequisites

♦ Hand multimeter -V.A.G 1526C- or multimeter -V.A.G 1715-

AG. Volkswagen AG d
agen oes
• Fuses must be OK. y Volksw not
gu
b ara
ed
• The battery voltage
ho
ris must be at least 11.5 V. nte
eo
t
au ra
• All electricalss consumers, e.g. lights and rear window heating, c
must be switched off.
ce
le
un
pt
an
d
itte
4.6.2 Checking function and voltage supply

y li
erm
ab
ility
ot p

wit
is n
h re

ole,
spec


t to the co

– Switch on ignition. Fuel pump must be heard to run.
rrectne

ss
If the fuel pump does not start:

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.

– Connect diode test lamp -V.A.G 1527 B- to outer contacts of

connector using auxiliary cables from auxiliary measuring set
-V.A.G 1594 C- .
– Switch on ignition. The LED must light up for about 2 seconds.
If LED does not light up
– Check actuation of fuel pump relay and wiring for open circuit
or short circuit. ⇒ Vehicle diagnosis, testing and information
system VAS 5051
If LED lights up (voltage supply OK):
– Check that electrical wiring between flange and fuel pump is
connected and has continuity.
If no open circuit can be found:
4.6.3 Checking current draw of fuel pump

– Set multimeter to measuring range 20 A and connect in series
between contacts -1- of connector and fuel pump using auxil‐
iary cables from auxiliary measuring set -V.A.G 1594 C- .
Note
The current pick-up clamp of multimeter -V.A.G 1715- can also

be attached to an auxiliary cable between contacts -1- of con‐
nector and fuel pump. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
by ua
– Connect contacts -4- of connector ris and fuel pump using an
ed ran
tee
auxiliary cable from auxiliary umeasuring
tho set -V.A.G 1594 C- . or
a ac
ss
ce
le
un
pt
an
– Measure current draw of fuel pump: Specification: max. 7.5

d
itte
y li
Amperes.
erm
ab
ility
ot p
– If the measured value is not within specifications:

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
co lksw
by
cted agen
Prote AG.

5 Repairing fuel supply system

Assembly overview - fuel filter
olks
wa⇒
gepage 140 . es n
ot g
V
by ua
Removing and installing
ris ed fuel cooler ⇒ page 141 ran
tee
ho
ut or
Assembly overview
ss
a - accelerator mechanism ⇒ page 142 . ac
ce
le
Checking tandem pump ⇒ page 143

un
pt
an
d
itte
y li
Removing and installing tandem pump ⇒ page 147
erm
ab
ility
ot p
5.1 Assembly overview - fuel filter
wit
is n
h re
ole,
spec
1 - Supply line
t to the co
❑ From fuel tank.
❑ White or with white
marking.
rrectne
ing.
ss o
cial p
2 - 8 Nm
f inform
mer
3 - Return line
atio
m
❑ To fuel cooler
o
n
c
i
or
❑ Check for secure seat‐ n thi

te
ing.
sd
iva
o
pr
❑ Blue or with blue mark‐

um
r
fo
en
ng
ing. yi
t.
Co
op py
4 - Plug for water extraction
t. C rig
gh ht
yri by
❑ Unscrew and drain ap‐ cop Vo
by lksw
prox. 100 cm3 of liquid
cted agen
Prote AG.
using diesel extractor -
VAS 5226-
5 - Seal
❑ Renew.
6 - Supply line
❑ To tandem pump
❑ White or with white
marking.
ing.
7 - Return line
❑ From tandem pump
❑ Blue marking
ing.
8 - Fuel filter upper part
9 - Fuel temperature sender -G81-
10 - Seal
❑ Renew.
11 - Filter insert
❑ Observe change intervals.
12 - Seal
❑ Renew.

AG. Volkswagen AG d
13 - Fuel filter lower part agen oes
olksw not
y V gu
d b ara
14 - 8 Nm orise nte
th eo
u ra
15 - Bracket ss a c
ce
e
nl
16 - Seal
pt
du
an
itte
❑ Renew.
y li
erm
ab
ility
17 - Retaining clip
ot p
wit
, is n
h re
hole
spec
18 - Return line
es, in part or in w
❑ With connection for fuel temperature sender -G81-
t to the co
19 - From tandem pump
rrectness of i
l purpos
5.2 Removing and installing fuel cooler

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
cted agen
Prote AG.
Removing
Note
The fuel cooler is located in the return line to fuel tank. It is located
on the vehicle underbody.
– Remove underbody panel.

– Separate fuel lines at fuel cooler.
– Remove securing nuts -arrows-.
Installing
♦ Tighten fuel cooler securing nuts to 15 Nm.
5. Repairing fuel supply system 141

5.3 Assembly overview - accelerator mechanism
1 - Connector
❑ Black, 6-pin.
2 - Accelerator position sender
-G79-
❑ Not adjustable.
❑ The accelerator position
sender passes the posi‐
tion of the accelerator
on to the engine control
unit.
❑ To remove, release us‐
ing release tool -
T10238- or release tool
-T10240- .
-A- openings for release tool -
T10238- .
3 - 10 Nm
4 - Cap
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5.3.1 Removing
h re
hole
spec

es, in part or in w
t to the co
♦ Release tool -T10238-

rrectness of i
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at
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ate
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for
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– Before removing accelerator pedal module, remove cover in

footwell by removing plastic nuts -arrows-.
– Lever out cap ⇒ Item 4 (page 142) using a screwdriver.
– Remove bolt ⇒ Item 3 (page 142) .
AG. Volkswagen AG d
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Releasing accelerator pedal moduleho ris nte
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– To remove accelerator pedals module, push release tool -
s c
T10238- (for right-hand drive vehicles release tool -T10240- )
ce
le
un
pt
into openings provided to stop.
an
d
itte
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rm
ab
– Separate electrical connection and pull wire guide off accel‐
pe
ility
erator pedal module.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
5.3.2 Installing
l purpos

note the following:
nform
mercia
– Push electrical connector -1- onto accelerator pedal module.
a
com
tion in
– Press accelerator pedal module onto securing pins -5-.
r
te o
thi
s
iva
– Insert centring pin -6- into hole in floor of vehicle.

do
r
rp
cum
fo
– Secure accelerator pedal module with bolt -2-, specified tor‐

en
ng
t.
que 10 Nm and fit cap -3-.
yi Co
Cop py
t. rig
– Install steering column trim.
gh ht
pyri by
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by c lksw
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Prote AG.
5.4 Checking tandem pump

Checking delivery pressure ⇒ page 143
Checking for internal leaks ⇒ page 146
5.4.1 Checking delivery pressure

♦ Vehicle diagnosis, testing and information system -VAS 5051-

. Volkswage
AG n AG d
agen oes
olksw not
♦ Diagnosis cable, 3 m withd bvoltage
yV supply -VAS 5051/1- or di‐ gu
ara
agnosis cable, 5 m without
orise voltage supply -VAS 5051/3- nte
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pt
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ab
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
♦ Tandem pump tester -VAS 5187-
l purpos
nf
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or c
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by
♦ Banjo bolt -5187/1A- cted agen
Prote AG.

Test prerequisites
• Coolant temperature must be at least 85 °C.
• Unit injectors OK
• Fuel filter and fuel lines must not be blocked.
• The non-return valve in the fuel supply hose must be OK.
• Intact fuel delivery unit

Procedure
– Remove plug -arrow-.
– Connect tandem pump tester -VAS 5187- as shown.

– Connect vehicle diagnosis, testing and information system -
VAS 5051- and select “vehicle self-diagnosis” operating mode.
– Press key “01 - Engine electronics” on display.
– Press diagnosis function “08 - Read
agemeasured
n AG. Volkswvalue
agen AGblock”.
do w es n
olks ot g
– Enter display group “1” using
ed
by number block (key pad) and
V ua
ran
confirm entry with Q key.
ho
ris tee
t or
au ac
– Read engine idlingssspeed in display zone “1”.
ce
e
nl
pt
– Increase engine speed to 4,000 rpm.
du
an
itte
– Observe pressure indicated on pressure gauge. y li

erm
ab
ility
ot p
Specification: min. 7.5 bar wit

, is n
h re
If the specification is not attained:
hole
spec
es, in part or in w
– Using a hose clip, clamp off return line between fuel filter and
t to the co
tandem pump.
– Increase engine speed to 4,000 rpm.
rrectness of i
– Observe pressure indicated on pressure gauge.

l purpos
Specification: min. 7.5 bar

If specification is now obtained:
nf
ercia
orm
Pressure loss at unit injectors.

m
atio
om
n in
– Renew unit injector O-rings.

or c
thi
e
If the specification is not attained:

t
sd
iva
o
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rp
cu
– Renew tandem pump. ⇒ page 147

o
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f
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t.
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Cop py
t. rig
gh
Note
ht
pyri by
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After removing pressure tester, tighten plug to 25 Nm. Always
Prote AG.
renew seal.

5.4.2 Checking for internal leaks
Note
The tandem pump must be checked for internal leaks between

fuel side and oil side after reinstalling a used tandem pump, for
example after renewing or repairing a cylinder head and/or when
installing a "short" engine. When leaking it is possible for the fuel
to mix with the oil which may cause the engine to fail.

♦ Tester -V.A.G 1687-
wage es n
Procedure yV
olks ot g
ua
b
ed ran
– Pull fuel supply
thor hose (white marking) and fuel return hose
is tee
or
(blue marking)
au off tandem pump. ac
ss
ce
e
– Seal fuel return union on tandem pump with a plug. Secure

nl
pt
du
sealing plug with a spring-type clamp.

an
itte
y li
erm
ab
Prepare test unit -V.A.G 1687- as follows:

ility
ot p
wit
– Unscrew pressure regulating valve -2- and close valves -3-

, is n
h re
and -4-.
hole
spec
– Connect test connection -5- to fuel supply union of tandem

es, in part or in w
t to the co
pump using a commercially available compressed air connec‐

tion and a section of fuel hose. Use a spring-type clamp to
secure.
rrectness of i
l purpos
Note
nform
To turn the pressure regulating valve -2- the knob must be pulled
ercia
upwards.
m
at
om
ion
c
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or
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ate
do
priv
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for
en
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t.
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Cop py
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pyri by
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Prote AG.

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

charge air system tester -V.A.G 1687- .
Note
olkswagen AG
en AG. V
If there is water in the sight
Vol
ksglass,
wag drain at water drain
does
nscrew
ot -6-.
y gu
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– Open valve -3-.
tho eo
s au ra
c
– Adjust pressure to 1.0 bar with pressure regulating valve -2-.
s
ce
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nl
pt
du
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itte
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Caution
erm
ab
ility
ot p
The maximum test pressure is 1.3 bar and this must not be
wit
, is n
h re
exceeded.
hole
spec
es, in part or in w
t to the co
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 1.0 bar.
rrectness of i
– Close valve -3- to retain pressure and observe the pressure
drop over a period of 1 minute.
l purpos
If the pressure does not drop the tandem pump can be reused, if
the pressure drops the tandem pump must be renewed.
nform
mercia
5.5 Removing and installing tandem pump

at
om
ion
c
in t
or
his
ate
DANGER!
do
priv
cum
for
en
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The tandem pump may, under no circumstances, be disman‐

n
t.
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tled as the vacuum part could otherwise malfunction. This t. Cop py
would result in the failure of the brake servo.
rig
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Prote AG.


equipment required
1331-
♦ Hand vacuum pump with
accessories -V.A.G 1390-
♦ Water drainage container -
V.A.G 1390/1-
5024 A-
AG. Volkswagen AG d
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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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nf
ercia
orm
m
atio
om
n in
c
5.5.1 Removing
or
thi
te
sd
iva
– Pull supply hose (white marking) and return hose (blue mark‐
o
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rp
cu
o
ing) off fuel filter.

m
f
en
ng
t.
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– Connect hand vacuum pump with accessories -V.A.G 1390- Cop py
t. rig
and water drainage container -V.A.G 1390/1- to return hose yri
gh by
ht
-2-.
op Vo
by c lksw
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Prote
– Operate hand vacuum pump until no more fuel comes out of
AG.
return hose. Be careful that no fuel is sucked into hand vacuum

pump.
pipe.

of mounting.
– Pull vacuum line from brake servo -1- off tandem pump -4-.
– Pull supply hose -2- (white marking) and return hose -3- (blue
marking) off tandem pump -4-.
– Remove securing bolts -arrows-.
– Remove tandem pump
wage
n-4-
AGfrom
. Volkscylinder
wagen AG head.
doe
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Vol t gu
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utho eo
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pt
du
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ab
ility
5.5.2 Installing
ot p
wit
, is n
h re

hole
spec
note the following:

es, in part or in w
t to the co
Note
rrectness of i
♦ Ensure that tandem pump coupling seats properly in cam‐

l purpos
shaft.
♦ Always renew tandem pump seals.
nf
ercia
orm
– Install tandem pump and tighten upper securing bolts to

m
atio
m
20 Nm.
o
n in
or c
thi
– Tighten lower securing bolts to 10 Nm.

te
sd
iva
o
r
– Attach return hose (blue marking) to return connection -3- of

rp
cu
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tandem pump.
f
en
ng
t.
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op
– Attach supply hose (white marking) to supply connection -2-
C py
t. rig
gh
and vacuum hose from brake servo -1- to tandem pump -4-.
ht
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– Connect supply hose (white marking) to fuel filter. cted agen
Prote AG.

– Connect hand vacuum pump with accessories -V.A.G 1390-

and water drainage container -V.A.G 1390/1- to return hose
-2-.
– Operate hand vacuum pump -V.A.G 1390- until fuel comes out
of return hose. Be careful that no fuel is sucked into hand vac‐
uum pump.
– Connect return hose (blue marking) to fuel filter.
lkswage es n
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pt
du
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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
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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Prote AG.

21 – Turbocharging/supercharging
1 Charge air system with turbocharger
Safety precautions ⇒ page 151
Rules for cleanliness ⇒ page 151 .
Installing hose connections with connector couplings
⇒ page 161
Assembly overview - turbocharger ⇒ page 152
Removing and installing turbocharger ⇒ page 156
Assembly overview - parts of charge air cooling ⇒ page 158
Checking charge air system for leaks ⇒ page 162
1.1 Safety precautions

AG. Volkswagen AG d
agen oes
WARNING
Vol
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d by ara
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ris
When doinguthany repair work, especially in the engine compart‐
o eo
ra
ment, payss aattention to the following due to the cramped condi‐ c
tions:
ce
le
un
pt
an
d
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rm
ab
pe
ility

ot
wit
sitions.
, is n
h re
hole

spec
hot components.
es, in part or in w
t to the co
Observe following if test and measuring instruments are required

rrectness of i
during a road test:

l purpos
♦ Test and measuring instruments must be secured to rear seat

and operated by a second person from this location.
nform
ercia
If test and measuring instruments are operated from front pas‐

senger seat and the vehicle is involved in an accident, there is a
m
possibility that the person sitting in this seat may receive serious
com
tion in
injuries when the airbag is triggered.

r
te o
thi
s
1.2 Rules for cleanliness

iva
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cum
fo
When working on the turbocharger, pay careful attention to the

en
ng
t.
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following rules for cleanliness: t. Cop py
rig
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yri
p by
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connecting.
c by lksw
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Prote AG.
♦ Place removed parts on a clean surface and cover. Do not use
fluffy cloths!
♦ Carefully cover opened components or seal if repairs cannot
tool boxes etc.).
♦ 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.
1. Charge air system with turbocharger 151


essary.
1.3 Assembly overview - turbocharger
Note
♦ All hose connections are secured.

♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Before screwing on oil supply line, fill turbocharger at connec‐
tion with engine oil.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.

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
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
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
152 Rep. Gr.21 - Turbocharging/supercharging

Engine codes BJB, BKC, BRU, BXE and BXF ⇒ page 153
Engine codes BLS and BXJ ⇒ page 155
1.3.1 Engine codes BJB, BKC, BRU, BXE and BXF
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 95 .
5 - Gasket
❑ Renew.
tion.
6 - Washer
7 - 25 Nm AG. Volkswagen AG d
agen oes
❑ Renew. olksw not
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8 - Support horis nte
eo
ut ra
❑ Between turbocharger ss a c
and cylinder block.
ce
le
un
pt
an
d
9 - 40 Nm
itte
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erm
ab
❑ First hand tighten all
ility
ot p
bolts
wit
is n
h re
10 - Connecting pipe
ole,
spec
❑ Air filter/turbocharger
t to the co
11 - Connecting piece
12 - Gasket
❑ Renew. rrectne
13 - Seal
ss o
❑ Renew.
cial p
f inform
mer
atio
m
15 - Oil return line

o
n
c
i
or
❑ To cylinder block.
thi
te
sd
va
❑ Tighten union nut to 30 Nm.

i
o
pr
cum
r
fo
16 - 17 Nm
en
ng
t.
yi Co
op py
17 - Vacuum hose t. C rig
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yri by
❑ To solenoid valve block op Vo
by c lksw
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Prote
18 - Turbocharger
AG.
❑ Can only be renewed with exhaust manifold.

❑ To remove turbocharger, remove right drive shaft ⇒ Running gear, axles, steering; Rep. Gr. 40 ; Re‐
moving and installing drive shafts .

19 - 20 Nm
❑ First hand tighten all bolts
20 - 20 Nm
❑ Renew.
21 - Heat shield
22 - Gasket
❑ Renew.
23 - Clamp, 7 Nm
24 - Front exhaust pipe
25 - Bracket
AG. Volkswagen AG d
❑ For oil supply line ⇒ Item 3 (page 153) . agen oes
olksw not
y V gu
❑ Before installing, secure oil supply line. rise d b ara
nte
tho eo
26 - 22 Nm s au ra
c
s
❑ Renew.
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nl
pt
du
an
itte
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erm
ab
❑ To bypass flap
ility
ot p
wit
, is n
h re
hole
❑ Renew.
spec
es, in part or in w
❑ Coat threads and bolt head seating surface with “G 052 112 A3”.
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
auth Golf 2004
or
ac ➤ , Golf Plus 2005 ➤
ss 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009
ce
e
nl
pt
du
an
1.3.2 Engine codes BLS and BXJ
itte
y li
erm
ab
ility
ot p
wit
, is n
1 - 10 Nm
h re
hole
spec
2 - Bracket
es, in part or in w
t to the co
3 - Heat shield
4 - Oil supply hose
rrectness of i
❑ To oil supply line con‐
nection on turbocharger
l purpos
❑ Before installing oil sup‐

ply line, ensure that it is
nform
ercia
not blocked.
❑ Before installing, fill tur‐
m
at
om
i
bocharger via oil supply
on
c
hose with engine oil
in t
or
his
ate
5 - Turbocharger
do
priv
cum
or
❑ Can only be renewed

f
en
ng
with exhaust manifold.

t.
yi Co
Cop py
t. rig
gh ht
yri
⇒ page 156 . p by
co Vo
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cted agen
6 - Vacuum hose Prote AG.
7 - Gasket
❑ Renew.
tion.
8 - To particulate filter
9 - Clamp, 7 Nm
❑ For turbocharger/partic‐
ulate filter
10 - Exhaust manifold
❑ Can only be renewed to‐
gether with turbocharg‐
er
11 - 25 Nm
❑ Renew.
12 - 25 Nm
13 - Gasket
❑ Renew
❑ For exhaust gas recirculation.
❑ Assembly overview - parts of exhaust gas recirculation ⇒ page 196
15 - 25 Nm
❑ Renew
16 - 15 Nm
17 - O-ring
❑ Renew
18 - Banjo bolt, 60 Nm
❑ Renew
19 - Support
❑ For turbocharger

❑ With oil return line
20 - Exhaust gas temperature sender bank 1 -G235- , 45 Nm
❑ Lubricate thread of sender using high-temperature paste -G 052 112 A3-
❑ Use tool set -T10395- to remove and install.
21 - Heat shield
22 - Connection
❑ For intake hose for air filter/turbocharger
❑ Assembly overview - air filter ⇒ page 177 . n AG. Volkswagen AG do
lkswage es n
23 - 9 Nm byV
o ot g
ua
d ran
ir se
24 - 10 Nm utho tee
or
a ac
ss
ce
le
un
pt
an
d
1.4 Removing and installing turbocharger

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
♦ Lambda probe open ring spanner set -3337-
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
♦ Tool set -T10395-
fo
en
ng
t.
yi Co
Cop py
t. rig
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Vo
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Prote AG.

Caution
When a mechanical fault is found on the turbocharger, e.g. a

destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To prevent this from causing further damage,
perform the followingwrepairs:
agen
AG. Volkswagen AG d
oe
olks s no
♦ Check airedfilter
by housing, air filter element and intake
ara hoses
V gu t
for soiling.
h oris nte
e
t or
au a
♦ Check
ss complete charged air routing and charge air cooler
c
for foreign objects.
ce
e
nl
pt
du
an
itte
If foreign objects are found in the charge air system, the charg‐
y li
erm
ab
ed air routing must be cleaned and the charge air cooler must
ility
ot p
be renewed, if necessary.
wit
, is n
h re
hole
spec
Removing
es, in part or in w
t to the co
or; Rep. Gr. 50 ; Body - front; Noise insulation .
rrectness of i
– Remove subframe and the right drive shaft ⇒ Running gear,
axles, steering; Rep. Gr. 40 .
l purpos
nform
ercia
– Pull electrical connector off exhaust gas pressure sensor 1 -

G450- ⇒ Item 2 (page 188) in engine compartment and un‐
m
at
screw securing bolts.
om
ion
c
in t
r
– Separate electrical connectors to particulate filter.

o
his
ate
do
riv
– Remove particulate filter.

p
cum
for
en

ng
t.
yi Co
op py
– Disconnect fasteners -arrows- of coolant pipes for auxiliary
. C rig
ht ht
rig
heater, if part of original equipment. py by
co Vo
by lksw
cted agen
Prote AG.

lkswage es n
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byV ua
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Golf 2004 ➤ , Golf Plus 2005 ➤ auth or
ac
ss
ce
le
un
pt
an
d
– Unbolt pendulum support -arrows-.
itte
y li
erm
ab
– Remove turbocharger support and oil return line.
ility
ot p
wit
is n
– Remove connecting pipe to exhaust gas recirculation cooler.
h re
ole,
spec
– Separate charge pressure line from turbocharger.
t to the co
– Pull vacuum hose off turbocharger.
– Separate oil supply line from turbocharger.
rrectne
– Unscrew securing bolts for exhaust manifold.
– Tilt the engine forwards in lower mounting and remove turbo‐
ss
charger with exhaust manifold downwards.
o
cial p
f inform
Installing mer
atio
– Installation is carried out in the reverse sequence of removal.
om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng
Torque setting of pendulum support ⇒ page 10 .

t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
1.5 Assembly overview - parts of charge air
c by lksw
cted agen
Prote AG.
cooling
Note
♦ Charge air system must be free of leaks.

♦ When making repairs, remove oil from connection and hose
ends.
♦ All hose connections of charge air system are secured by
spring-type clips or by connector couplings.
♦ Checking charge air system for leaks ⇒ page 162

Engine codes BJB, BKC, BRU, BXE and BXF ⇒ page 159
⇒ page 161
1.5.1 Engine codes BJB, BKC, BRU, BXE and BXF
1 - 8 Nm
❑ Fitting location
⇒ page 160
2 - Bracket
tion.
3 - Charge air cooler
4 - Connecting hose
5 - 8 Nm
AG. Volkswagen AG d
agen oes
6 - To turbocharger. olksw not
V gu
d by ara
e
7- Connecting pipe ho ris nte
eo
aut ra
8- To intake connecting
ss pipe. c
ce
e
nl
pt
9 - Vacuum reservoir
du
an
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10 - 15 Nm
erm
ab
ility
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11 - 8 Nm
wit
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12 - O-ring h re
hole
spec
es, in part or in w
t to the co
13 - Charge air pressure send‐

er -G31- with intake air tem‐
perature sender -G42-
rrectness of i
14 - 3 Nm
l purpos
nform
mercia
at
om
ion
c
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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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pyri by
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Prote AG.

AG. Volkswagen AG d
agen oes
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r
Golf 2004 ➤ , Golf
ut
ho Plus 2005 ➤ eo
ra
a
4-cylinder diesel
ss engine (1.9 l engine) - Edition 01.2009 c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
1 - 8 Nm
, is n
h re
hole
Fitting location ⇒ page 160
spec
es, in part or in w
t to the co
2 - Bracket
tion.
rrectness of i
3 - Charge air cooler
l purpos
❑ To remove, bring lock

carrier into service posi‐
nform
ercia
tion ⇒ General body re‐

pairs, exterior; Rep. Gr.
m
at
50 ; Body - front; Lock
om
ion
carrier - service position
c
in t
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4 - Sealing strip
a
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❑ Pushed onto top and
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bottom of charge air

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5 - 3 Nm p by
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6 - Charge air pressure sender Prote AG.
-G31- with intake air tempera‐
ture sender -G42-
7 - O-ring
8 - Bracket
9 - 5 Nm
10 - Connecting hose
11 - Charge air pipe
❑ To intake manifold flap
motor -V157-
❑ Assembly overview - in‐
take manifold ⇒ page 174
13 - 8 Nm
Securing bolts for charge air cooler

To loosen or tighten securing bolts -arrow-, bumper cover must
be removed.

1.6 Hose connections

⇒ page 161
Hose connections with spring band ring ⇒ page 162
1.6.1 Installing hose connections with con‐

nector couplings
Caution
The seal in the plug-in connector can be damaged if the se‐

curing clip is in the locked position when fitting the connector.
This can cause leakage. Observe installation instructions.
Removing
– Release plug-in connector by pulling out retaining clip
-arrow-. Separate hose/pipe without tools.
Installing
– If renewed, place seal in groove of charge air hose. Ensure
the seal is correctly seated in the groove.
– Lubricate sealing surface and seal with oil.
– Bring securing clip to release
wage position
n AG. Volkswag-1-.
en AG
doe
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– Push charge airedhose
by into coupling to stop. ara
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un
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– Bring securing clip to locking position -2- and then push charge
an
d
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air hose again.

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ab
ility
– Check if connector coupling seats correctly and is properly

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engaged by pulling hose.

is n
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spec
t to the co
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f inform
mer
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Cop py
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Prote AG.

1.6.2 Hose connections with spring band ring
Note
There is a danger of a “hose detaching” whilst driving after re‐

moving and reinstalling charge pressure lines with spring-type
clamps. For this reason, spring band rings are used which can be
opened if a defect item requires the charge pressure line has to
be disconnected. In cases of repair, destroy the spring band ring
using a suitable tool and renew it with a replacement part from ⇒
ETKA (electronic parts catalogue) .
AG. Volkswagen AG d
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1.7 Checking charge air system for leaks ss a ra
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♦ Charge air system tester -V.A.G 1687-
erm
ab
ility
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– Remove intake hose -1- from air filter.
ole,
spec
– Insert adapter -V.A.G 1687/10- in intake hose -1- and secure
t to the co
with clip.
Prepare charge air system tester -V.A.G 1687- as follows:
rrectness o
cial p
f inform
mer
atio
om
n
c
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– Turn pressure regulating valve -2- anti-clockwise onto stop.

– Close valves -3- and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.

AG. Volkswagen AG d
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d by ara Golf 2004 ➤ , Golf Plus 2005 ➤
ise nte
r
ut
ho 4-cylindere odiesel
ra engine (1.9 l engine) - Edition 01.2009
a c
ss
– Connect charge air system tester -V.A.G 1687- to adapter -
ce
le
un
pt
V.A.G 1687/10- as shown.
an
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ab
pe
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– Connect compressed air hose -1- (compressed air source) to

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charge air system tester -V.A.G 1687- .
t. Cop py
rig
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pyri by
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Notected agen
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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.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 0.5 bar.
– Check the charge air system for leaks by hearing, touching,
with leak detector spray or using ultrasonic tester -V.A.G
1842- .
Note
♦ How to use the ultrasonic tester -V.A.G 1842- ⇒ operating

instructions
♦ If leaks occur, when doing any repair work observe notes for
charge air system ⇒ page 158 .
♦ Depressurise test circuit by detaching coupling from adapter -
V.A.G 1687/10- before removing adapter.

AG. Volkswagen AG d
4-cylinder diesel engine (1.9 agen
lwengine) - Edition 01.2009
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1.8 Vacuum hose schematic diagram r nte
tho eo
s au ra
c
s
Vehicles with particulate filter ⇒ page 164
ce
le
un
pt
an
Vehicles without particulate filter ⇒ page 165 itte
d
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ab
1.8.1 Vehicles with particulate filter
pe
ility
ot
wit
, is n
h re
hole
1 - Turbocharger
spec
es, in part or in w
2 - Connecting pipe air filter/
t to the co
turbocharger
3 - Non-return valve
rrectness of i
l purpos
tion.
4 - To brake servo
nform
ercia
5 - Charge pressure control

m
a
solenoid valve -N75-
com
tion in
6 - Air filter
r
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s
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8 - Intake manifold
Co
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9 - Bypass flap
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❑ For exhaust gas recircu‐ Prote
cted AG.
agen
lation cooler.
10 - Cooler
❑ For exhaust gas recircu‐
lation.
11 - Exhaust gas recirculation
valve -N18-
cooler change-over valve -
N345-
tion.
14 - Vacuum unit
❑ Turbocharger

1.8.2 Vehicles without particulate filter
1 - Solenoid valve block

tion.
3 - To brake servo
4 - Connecting pipe air filter/ AG. Volkswagen AG d
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5 - Air filter rised b ara
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6 - Intake manifold aut ra
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8 - Vacuum reservoir
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spec
lation cooler.
es, in part or in w
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10 - Cooler
lation.
rrectness of i
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valve -N18-
12 - Turbocharger
nform
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or
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Prote AG.

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.
Safety precautions ⇒ page 166
Rules for cleanliness ⇒ page 167 .
Assembly overview - unit injector ⇒ page 167
Removing and installing unit injector ⇒ page 169
Adjusting non-contact gap of unit injectors ⇒ page 171
Removing and installing O-rings for unit injector ⇒ page 172
Repairing intake manifold flap ⇒ page 174
Assembly overview - air filter ⇒ page 177 .
1.1 Safety precautions
WARNING

tions:
vated charcoal filter system, coolant and refrigerant, brake
sitions.
hot components. en AG. V
olkswagen AG
ag does
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Observe followingthiforitest and measuring instruments are required eo
during a road test:
au ra
c
ss
ce
le
♦ Test and measuring instruments must be secured to rear seat

un
pt
and operated by a second person from this location.

an
d
itte
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ab
♦ If test and measuring instruments are operated from front pas‐

ility
ot p
senger seat and the vehicle is involved in an accident, there

wit
is n
is a possibility that the person sitting in this seat may receive

h re
ole,
serious injuries when the airbag is triggered.

spec
To prevent injuries to persons and/or destruction of the injection

t to the co
and glow plug system, the following must be noted:

♦ The ignition must be switched off before connecting or dis‐
rrectne
connecting injection or glow plug system wiring or tester ca‐

bles.
s
♦ If the engine is to be turned at starter speed, without starting,

s o
cial p
e.g. when checking compressions, disconnect unit injector

inform
connector on cylinder head.

mer
atio
♦ Before disconnecting battery, obtain radio code for radios with

om
anti-theft coding.
c
i
or
n thi
te
♦ Disconnecting and connecting the battery must only be done

sd
iva
o
r
with the ignition switched off, as otherwise the control unit for
p
cum
r
fo
diesel direction injection system could become damaged.

en
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166
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Rep. Gr.23 - Mixture preparation - injection
agen Golf 2004 ➤ A, GGolf
doesPlus 2005 ➤
AG. Volkswagen
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ol
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1.2 Rules for cleanliness
th
au ra
ss c
ce
e
When working on fuel supply and injection system, pay careful
nl
pt
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an
attention to the following rules for cleanliness:
itte
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ility
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connecting.
wit
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♦ Place removed parts on a clean surface and cover. Do not use
hole
spec
fluffy cloths!
es, in part or in w
t to the co
♦ Carefully cover opened components or seal if repairs cannot
rrectness of i
l purpos
tool boxes etc.).
nf
ercia
or
m
m
atio
essary.
om
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or c
♦ Also ensure that no diesel fuel runs on to the coolant hoses.
thi
te
sd
Should this occur, the hoses must be cleaned immediately.
iva
o
r
Damaged hoses must be renewed.

rp
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1.3 Assembly overview - unit injector
yi Co
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♦ Observe rules for cleanliness ⇒ page 167 . yri
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♦ Always renew seals and O-rings
agen
Prote AG.
1. Diesel direct injection system 167

AG. Volkswagen AG d
agen oes
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V gu
d by ara
Golf 2004 ➤ ,oGolfris
e Plus 2005 ➤ nte
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4-cylinder diesel
aut engine (1.9 l engine) - Edition 01.2009 ra
c
ss
ce
e
nl
1 - 20 Nm + 1/4 turn (90°) fur‐
pt
du
an
ther itte
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erm
ab
❑ Renew
ility
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wit
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2 - Rocker arm shaft
h re
hole
❑ With rocker arms
spec
es, in part or in w
t to the co
⇒ page 169 .
3 - Lock nut, 30 Nm
rrectness of i
4 - Adjuster screw
l purpos
❑ Renew
5 - Ball stud
nform
ercia
❑ Renew
m
at
om
io
6 - Unit injector
n
c
in t
or
his
ate
⇒ page 169 .
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or
7 - O-ring
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t.
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❑ Renewing ⇒ page 172 t. Cop py
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8 - O-ring pyri by
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❑ Renewing ⇒ page 172 cted agen
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9 - O-ring
❑ Renew ⇒ page 172 .
10 - Heat shield seal
❑ Renew
11 - Circlip
12 - Cylinder head
13 - Tensioning block
14 - 12 Nm + 3/4 turn (270°)
further
❑ Renew.
168 Rep. Gr.23 - Mixture preparation - injection

1.4 Removing and installing unit injector

equipment required
♦ Universal dial gauge brack‐
et -VW 387-
AG. Volkswagen AG d
♦ Special wrench, long reach agen oes
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♦ Special wrench, long reach ut
ho eo
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-T10054- ss a c
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nl
♦ Puller -T10055-
pt
du
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♦ Torque wrench - erm
ab
V.A.G 1331-
ility
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es, in part or in w
t to the co
rrectness of i
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nf
ercia
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n in
or c
thi
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1.4.1 Removing
– Remove toothed belt guard upper part.
– Remove cylinder head cover. ⇒ page 48
– Turn crankshaft until the cam pair point evenly upwards for the
unit injector which is to be removed.
– Loosen lock nuts of adjustment screws -1- and remove ad‐
justment screws.
– Remove rocker arm securing bolts -2- (from outwards to in‐
wards) with socket XZN 10 -3410- and remove rocker arm
shaft.
– Remove tensioning block securing bolt -3- with special
wrench, long reach -T10054- and remove the block.
– Lever connector off unit injector with a screwdriver. To avoid
canting, support opposite side of connector with light finger
pressure.
Observe unit injector cylinder allocation.

– Insert puller -T10055- in place of the clamping block in the slot

on the side of the unit injector.
– Pull unit injector out of cylinder head seat
wage
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ility
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es, in part or in w
t to the co
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1.4.2 Installing
nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
te
♦ Each time work is performed which requires adjustment of the
sd
iva
o
r
unit injector, the adjustment screw in the rocker arm and also
rp
cu
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the unit injector ball stud must be renewed.
f
en
ng
t.
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op
♦ New unit injectors are supplied with O-rings and heat shield
C py
ht. rig
seal. rig ht
py by
co Vo
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– Heat shield seal and O-rings must be renewed if old unit in‐
AG.
jector is reused. ⇒ page 172

– Check that the three O-rings and the heat shield seal along
with securing clip are seated correctly before installing unit in‐
jector.
Note
The seals must not be twisted.
– Oil the seals and fit the unit injector into the seat in cylinder
head with great care.
– Push the unit injector evenly into the cylinder head onto its limit
stop.
– Insert tensioning block in slot on side of unit injector.
Note
If the unit injector is not at right angles to the tensioning block the
securing bolt may loosen and this can damage the unit injector or
the cylinder head.
– Therefore align the unit injector as follows.

– Screw the new securing bolt into the tensioning block until the
unit injector can still be turned easily.
– Now align unit injector at right angles to camshaft bearing seat.

– Check dimension “a” from outer edge of cylinder head to roun‐

ded surface of unit injector with a vernier gauge (measuring
range min. 400 mm).
Cylinder Dimension “a” n AG. Volkswagen AG do
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1 333,0 ± 0.8 mmised b ua
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2 245,0 ± 0.8 amm
uth or
ac
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3 153,6 ± 0.8 mm
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nl
pt
du
4 65,6 ± 0.8 mm
an
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erm
ab
– If necessary, adjust the unit injector and tighten the securing
ility
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bolt as follows:
wit
, is n
h re
– Tighten securing bolt to 12 Nm and turn 270° (3/4 turn) further
hole
spec
(turning further can be done in several stages).
es, in part or in w
t to the co
– Fit rocker arm shaft and tighten new securing bolts as follows:
– First evenly tighten inner bolts -2- and then outer bolts -1-
rrectness of i
hand-tight. Then using same sequence, tighten to 20 Nm and
90° (1/4 turn) further evenly.
l purpos
– Adjust non-contact gap of unit injectors ⇒ page 171 .
nform
mercia
at
om
ion
c
in t
or
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ate
do
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for
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1.5 Adjusting non-contact gap of unit injec‐ Cop py
t. rig
gh ht
tors pyri by
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by
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Prote
– Fit dial gauge onto adjustment screw of unit injector as shown.
AG.
– Turn crankshaft in direction of engine rotation until roller of

rocker arm is located at tip of drive cam. Roller side
-arrow A- positioned at highest point, 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 adjustment screw 180° back off stop.

– Hold adjuster screw in this position and tighten lock nut to 30
Nm.
– Connect unit injector connector.
– Install cylinder head cover ⇒ page 48 .

1.6 Removing and installing O-rings for unit

injector
♦ Assembly sleeves -T10056-
1.6.1 Removing
– Lever old O-rings very carefully out of unit injector.
– Ensure above all that no burrs are formed on O-ring seat. agen
AG. Volkswagen AG d
oes
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1.6.2 Installing by gu
d ara
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or eo
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aut ra
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Note
ce
e
nl
pt
du
an
itte
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♦ Always use the assembly sleeves to fit the O-rings. There is a
erm
ab
danger of damaging the O-rings if the sleeves are not used.
ility
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wit
, is n
♦ Gradual introduction of O-rings without different coloured
h re
markings. Note the correct allocation of O-rings to grooves:
hole
spec
the thickness of the rings reduces towards injector nozzle.
es, in part or in w
t to the co
♦ Prevent O-rings from rolling when sliding them on. The O-rings
must not be twisted in their seats in unit injector.
rrectness of i
– Pull heat shield seal off together with securing clip.
l purpos
– Clean seating surfaces for O-rings on unit injector very care‐

fully. nform
ercia
– Place assembly sleeve -T10056/1- onto stop on unit injector.

m
at
om
– Push the upper, thicker O-ring carefully onto assembly sleeve

on
c
in t
and into seat on unit injector.

or
his
ate
– Remove assembly sleeve.

do
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for
en
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Prote AG.


– Slide the middle, thinner O-ring carefully onto assembly sleeve
and into seat on unit injector.

– Push the lower O-ring carefully onto the assembly sleeve and
into the seat of the unit injector.
– Fit new heat shield seal together with securing clip.
lkswage es n
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pt
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es, in part or in w
t to the co
rrectness of i
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c
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ate
do
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AG. Volkswagen AG d
agen oes
1.7 Assembly overview - intake manifold d byV
olksw not
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Engine codes BKC, BRU, BXE and BXF ⇒uthpage 174
o eo
ra
s a c
Engine code BJB ⇒ page 175 s
ce
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un
pt
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1.7.1 Engine codes BKC, BRU, BXE and BXF
ility
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ole,
1 - Intake manifold
spec
❑ Tighten securing bolts
t to the co
to 22 Nm.
2 - O-ring
rrectne
❑ Renew.
3 - Intake connecting pipe
ss o
❑ With exhaust gas recir‐
cial p
f in
culation valve
form
mer
atio
4 - 10 Nm
om
n
c
i
5 - Intake manifold flap motor -
or
n thi
e
V157-
t
sd
iva
o
pr
c
❑ The intake manifold flap
um
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fo
is closed for approx. 3
en
ng
t.
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seconds when stopping
Co
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stop jolt.
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Prote AG.
6 - 10 Nm
7 - Connecting pipe
❑ To exhaust gas recircu‐
lation cooler.
8 - 22 Nm
9 - Gasket
❑ Renew.

1.7.2 Engine code BJB
1 - Intake manifold
to 22 Nm.
2 - O-ring
❑ Renew.
3 - Intake connecting pipe
culation valve and in‐
take manifold flap
4 - 10 Nm agen
AG. Volkswagen AG d
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5 - Gasket d by gu
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❑ Renew. utho eo
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6 - Connecting pipe s
ce
le
un
pt
❑ To exhaust gas recircu‐
an
d
itte
lation cooler.
y li
rm
ab
pe
ility
7 - 10 Nm
ot
wit
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8 - Bracket
h re
hole
spec
9 - Vacuum unit
es, in part or in w
t to the co
10 - To solenoid valve block
11 - 22 Nm
rrectness of i
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Golf 2004 ised ➤
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ut
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ra
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s
ce
1.7.3
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d
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ab
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ility
1 - Gasket
ot
wit
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❑ Renew.
h re
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spec
2 - Intake manifold
es, in part or in w
t to the co
to 22 Nm
3 - Seal
rrectness of i
❑ Renew
l purpos
4 - Connection
5 - Intake manifold flap motor -
nform
ercia
V157-
m
a
❑ The intake manifold flap
com
tion in
is closed for approx. 3
r
te o
thi
seconds when stopping
s
iva
engine and then opens
do
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again. This reduces the
um
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stop jolt.
n
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6 - From charge air cooler
t. C rig
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7 - 10 Nm
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valve -N18- with exhaust gas
recirculation potentiometer -
G212-
❑ Assembly overview - ex‐
haust gas recirculation
⇒ page 196
9 - Gasket
❑ Renew
lation cooler.
❑ Assembly overview -
parts of exhaust gas re‐
circulation
⇒ page 193
11 - 22 Nm
12 - Bracket
13 - 22 Nm
1.8 Cleaning the intake manifold flap sup‐

port, Engine code BLS and BXJ
Note
Carbon deposits can occur in the throttle valve support through

the combination of unfavourable factors. If these are found, e.g.
when disassembling the exhaust gas recirculation valve -N18- or
the intake manifold flap motor -V157,- , the support will have to
be cleaned.

WARNING
Acetone is highly inflammable. Please observe the accidental

regulations and safety notes when handling with highly inflam‐
mable fluids. Wear eye protection and protective clothing to
avoid possible injury and skin contact.
– Remove intake manifold flap connection.

G. Volkswagen
– Remove the exhaust gas recirculation wvalve
agen -N18- and the
A
in‐es n
AG do
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take manifold flap motor -V157-
d by. V ot g
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– Thoroughly clean intake manifold
ut
ho flap support, especially or
around exhaust gas return
ss valve, using commercially available
a ac
acetone according to DIN 53247 and cleaning brush.
ce
le
un
pt
an
d
– Wipe off intake manifold flap support using a lint-free cloth.

itte
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erm
ab
– Allow the acetone to evaporate fully, assemble the cleaned
ility
ot p
intake manifold flap support, replace the seals and insert it
wit
is n
back in position.
h re
ole,
spec
1.9 Assembly overview - air filter
t to the co
1 - Intake hose
rrectne
2 - Air mass meter -G70-
ss o
cial p
f
3 - O-ring
inform
mer
atio
m
4 - 8 Nm
o
n
c
i
or
n thi
5 - Air filter upper part
te
sd
iva
o
r
6 - 8 Nm
p
cum
r
fo
en
ng
7 - Vacuum hose
t.
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op py
❑ To solenoid valve block
t. C rig
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8 - Filter element
c by lksw
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9 - Air duct
❑ To lock carrier.
10 - Air filter lower part
11 - 10 Nm

2 Engine control unit

Reading and clearing engine control unit fault memory
⇒ page 178
AG. Volkswagen AG d
Adapting functions and components ⇒ page 179 . agen oes
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Removing and installing engine control unit, Golf ⇒ page 180 . ris ed
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Removing and installing anti-theft engine control unit, Golf ss a ra
c
⇒ page 180 .
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an
Removing and installing engine control unit, Golf Plus
itte
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⇒ page 183 .
erm
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Removing and installing anti-theft engine control unit Golf Plus
wit
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⇒ page 183 .
h re
hole
spec
2.1 Reading and erasing engine control unit
es, in part or in w
t to the co
fault memory
rrectness of i
♦ Vehicle diagnostic, testing and information system -VAS 5051-
l purpos
nform
mercia
at
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ion
c
in t
or
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ate
do
priv
cum
for
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t.
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rig ht
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co Vo
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Prote
– Connect vehicle diagnostic, testing and information system -
AG.
VAS 5051- as follows:

– Push diagnosis cable connector onto diagnosis connector.

Only when engine does not start:
Select operating mode
– Press button on display for “Vehicle self-diagnosis”.
Select vehicle system
– Press button “01 - Engine electronics” on display.
The control unit identification and coding are indicated on display.
Select diagnostic function
– Press button “02 - Read fault memory” on display.
– If no fault is stored in engine control unit “0 fault detected” is
displayed.
– If faults are stored in the engine control unit, these are shown
one below the other on the display.
– Press ← button.
– Press button “05 - Clear fault memory” on display.
– Press function “06-End output”.
2.2 Adapting functions and components

Special tools and workshop equipment required AG. Volkswagen AG d
agen oes
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♦ Vehicle diagnostic, testing and information system -VAS 5051- byV
ol not
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es, in part or in w
t to the co
rrectness of i
Select “guided fault finding” in vehicle diagnostic, testing and in‐
formation system -VAS 5051- .
l purpos
When all control units have been read:

nform
ercia
– Press “GoTo” button.

m
– Select “Function/component selection”.

at
om
ion
c
– Select “Drive train”.

in t
or
his
ate
– Select “Engine code”.

do
priv
cum
or
– Select “01-Systems capable of self-diagnosis”.

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op
– Select “Engine management”. C py
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– Select “Functions”. copy Vo
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– Select “Function or component”.
AG.
2. Engine control unit 179

Golf 2004 ➤ , Golf Plus 2005 ➤ AG. Volkswagen
n AG do
4-cylinder diesel engine (1.9 wage
olksl engine) - Edition 01.2009
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ir se nte
2.3 Removing and installing engine control aut
ho eo
ra
unit, Golf ss c
ce
e
nl
pt
du
– Before removing engine control unit, read the control unit iden‐
an
itte
y li
tification and thus the coding of the current control unit.
erm
ab
⇒ page 179
ility
ot p
wit
, is n
Removing
h re
hole
spec
es, in part or in w
t to the co
– Remove wiper arms, plenum chamber cover and plenum
chamber bulkhead: ⇒ Electrical system; Rep. Gr. 92 ; Wind‐
screen wiper system; Removing and installing windscreen
rrectness of i
wiper system .
l purpos
– Bend catch open slightly -1-.

– Then push engine control unit out of retainer -arrow-.
nf
ercia
o
– Now release connector on engine control unit and pull off con‐
rm
m
nector.
atio
om
n in
c
Installing
or
thi
te
sd
a
– Fit connector to engine control unit and lock connector in po‐

iv
o
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sition.
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– Push engine control unit onto bracket.
Co
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pyri by
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– Press catch -1- against engine control unit.
– Install plenum chamber bulkhead, plenum chamber cover and
wiper arms ⇒ Electrical system; Rep. Gr. 92 ; Windscreen
wiper system; Removing and installing windscreen wiper sys‐
tem .
2.4 Removing and installing anti-theft en‐

gine control unit, Golf
Removing and installing anti-theft engine control unit Golf Plus
⇒ page 183 .
♦ Electric cutter -V.A.G 1561 A-
♦ Saw set -V.A.G 1561/14-

♦ Grip pliers
AG. Volkswagen AG d
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Note
ole,
spec
♦ If the engine control unit is to be renewed, connect vehicle
t to the co
diagnostic, testing and information system -VAS 5051B- and
perform “Renewing engine control unit” in guided functions.
rrectne
♦ The shear-head bolt threads are coated with locking com‐
pound. To simplify removing, the shear-head bolts can be
heated using hot air blower -VAS 1978/14- . When doing this,
ss o
ensure that no adjacent cables, connectors or components are
cial p
damaged! f inform
mer
atio
m
Removing
o
n
c
i
or

thi
te
sd
iva
o
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– Remove wiper arms, plenum chamber cover and plenum

p
cum
r
fo
chamber bulkhead: ⇒ Electrical system; Rep. Gr. 92 ; Wind‐

en
ng
t.
yi
screen wiper system; Removing and installing windscreen
Co
op py
wiper system . t. C rig
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pyri by
– Cut into heads of shear-head bolts so that two parallel surfa‐
o Vo
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ces are created -arrows-.
agen
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– Remove bolts with grip pliers .
– Insert a screwdriver between protective housing -A- and

bracket -arrow-.

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gen AG does
– Lever up protective housing using screwdriverVol
k-A-
swa and pull to not
side off bracket -arrow-. ed
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es, in part or in w
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– Bend catch open slightly -1-.
rrectness of i
– Then push engine control unit out of retainer -arrow-.
l purpos
– Now release connector on engine control unit and pull off con‐
nector.
nform
ercia
Installing
m
at
om
i
– Fit connector to engine control unit and lock connector in po‐
on
c
in t
sition.
or
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ate
– Push engine control unit onto bracket.
do
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– Press catch -1- against engine control unit. yri
p by
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cted
– Push protective housing onto bracket.
agen
Prote AG.
– Tighten new shear-head bolts -1- evenly until heads shear-

head off.
– Install plenum chamber bulkhead, plenum chamber cover and
wiper arms ⇒ Electrical system; Rep. Gr. 92 ; Windscreen
wiper system; Removing and installing windscreen wiper sys‐
tem .

2.5 Removing and installing engine control

unit, Golf Plus
Note
If the engine control unit is to be renewed, connect vehicle diag‐

nostic, testing and information system -VAS 5051B- and perform
“Renewing engine control unit” in guided functions.
Removing:
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. Gr. 50 ; Body - front; Plenum chamber bulkhead .
– Loosen securing nuts -arrows-.
– Release connectors on engine control unit and pull off con‐
nector.
AG. Volkswagen AG d
agen oes
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– Push bracket -1- off engine control unit in direction of arrow.
hole
spec
es, in part or in w
Installing:
t to the co
– Push bracket onto engine control unit.
rrectness of i
l purpos
nform
mercia
a
com
tion in
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– Tighten securing nuts -arrows- to 10 Nm.

do
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cum
fo
– Fit connectors and lock in position.

en
ng
t.
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op
– Install plenum chamber bulkhead ⇒ General body repairs;
C py
t. rig
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ht
pyri by
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cted agen
Prote AG.
2.6 Removing and installing anti-theft en‐

gine control unit, Golf Plus
♦ Grip pliers

Note
♦ If the engine control unit is to be renewed, connect vehicle

diagnostic, testing and information system -VAS 5051B- and
perform “Renewing engine control unit” in guided functions.
♦ The shear-head bolt threads are coated with locking com‐
pound. To simplify removing, the shear-head bolts can be
heated using hot air blower -VAS 1978/14- . When doing this,
ensure that no adjacent cables, connectors or components are
damaged!
Removing
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. Gr. 50 ; Body - front; Plenum chamber bulkhead . olkswagen AG
en AG. V ag does
lksw not
– Twist shear-head bolts -arrows- out using grip
y V pliers and re‐
o gu
db ara
move cover from protective housing. ris e nte
ho eo
ut
– Then remove securing nuts for control
ss
a unit bracket -arrows-. ra
c
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nl
pt
du
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
– Release connectors on engine control unit and pull off con‐
rrectness of i
nector.
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
gh ht
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– Press catches -1- and -2- outwards. Then pull engine control op Vo
by c lksw
unit off control unit bracket in direction of arrow. cted agen
Prote AG.
Installing
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Fit connectors to engine control unit and lock in position.

n AG. Volkswagen AG do Golf 2004 ➤ , Golf Plus 2005 ➤
lkswage es n
byV
o
4-cylinder diesel
ot g
uengine
ara (1.9 l engine) - Edition 01.2009
ed nte
oris eo
– Tighten th
securingaubolts -arrows- to 10 Nm. ra
ss c
– Install cover of protective housing.
ce
e
nl
pt
du
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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
– Tighten new shear-head bolts -arrows- evenly until heads

shear-head off.
nf
ercia
– Install plenum chamber bulkhead ⇒ General body repairs;
orm
m
atio
om
n in
or c
thi
te
sd
iva
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26 – Exhaust system
1 Exhaust system
Assembly overview - front exhaust pipe with catalytic converter
⇒ page 186 .
Assembly overview - front exhaust pipe with particulate filter
⇒ page 187
Assembly overview - silencer with mountings (vehicles with front
wheel drive) ⇒ page 189 .
Assembly overview - silencer with mountings (vehicles
nAG. Volkswawith four-
gen AG
wheel drive) ⇒ page 191 . wage does
olks no t gu
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1.1 Assembly overview - front exhaust pipe with catalytic converter tho
rise nte
eo
s au ra
c
s
ce
e
1 - Front exhaust pipe with cat‐

nl
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an
alytic converter
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2 - 40 Nm
ility
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3 - Support
h re
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4 - Marking
spec
es, in part or in w
❑ For clamp.
t to the co
❑ Installation position of
clamp ⇒ page 187 .
rrectness of i
5 - To front silencer
l purpos
6 - 25 Nm
7 - Mounting
nf
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or
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atio
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8 - 7 Nm
o
n in
or c
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9 - Gasket
t
sd
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tion.
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10 - Clip
C py
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186 Rep. Gr.26 - Exhaust system

Installation position of clamp

Position clamp at distance -a- = 5 mm from marking on front ex‐
haust pipe.
AG. Volkswagen AG d
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1.2 Assembly overview - front exhaust pipe
ab
ility
ot p
with particulate filter
wit
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hole
spec
es, in part or in w
♦ Lambda probe open ring spanner set -3337-
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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ate
do
priv
cum
for
en
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t.
♦ Tool set -T10395-
yi Co
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Note
If the particulate filter or the exhaust gas pressure sensor 1 -

G450- is changed, the exhaust gas pressure sensor 1 -G450-
must always be adapted using diagnostic tester : Guided
functions; adapting exhaust pressure sensor 1 -G450- .
1. Exhaust system 187

Golf 2004 ➤ , Golf Plus 2005 ➤ n AG. Volkswagen AG do
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1 - 8 Nm tho
or
au ac
ss
2 - Exhaust gas pressure sen‐
ce
e
nl
sor 1 -G450-
pt
du
an
itte
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3 - Bracket
erm
ab
ility
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❑ For control lines
wit
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h re
4 - 10 Nm
hole
spec
5 - Control line, 45 Nm
es, in part or in w
t to the co
6 - Lambda probe -G39- , 50
Nm
❑ Grease only the threads
rrectness of i
with high-temperature
l purpos
paste -G 052 112 A3- ;

high-temperature paste
-G 052 112 A3- must not
nf
ercia
get into the slots of
orm
probe body.
m
atio
om
❑ To remove use lambda
n in
or c
probe open ring span‐
thi
te
sd
ner set -3337-
iva
o
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rp
cu
7 - Exhaust gas temperature
o
m
f
en
ng
sender bank 2 -G448- , 45 Nm

t.
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Cop py
❑ Lubricate thread of
t. rig
gh ht
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sender using high-tem‐ p by
co Vo
lksw
perature paste -G 052
by
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112 A3-
AG.
8 - Particulate filter
❑ is removed downwards
with exhaust gas pres‐
sure sensor 1 -G450-
❑ To remove, remove
subframe and steering
⇒ Running gear, axles,
steering; Rep. Gr. 40 .
9 - Front exhaust pipe
10 - Marking
❑ For clamp.
❑ Installation position of clamp ⇒ page 189 .
11 - To front silencer
12 - 25 Nm
13 - Mounting
14 - Temperature sender after particulate filter -G527-
❑ 45 Nm
❑ Lubricate thread of sender using high-temperature paste -G 052 112 A3-
15 - From turbocharger
16 - Clamp, 7 Nm
17 - Gasket
❑ Renew

18 - 40 Nm
19 - Bracket
❑ Bolted to cylinder head
AG. Volkswagen AG d
agen oes
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Installation position
ed by V of clamp gu
ara
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– Positionaut double clamp -a- = 5 mm from marking on front
ho eo
ra ex‐
haust
s pipe of particulate filter.
s c
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
1.3 Assembly overview - silencer with mountings (vehicles with front wheel
rrectness of i
drive)
l purpos
nf
ercia
1 - 25 Nm
orm
m
❑ Renew atio
om
n in
c
2 - Retaining ring
or
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3 - Separating point
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❑ Marked by indentation
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on exhaust pipe ht. rig
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❑ During production, front co Vo
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and rear silencers are
agen
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installed as a single
component. For repairs,
front and rear silencers
are supplied separately.
❑ The connection is made
with a clamp.
❑ Cutting exhaust pipe
⇒ page 190
❑ Installation position of
rear clamp (repair dou‐
ble clamp)
⇒ page 190 .
❑ Evenly tighten threaded
connections of clamp
(repair double clamp).
❑ Specified torques for
clamp (repair double
clamp): M8 = 25 Nm,
M10 = 40 Nm.
❑ Before tightening, align
cold exhaust system
free of tension
⇒ page 192
4 - Rear silencer
5 - Mounting

6 - 25 Nm
7 - Tunnel bridge
8 - Front silencer
9 - Mounting
Installation position of rear clamp (repair double clamp)

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
• Bolt connection faces to left.
1.3.1 Separating front and rear silencers

♦ Pneumatic sabre saw -V.A.G 1523 A-
AG. Volkswagen AG d
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t to the co
♦ Eye protection
Procedure
rrectne
WARNING
ss o
Wear eye protection.

cial p
f inform
mer
atio
m
– Cut exhaust pipe at right angles at separating point

o
n
c
-arrow 2-.
i
or
n thi
te
sd
a
– When installing, position repair double clamp -4- at side mark‐

iv
o
pr
ings -arrow 1- and -arrow 3-.

um
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

– Install repair double clamp so that end of bolt does not extend
beyond lower edge of clamp.
• Bolted connection faces rear.
– Align cold exhaust system free of stress ⇒ page 192 .
– Tighten bolts on repair double clamp.
Specified torque, M8: 25 Nm
1.4 Assembly overview - silencer with mountings (vehicles with four-wheel

drive)
1 - From particulate filter

2 - Clamp
❑ Align exhaust system
free of stress before
tightening clamp
⇒ page 192 .
❑ Installation position
⇒ page 192
❑ Tighten threaded con‐
nections evenly.
3 - Bracket
❑ For retaining ring
4 - 25 Nm agen
AG. Volkswagen AG d
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5 - Retaining ring ed by gu
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❑ Renew if damaged. ut
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6 - Rear silencer
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7 - Mounting
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es, in part or in w
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mercia
at
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ion
c
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ate
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for
en
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Cop py
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Prote AG.

Installation position of clamp

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
AG. Volkswagen AG d
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aut ra
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1.5 Aligning exhaust system free of stress
s
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Prerequisite itte
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ab
• Engine must be cold
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Procedure
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hole
spec
– Loosen bolted connection of clamp between front exhaust
es, in part or in w
pipe and silencer.
t to the co
– Position clamp at distance -a- = 5 mm from marking on front
exhaust pipe and lightly tighten front bolted connection.
rrectness of i
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mercia
at
om
ion
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ate
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for
en
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op
– Push exhaust pipe with silencer forwards into clamp until di‐ C py
t. rig
gh
mension -a- 15...17 mm is attained between mounting attach‐
ht
pyri by
ment points for body and rear silencer. -Arrow- points in
o Vo
by c lksw
cted agen
direction of travel. Prote AG.
– Align rear silencer horizontally.

– With parts in this position, tighten bolted connections of clamp.
– Once clamp has been tightened, check distance -a- and cor‐
rect if necessary.

2 Exhaust gas recirculation system
2.1 Assembly overview - parts of exhaust

gas recirculation
Engine codes BKC, BRU, BXE and BXF ⇒ page 193
Engine code BJB ⇒ page 195 AG. Volkswagen AG d
agen oes
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Engine codes BLS and BXJ ⇒ page ed b 196 ara
nte
ris
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2.1.1 Engine codes BKC, BRU, BXE and BXF ss aut ra
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Note
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♦ The exhaust gas recirculation system is activated by the diesel
wit
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direct injection system control unit -J248- via exhaust gas re‐
h re
hole
circulation valve -N18- (electric-pneumatic) to the exhaust gas
spec
recirculation valve (mechanical).
es, in part or in w
t to the co
♦ The electro-pneumatic exhaust gas recirculation valve -N18-
is located in the solenoid valve block.
rrectness of i
♦ The cone-shaped plunger in the mechanical exhaust gas re‐
circulation valve ensures that various cross sectional openings
l purpos
are possible at different plunger lifts.

♦ Pulsed control enables every conceivable valve position.
nform
ercia

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at
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ion
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Cop py
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Prote AG.
2. Exhaust gas recirculation system 193

1 - 22 Nm
2 - Intake manifold
culation valve and in‐
take manifold flap motor
-V157- .
to 22 Nm.
3 - Gasket
❑ Renew lkswage es n
o ot g
yV ua
4 - Connecting pipe ir se
d b ran
tee
tho
or
5 - Cooler au ac
ss
ce
le
un
pt
lation.
an
d
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6 - 10 Nm
ab
ility
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ole,
8 - Connecting pipe
spec
Tightening sequence:
t to the co
❑ 1. Attach to bypass flap
❑ 2. Attach to manifold
rrectne
❑ 3. Tighten to bypass flap
❑ 4. Tighten to manifold
ss o
cial p
f
9 - Bypass flap
inform
mer
❑ When activated, directs

atio
exhaust gas to exhaust
om
gas recirculation cooler

n
c
i
or
via the electro-pneu‐

thi
te
sd
a
matic exhaust gas recir‐

iv
o
pr
culation valve -N18- .

um
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fo
en
ng
t.
10 - Bracket
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❑ For bypass flap
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11 - 5 Nm
c by lksw
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Prote AG.
Connector assignment on solenoid valve block, engine codes

BKC, BRU, BXE and BXF
1- Vacuum connection (on non-return valve for brake servo)
2- Exhaust gas recirculation valve
3- Bypass flap
4- Air filter
5- Vacuum reservoir
6- Vacuum unit on turbocharger

2.1.2 Engine code BJB
Note

direct injection system control unit -J248- via exhaust gas re‐
circulation valve -N18- (electric-pneumatic) to the exhaust gas
recirculation valve (mechanical).
♦ The electro-pneumatic exhaust gas recirculation valve -N18-
is located in the solenoid valve block.
♦ The cone-shaped plunger in the mechanical exhaust gas re‐
circulation valve ensures that various cross sectional openings
are possible at different plunger lifts.
♦ Pulsed control enables every conceivable valve position.
1 - Intake manifold AG. Volkswagen AG d

agen
❑ With exhaust gas recir‐ Volksw
oes
not
gu
culation valve and in‐ d by ara
ise nte
take manifold flap thor eo
u ra
❑ Tighten securing bolts ss a c
to 22 Nm.
ce
le
un
pt
an
d
2 - From charge air cooler

itte
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erm
ab
3 - Gasket
ility
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❑ Renew
is n
h re
ole,
4 - 22 Nm
spec
t to the co
6 - Connecting pipe
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
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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.

Pin assignment on solenoid valve block for engine code BJB

1- Vacuum connection (on non-return valve for brake servo)
2- Exhaust gas recirculation valve
3- Intake manifold flap
4- Air filter
5- Vacuum reservoir
6- Vacuum unit on turbocharger
Note

direct injection system control unit -J248- via the exhaust gas
recirculation potentiometer -G212- .
1 - Coolant hose
❑ To connection
2 - Gasket
❑ Renew
3 - 22 Nm n AG. Volkswagen AG do
lkswage es n
o ot g
4 - Connecting pipe d byV ua
ran
ir se tee
5 - From exhaust manifold utho
or
a ac
ss
6 - 25 Nm
ce
le
un
pt
❑ Renew
an
d
itte
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erm
ab
7 - To connection for exhaust

ility
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gas recirculation valve -N18-

wit
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with exhaust gas recirculation

h re
potentiometer -G212-
ole,
spec
❑ Assembly overview - in‐

t to the co
take manifold
⇒ page 176
rrectne
cooler
9 - 10 Nm
ss o
cial p
10 - Coolant hose
inform
mer
❑ From rear coolant pipe

atio
m
o
n
c
i
or
n thi

te
sd
va
cooler change-over valve -

i
o
pr
cum
N345-
r
fo
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t.
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Co
Cop py
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14 - Vacuum unit yri
p by
co Vo
by lksw
❑ For bypass flap cted agen
Prote AG.

❑ Renew only together
with exhaust gas recirculation cooler
AG. Volkswagen AG d
agen oes
olksw not
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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
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
do
priv
cum
for
en
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t.
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Cop py
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co lksw
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cted agen
Prote AG.

28 – Glow plug system

1 Checking glow plug system
Removing, installing and checking glow plugs ⇒ page 198
Characteristics of ceramic glow plugs ⇒ page 199
Removing, installing and checking ceramic glow plugs
⇒ page 200
1.1 Removing, installing and checking glow

plugs
AG. Volkswagen AG d
agen oes
olksw not
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tho eo
au ra
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pt
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ab
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♦ Jointed spanner -3220-

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
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Test requirements
sd
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• Battery voltage at least 11.5 V

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• Ignition switched off t. Cop py
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Test procedure pyri by
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– Pull glow plug connectors off glow plugs. Prote AG.
198 Rep. Gr.28 - Glow plug system

– Connect voltage tester -V.A.G 1527 B- cable to battery posi‐

tive, using clamps from adapter set -V.A.G 1594 C- .
– Place probe of diode test lamp -V.A.G 1527 B- on each glow
plug one after the other. If diode lights up, glow plug is OK. If
diode does not light up, replace glow plug.
– Remove and install glow plugs using jointed spanner -3220- .
Specified torque: 15 Nm.
1.2 Characteristics of ceramic glow plugs

AG. Volkswagen AG d
agen oes
olksw not
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WARNING ise
d b ara
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or eo
th
u ra
The ceramic glow plugs ⇒ page 199 are sensitive to
ss a
jolts and c
bending. For this reason a glow plug which has dropped from
ce
e
nl
pt
a small height (approx. 2 cm) must not be used, even if there
du
an
itte
is no obvious damage. It is absolutely necessary to follow the
y li
erm
ab
installation instructions, otherwise the heater pin of the glow
ility
ot p
plug can break and cause engine damage.
wit
, is n
h re
hole
spec
Visual features of ceramic glow plugs
es, in part or in w
t to the co
Vehicles with 2 valves per cylinder head
-A- = Metal glow plug, colour-coded -arrow-.
rrectness of i
-B- = Ceramic glow plug with support tube -arrow-, not colour-
l purpos
coded.
Vehicles with 4 valves per cylinder head
nf
ercia
o
-C- = Metal glow plug, colour-coded -arrow-.
rm
m
atio
m
-D- = Ceramic glow plug with support tube -arrow-, not colour-
o
n in
c
coded.
or
thi
te
sd
iva
Remove and install or check ceramic glow plugs ⇒ page 200 .
o
r
rp
cu
o
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f
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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.
1. Checking glow plug system 199

1.3 Removing, installing and checking ceramic glow plugs

equipment required
♦ Jointed spanner -3220-
♦ Torque wrench (5…50 Nm)
-V.A.G 1331-
. Volkswagen AG
♦ Hand-held multimeter - kswagen AG does
not
V.A.G 1526 A- Vol gu
by d ara
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♦ Auxiliary measuring
ut
ho
r
set - eo
V.A.G 1594 sC-
s a ra
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
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
Test prerequisites
• Engine is cold
• Ignition switched off
Procedure
Note
Do not cant ceramic glow plugs when removing and installing.

Remove any components hindering assembly.
– Pull connectors off ceramic glow plugs.

– Remove ceramic glow plugs using U/J extension and socket,
10 mm -3220- .
note the following:
– Before installing the drilling in cylinder head and the threads
must completely cleaned of all deposits.
200 Rep. Gr.28 - Glow plug system

Note
Never oil or grease thread of cylinder head bore or of ceramic

glow plugs.
– Screw ceramic glow plugs into cylinder head by hand using U/

J extension and socket, 10 mm -3220- .
– Then tighten the ceramic glow plugs. Specified torque: 15 Nm.
WARNING AG. Volkswagen AG d

agen oes
olksw not
V gu
♦ After installing and before the engine is started, salways
d by ara
i e nte
perform a resistance test on all ceramic glowthplugs
or when eo
engine is cold. ss au ra
c
ce
♦ If the defective ceramic glow plug is broken, remove all e
nl
pt
du
fragments from the engine, otherwise these can cause
an
itte
y li
damage to the engine.
erm
ab
ility
ot p
wit
, is n
h re
♦ Specification: max. 1 Ω
hole
spec
– If the specification is exceeded, renew the defective ceramic
es, in part or in w
t to the co
glow plug.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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t.
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Cop py
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pyri by
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by
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Prote AG.
1. Checking glow plug system 201

4-Cylinder Diesel Engine 1.9 L Engine PDF

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Service

Service Department. Technical Information

15 - Cylinder head, valve gear

28 - Glow plug system

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg K0059000420

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.3 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.3 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.4 Draining and filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

1.7 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

1.8 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

1.9 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

3 Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1.4 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

1.1 Engine number

Emissions fulfil EU3 EU4 EU4 EU4 EU4 pt EU4 EU4

standard standard standard standard standard y li standard standard

rpm 4000 4000 4000 4000 4000 4000 4000

Torque Nm at 250/ 250/ 210/ 250/ 250/ 210/ 210/

rpm 1900 1900 1800...250 1900 1900 1800 1800...250

Stroke mm 95.5 95.5 95.5 95.5 95.5 95.5 95.5

Compression ratio 19.0 19.0 19.0 18.5 18.5 19.0 19.0

Fuel accord‐ DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN

ing to 590 590 590 590 590 590 590

Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

Catalytic converter yes yes yes yes yes yes yes

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

2 Rep. Gr.10 - Removing and installing engine

♦ Torque wrench -V.A.G

♦ Before carrying out further work, disconnect battery earth

strap. First check whether a coded radio is fitted. Obtain anti-

theft coding first if necessary.

♦ The engine is removed downwards together with the gearbox.

removed must be replaced in the same position when engine

1. Removing and installing engine 3

When doing any repair work, especially in the engine compart‐

Two-piece engine cover

4 Rep. Gr.10 - Removing and installing engine

of repair work on the fuel system!

– Remove insulation tray ⇒ General body repairs, exterior; Rep.

– Bring lock carrier into service position ⇒ General body repairs,

exterior; Rep. Gr. 50 ; Body - front; Lock carrier - service po‐

To prevent damage to condenser or to refrigerant lines/hoses,

To facilitate removing and installing engine without opening re‐

– Remove poly V-belt ⇒ page 13 .

– Secure air conditioner compressor to lock carrier so that re‐

1. Removing and installing engine 5