Diesel Engine 4 Cylinder Injection 2005

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Service

Workshop Manual
Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸
Engine ID BHY

Edition 09.2005
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Service Department. Technical Information

This is the cut pages sample. Download all 136 page(s) at: ManualPlace.com
 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, Valve gear
17 - Lubrication
19 - Cooling system
20 - Fuel supply system
24 - Mixture preparation, Injection
26 - Exhaust system
28 - Ignition system

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Technical information should always be available to the foremen and mechanics, because their
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All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg SAR5R025020

 Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005

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 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . .V.ol.ks.w.a. . . . . . . . . . . . . . . . . . . . . . . . 15
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2 Dismantling and assembling pistons and conrods wage . . . . . . . . . . . . .d.oe . s. n.ot. . . . . . . . . . . . . . . 18
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2.1 Assembly overview - Pistons and conrods d by . . . . . . . . . . . . . . . . . . . . . . . . g.u.ar. . . . . . . . . . . . 18
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2.2 Checking pistons, piston rings anduthcylinder bores . . . . . . . . . . . . . . . . . . . . . . .e.or. . . . . . . . 21
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2.3 Piston and cylinder dimensionsss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . 23

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3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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3.1 Colour identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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1.1 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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1.2 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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2.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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2.2 Renewing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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2.3 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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2.4 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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2.6 Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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2.7 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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1.2 Assembly overview - Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.3 Assembly overview - Oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.4 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.1 Assembly overview - parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Assembly overview - parts of cooling system - body side . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.5 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.6 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 75

Contents i
 Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005

1.7 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

1.8 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

1 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 80
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.3 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.4 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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. . . . . . .d.oe. s. . . . . . . . . . . . . . . . . . . 84
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2 Repairing fuel supply . . . . . . . . . .ed. b. . . . . . . . . . . . . . . . . . . . . . . . . . .gu. a.ra. . . . . . . . . . . . . .
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2.1 Safety precautions when working tho on the fuel supply system . . . . . . . . . . . . e. o.r . . . . . . . . . . 88
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2.2 Rules for cleanliness . . . . .ss.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c. . . . . . . . . 88
2.3 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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2.4 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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2.5 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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3 Checking electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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3.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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3.2 Assembly overview - accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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3.3 Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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4 Active charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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4.2 Assembly overview - active charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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4.3 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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1.1 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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1.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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1.5 Dismantling and assembling intake manifold - upper part . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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1.6 Dismantling and assembling intake manifold - lower part . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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1.7 Fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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1.8 Dismantling and assembling air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.9 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.10 Removing and installing fuel rail with intake manifold flaps . . . . . . . . . . . . . . . . . . . . . . . . 114
1.11 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.12 Renewing Teflon seal on injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.13 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.1 Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.2 Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.1 Front exhaust pipe and catalytic converter with attachments . . . . . . . . . . . . . . . . . . . . . . . . 125
1.2 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.3 Separating middle and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.4 Aligning exhaust system stress free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

ii Contents
 Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005

1.3 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

1.4 Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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iv Contents
 Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005

00 – Technical data
1 Technical data
Engine number ⇒ page 1 .
Engine data ⇒ page 1 .

1.1 Engine number

The engine number (“engine code” and “serial number”) can be
found at the front on the joint between engine and gearbox.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.
In addition, there is a sticker on the toothed belt guard with “engine
code” and “serial number”.
The engine code is also included on the vehicle data sticker.

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Stroke mm 92.8
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Inland 91 unleaded
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Knock control yes

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Self-diagnosis yes
Lambda regulation yes
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Catalytic converter yes

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Electronic power control yes

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1. Technical data 1
 Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005

10 – Removing and installing engine

1 Removing and installing engine

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332-
♦ Engine-/gearbox jack -
V.A.G 1383/A-
♦ Pliers -VAS 5024/A-
♦ Step ladder -VAS 5085- agen
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Removing engine ⇒ page 2 .
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Securing engine to assembly stand ⇒ page 7 .
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Installing engine ⇒ page 8 .
Assembly mountings ⇒ page 10 .

1.1 Removing engine

Securing engine to assembly stand ⇒ page 7 .

2 Rep. Gr.10 - Removing and installing engine

 Golf - Jetta 2005 ➤
4-cylinder injection engine, 2005▸ - Edition 09.2005

Note

♦ Before carrying out further work, disconnect battery earth

strap. First check whether a coded radio is fitted. Obtain radio
code first if necessary.
♦ The engine is removed downwards together with the gearbox.
♦ All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.

Caution

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

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all types of lines (e.g. for fuel, hydraulics, active
charcoal filter system, coolant, refrigerant, brake fluid and
vacuum) and electrical wiring in their original positions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components. . Volkswage
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– Disconnect earth strap at battery oriswith ignition switched off ⇒
e nte
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Electrical system; Rep. Gr. 27 aut; Disconnecting and connecting
h
ra
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– Remove engine cover.

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– Remove air filter housing with connecting hoses.

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1. Removing and installing engine 3

Diesel Engine 4 Cylinder Injection 2005
Full download: http://manualplace.com/download/diesel-engine-4-cylinder-injection-2005/

Golf - Jetta 2005 ➤

4-cylinder injection engine, 2005▸ - Edition 09.2005

– Remove battery and battery tray -arrows-.

– Remove top part of intake manifold.
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body front; Plenum chamber bulkhead.
– Detach connectors from the following components:
♦ Ignition transformer -N152-
♦ Injector for cylinder 1 -N30-
♦ Injector for cylinder 2 -N31-
♦ Injector for cylinder 3 -N32-
♦ Injector for cylinder 4 -N33-
♦ Coolant temperature sender -G62-
♦ Engine speed sender -G28-
♦ Knock sensor 1 -G61-
♦ Knock sensor 2 -G66-
♦ Secondary air pump motor -V101-
♦ Oil pressure switch -F1-
♦ Throttle valve control module -J338-
♦ If necessary A/C system shutoff thermal switch -F163-
– Pull engine wiring harness connector off engine control unit.
– Separate all connectors betweenenengine
. Volkwiring harness
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WARNING
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The fuel supply line is under pressure! Wear protective glasses

nl

pt
du

and clothing to avoid injuries and skin contact. Before loosen‐

an
itte

y li

ing hose connections, wrap a cloth around the connection.

erm

ab

Then release pressure by carefully pulling hose off connection.

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– Disconnect breather line -1-and fuel supply line -2-.

es, in part or in w

t to the co

– Remove noise insulation tray ⇒ General body repairs, exteri‐

or; Rep. Gr. 50 ; Body front; Noise insulation.
rrectness of i

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

Rep. Gr. 50 ; Body front; Lock carrier service position .
l purpos

– Drain coolant ⇒ page 69 .

nform
ercia

– Remove left wheel housing liner.

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4 Rep. Gr.10 - Removing and installing engine

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