5cyl 2.5L Engine - Mechanical - Fuel - Injection - and - Ignition

Service
Repair Manual
Golf 2004 ➤
Golf 2009 ➤
Engine Mechanical, Fuel Injection and Ignition
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Engine ID
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00 - General, Technical Data d byV
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24 - Multiport Fuel Injection
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26 - Exhaust System, Emission Controls
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28 - Ignition/Glow Plug System
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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 © 2015 Volkswagen AG, Wolfsburg D3E8020B3C3

Golf 2004 ➤ , Golf 2009 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 07.2014
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Engine Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Cylinder Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Engine Number/Engine Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Engine Mount Adjustment, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Engine and Transmission, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Engine, Securing to theagEngine n AG. VoandlkswaTransmission
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4 Special Tools
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13 - Crankshaft, Cylinder
s Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1.1 New Connecting Rod, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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2.1 Ribbed Belt Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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2.2 Ribbed Belt Drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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2.3 Engine Overview, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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2.4 Engine Overview, Front/Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.5 Sealing Flange and Drive Plate/Flywheel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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2.6 Flywheel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.7 Crankshaft Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2.8 Crankshaft, Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.9 Pistons and Connecting Rod Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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3.1 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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4.1 Crankshaft Axial Clearance, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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4.2 Crankshaft Radial Clearance, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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4.3 Pistons and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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5.1 Ribbed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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5.2 Ribbed Belt Tensioner, A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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5.3 Ribbed Belt Tensioner, Generator, Power Steering Pump and Coolant Pump . . . . . . . . . . 47
5.4 Vibration Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.5 Sealing Flange, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.6 Seal, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.7 Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.8 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.9 Sealing Flange, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.10 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Contents i
Golf 2004 ➤ , Golf 2009 ➤
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.1 Cylinder Head Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Timing Chain Routing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.3 Camshaft Timing Chain Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.4 Oil Pump Timing Chain Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.5 Valvetrain Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.1 Valve Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.1 Compression Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.2 Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.3 Valve Timing, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.4 Valve Guide, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.1 Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.2 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.3 Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.4 Timing Chain Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.5 Timing Chain Cover Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.6 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.7 Valve Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1 General Information . . . . . . . . . . . . . V. o.lk.s.w.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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1.2 Oil Filter Housing, Drainingd by . . . . . . . . . . . . . . . . . . . . . . g. u.ar.a . . . . . . . . . . . . . . . . . . . . . . . 100
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2 Description and Operation
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2.1 Oil Pan and OilsPump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . 102
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2.2 Oil Filter Adapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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3.1 Oil Pressure and Oil Pressure Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

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4.1 Lower Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

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4.2 Upper Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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4.3 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

4.4 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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1.1 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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2.1 Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

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2.2 Coolant Pump and Thermostat Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

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2.3 Radiator and Fan Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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3.1 Cooling System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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4.1 Coolant Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ii Contents
Golf 2004 ➤ , Golf 2009 ➤
4.2 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

4.3 Fan Shroud and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.4 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1.1 Fuel System, Filling and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.1 Fuel Injection System Component Location Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.2 Engine Cover with Air Filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.3 Intake Manifold Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.4 Fuel Rail and Injectors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.5 Intake Manifold Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.6 Fuel Rail and Injectors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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4 Diagnosis and Testing s.w.ag. e.n.A.G.. V. o. l . .w.a.ge. n.A.G. d.o.es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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or . . . . . . . . . . . . . . . . . . . . . . . .te.e.o . . . . . . . . . . . . . . . . . . . . . . . . 159
5.1 Engine Cover au with Air Filter . . . . . . . . . . . . . . . . . . . . . . . . r.ac. . . . . . . . . . . . . . . . . . . . . . . 159
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5.2 Throttle Valve Control Module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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5.3 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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5.4 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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5.6 Engine Control Module. with Anti-Theft Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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5.7 Engine Control Module, without Anti-Theft Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

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5.8 Engine Control Module, with Anti-Theft Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t to the co

170
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

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1.1 Secondary Air Injection System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1.2 Exhaust Manifold Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
nform
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1.3 Exhaust Pipe with Catalytic Converter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

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1.4 Exhaust Pipe with Catalytic Converter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

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1.5 Muffler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

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2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
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3.1 Secondary Air Injection Solenoid Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
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4.1 Secondary Air Injection Pump Motor V101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote AG.
187
4.2 Secondary Air Injection Solenoid Valve N112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.3 Exhaust Pipe with Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.4 Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4.5 Exhaust System, Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

1.1 Ignition System Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.2 Knock Sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Contents iii
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Engine Mechanical, Fuel Injection and Ignitionth - Edition 07.2014
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2.1 Test Data and Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
le
198
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3.1 Ignition Coil with Power Output Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
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5 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
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00 – General, Technical Data
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⇒ “1.1 Safety Precautions”, page 1
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⇒ “1.2 Clean Working Conditions”, page 3
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⇒ “1.3 Engine Contaminants”, page 4

⇒ “1.4 Cylinder Numbering”, page 4
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1.1 Safety Precautions
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⇒ “1.1.1 Fuel Supply System”, page 1
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⇒ “1.1.2 Road Test with Testing Equipment”, page 2

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⇒ “1.1.3 Cooling System ”, page 2
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⇒ “1.1.4 Ignition System”, page 3 . Cop py
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WARNING
Fuel lines are under pressure.

Danger of personal injury to eyes and skin.
Wear protective eyewear and protective clothing in order to
avoid injury and contact with the skin. Wrap a cloth around the
connection before disconnecting a fuel hose. Open the con‐
nection carefully and release the pressure.
For safety reasons, interrupt the current to the fuel pump before
opening the fuel system. Otherwise, the fuel pump will activate
when the drivers door opens or when the ignition is turned on.
It is possible to interrupt the current flow by using one of the
following possibilities:
♦ Battery, disconnecting
or
♦ Removing the Fuel Pump - G6- fuse.
or
♦ Disconnecting the connector from the fuel delivery unit
flange.
Always observe the following when removing and installing the

fuel level sensor or the fuel pump from a full or partially filled fuel
tank.
♦ Before starting work, switch the exhaust extraction system on
and place an extraction hose close to the fuel tank opening to
extract the fuel fumes. If no exhaust extraction system is avail‐
able, a radial fan (as long as motor is not in air flow) with a
displacement greater than 15 m3/h can be used.
♦ Prevent fuel from contacting skin! Wear fuel-resistant gloves!
1. General Information 1
Golf 2004 ➤ , Golf 2009 ➤
Caution
Note the following whenever working inside the engine com‐

partment due to limited space:
♦ Route all lines and wires in their original locations.
♦ Ensure sufficient clearance to all moving or hot compo‐
nents.
1.1.2 Road Test with Testing Equipment

If special testing equipment is required during a road test, note
the following:
♦ Test equipment must always be secured to the rear seat and
operated from there by a second person.
If the vehicle is involved in a collision while testing and measuring
equipment is operated from the front passenger seat, the person
sitting in that seat could be seriously injured when the airbag de‐
ploys.
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1.1.3 Cooling System
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The coolant system is under pressure when the engine is

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Risk of scalding due to hot steam and hot coolant.

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Reduce pressure by covering the coolant expansion tank cap

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with a cloth and opening carefully.

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♦ Secure all hose connections with hose clamps, allocation. Re‐

fer to the Parts Catalog.
♦ Use spring type clamp pliers to install spring clamps.
♦ Always replace gaskets and seals.
♦ The arrows on coolant pipes and coolant hoses must line up
across from each other.
2 Rep. Gr.00 - General, Technical Data

Golf 2004 ➤ , Golf 2009 ➤
1.1.4 Ignition System

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Fuel lines areauunder
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Danger of personal injury to eyes and skin.
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avoid injury and contact with the skin. Wrap a cloth around the
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connection before disconnecting a fuel hose. Open the con‐
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nection carefully and release the pressure.
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To reduce the risk of personal injury and/or damage to the fuel
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injection and ignition system, always observe the following:
♦ Do not touch or remove ignition wires when the engine is run‐
rrectness of i
ning or turning at starter speed.
♦ Only disconnect and reconnect wires for the injection and ig‐
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nition system, including test leads, if the ignition is turned off.
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♦ The fuel pump is activated by turning on the ignition and by a
or
drivers door contact switch. If the battery was not disconnec‐
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om
delivery unit or the fuse for the Fuel Pump Control Module -
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J538- must be removed before opening the fuel system.
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♦ Route all lines and wires in their original locations. Prote AG.

nents.
1.2 Clean Working Conditions

When working on the fuel supply/injection system, pay careful at‐
tention to the following “5 rules” of cleanliness:
♦ Always clean the connection locations and the areas around
them before loosening.
♦ Place removed parts on a clean surface and cover them using
lint free cloths.
♦ Carefully cover or seal, unpacked components if repairs can‐
not be performed immediately.
♦ Only install clean components: Remove the replacement parts
from their packaging just prior to installing them. Do not use
parts that have been stored loose (for example, in a tool box,
etc.).
♦ When the system is open: Avoid working with compressed air
if possible. Do not move the vehicle unless absolutely neces‐
sary.
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1.3 Engine Contaminants ss
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♦ Close off any open intake or exhaust passages with plugs
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1.4 Cylinder Numbering
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– Remove the engine cover with air filter. Refer to
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⇒ “5.1 Engine Cover with Air Filter”, page 159 .
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Note
Cylinder 1 is located opposite the force producing side.
Ignition sequence 1-2-4-5-3

Golf 2004 ➤ , Golf 2009 ➤
AG. Volkswagen AG d
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2.1 Engine Number/Engine Characteristics
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Engine Number
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The engine code -arrow A- and engine number -arrow B- (“serial
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The engine code is also stamped on the right cylinder head and
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A label with the “engine code” and “serial number” is also affixed
to the toothed belt guard.
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The first three digits describe the mechanical structure of the en‐
gine and are still stamped on the engine. The fourth position
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describes the engine output and torque. It depends on the Engine

Control Module (ECM). Four digit engine codes are found on the
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type plate and vehicle data label. It can also be read via the ECM.
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For the vehicle data label location. Refer to Maintenance Proce‐

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Engine Codes Prote
BGP BGQ CBTA CBUA
AG.
Manufactured
Rabbit, Model Year (MY) 2006 from 01/06 from 01/06 from 05/07 from 05/07
through 2009 through 05/07 through 05/07 through end of through end of
production production
Golf, from MY 2010 --- --- from 05/09 from 05/09
Emission values in accordance with
Rabbit, from MY 2006 through 2009 ULEV 2 1 SULEV 2 ULEV 2 1 SULEV 2
Golf, from MY 2010 --- --- Tier2/BIN5 (US SULEV 2
coalition)
Displacement cm³ 2480 2480 2480 2480
Output kW at RPM 110 at 5000 110 at 5000 125 at 5700 125 at 5700
Torque Nm at RPM 228 at 3750 228 at 3750 240 at 4250 240 at 4250
Bore diameter mm 82.5 82.5 82.5 82.5
Stroke mm 92.8 92.8 92.8 92.8
Compression ratio 9.5 9.5 9.5 9.5
Valves per cylinder 4 4 4 4
RON minimum 91 unleaded 91 unleaded 95 unleaded3 95 unleaded3
Fuel injection, ignition Motronic ME Motronic ME Motronic ME 17.5 Motronic ME 17.5
7.1.1 7.1.1
Engine idle speed 6804 6804 RPM 6804 6804
Engine speed RPM approximately approximately approximately approximately
(RPM) limitation 5800 5800 6300 6300
Knock control 2 sensors 2 sensors 2 sensors 2 sensors
Variable valve timing yes yes yes yes
Variable intake manifold no no no no
Oxygen Sensor (O2) regulation 2 sensors 3 sensors 2 sensors 3 sensors
2. Specifications 5
Golf 2004 ➤ , Golf 2009 ➤
Engine Codes BGP BGQ CBTA CBUA

Catalytic converter yes yes yes yes
Exhaust Gas Recirculation (EGR) no no no no
Turbocharger, Supercharger no no no no
Secondary Air Injection (AIR) System
Rabbit, from MY 2006 through 2009 yes yes yes yes
Golf, from MY 2010 no yes no yes
♦ 1 ULEV 2 = Ultra Low Emission Vehicles 2
♦ 2 SULEV = Super Ultra Low Emission Vehicles
♦ 3 Also 91 RON but with reduced performance
♦ 4Applies to manual and automatic transmissions. If the volt‐
age supply for the Engine Control Module (ECM) drops below
12 volts, the idle speed gradually increases up to 780 RPM.
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Golf 2004 ➤ , Golf 2009 ➤
10 – Engine Assembly
1 Specifications
⇒ “1.1 Fastener Tightening Specifications”, page 7
1.1 Fastener Tightening Specifications

Engine Mount
1- = 40 Nm + an additional 90° (1/4) turn 1
Transmission Mount
A - = 40 Nm + an additional 90° (1/4) turn 1
B - = 60 Nm + an additional 90° (1/4) turn 1
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A - Strength category 8.8: = 40 Nm + an additional 90° (1/4) turn

1
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A - Strength category 10.9: = 50 Nm + an additional 90° (1/4) turn

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B - = 100 Nm + an additional 90° (1/4) turn 1

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Removing: First remove the bolt -B-, then the bolts -A-.
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Installing: First install the bolts -A-, then the bolt -B-.
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1. Specifications 7
Golf 2004 ➤ , Golf 2009 ➤
2 Diagnosis and Testing

⇒ “2.1 Engine Mount Adjustment, Checking”, page 8
2.1 Engine Mount Adjustment, Checking

• There must be at least 10 to 13 mm -a- between the engine
mount bracket -2- and
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Distance -a- can also be checked with corresponding round stock.
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Only if there is a noise (the engine or transmission hitting the lon‐
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gitudinal member when driving around curves) and dimension
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-a- is not within 10 to 13 mm:
– Adjust the engine mount.
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8 Rep. Gr.10 - Engine Assembly

Golf 2004 ➤ , Golf 2009 ➤
3 Removal and Installation

⇒ “3.1 Engine Cover”, page 9
⇒ “3.2 Engine, Removing”, page 9
⇒ “3.3 Engine and Transmission, Separating”, page 14
⇒ “3.4 Engine, Securing to the Engine and Transmission Holder
VAS6095 ”, page 18
⇒ “3.5 Engine, Installing”, page 20
3.1 Engine Cover

– The engine cover is a single component with the air filter hous‐
ing. Refer to ⇒ “5.1 Engine Cover with Air Filter”, page 159 .
3.2 Engine, Removing
Note
If the engine oil must be drained because of work performed on

the removed engine, it should be drained with the engine swa
geninstal‐
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Special tools and workshop equipment required

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♦ Hose Clip Pliers - VAS6340-
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♦ Engine-/Gearbox Jack - VAG1383A-
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♦ Tensioning Strap - T10038-
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♦ Step Ladder - VAS5085-
♦ Engine Holder Bracket - T03000-
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♦ Cable Ties
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♦ Foam Mat
For information on securing the engine to the engine stand. Refer
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⇒ “3.4 Engine, Securing to the Engine and Transmission Holder

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♦ The engine is removed downward together with the transmis‐
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sion.
♦ All cable ties which are opened or cut off when removing the
engine, must be replaced in the same position when installing
the engine.
3. Removal and Installation 9

Golf 2004 ➤ , Golf 2009 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 07.2014 agen AG. Volkswagen AG do
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Caution tho or
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When doing any repair work, especially in the engine compart‐
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ment, pay attention to the following due to clearance issues:
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♦ To prevent damage to the lines, make sure there is suffi‐
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cient clearance to all moving or hot components.
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– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Removal and Installation .
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– Remove the cover -1- for the E-box and remove the wire -2-.
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– Remove the battery tray bolts -arrows- and remove the battery
or
tray from the vehicle.
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– Disconnect the engine wiring harness connector from the En‐

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– Release the pass-through for the engine wiring harness in di‐

rection of -arrow- and pull off upward.

Golf 2004 ➤ , Golf 2009 ➤
– Open locking mechanisms -arrows- on the wire guide on the

longitudinal member.
– Disconnect the connector -4-, open the locking mechanism
and lay the engine wiring harness -3- on the engine.
– Disconnect the ground cable -1- and the starter connections

-2 and 5-.
With a Automatic Transmission
AG. Volkswagen AG d
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– Disconnect the connectorV-6-
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– Remove the selector rislever cable from the transmission. Refer ntee
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With a Manual Transmission
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– Remove the shift mechanism from the transmission. Refer to
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⇒ Manual Transmission; Rep. Gr. 34 ; Removal and Instal‐
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lation .
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hole
spec
es, in part or in w
t to the co
rrectness of i
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tion in
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Golf 2004 ➤ , Golf 2009 ➤
– Remove the brace -1-.

– Remove the slave cylinder bolts -arrows- and cylinder, set it
aside, do not open line system. en AG. V
olkswagen AG
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Caution ris
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Do not press the clutch pedal after
ss removing the slave cylinder. c
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The slave cylinder may be damaged by doing this. e
nl
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erm
ab
ility
– Disconnect the connector for the backup light switch on the
ot p
transmission.
wit
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hole
Continuation for All
spec
es, in part or in w
– Disconnect the vacuum hose from the brake booster.
t to the co
– Disconnect the connector from the Heated Oxygen Sensor -
G39- on the bulkhead and free up the electric wiring harness.
rrectness of i
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WARNING
Hot steam may escape when opening the expansion tank cap.
nform
ercia
Wear protective goggles and protective clothing to prevent

m
damage to eyes and scalding. Cover the cap with a cloth and
at
om
io
open very carefully.
n
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ate
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– Drain the coolant. Refer to
um
for
⇒ “1.1 Coolant, Draining and Filling”, page 121 .

en
ng
t.
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op py
– Remove the front section of the right wheel housing liner. Re‐ . C rig
ht ht
fer to ⇒ Body Exterior; Rep. Gr. 66 ; Removal and Installation .
rig by
copy Vo
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cted
– Move the lock carrier into the service position. Refer to ⇒ Body
agen
Prote AG.
Exterior; Rep. Gr. 50 ; Description and Operation .
So that it is possible to remove the engine without opening the
refrigerant circuit:
– Remove the ribbed belt. Refer to
⇒ “5.1 Ribbed Belt”, page 45 .
– Unbolt the Air Conditioning (A/C) compressor from the acces‐
sory bracket. Refer to “Refrigerant Circuit Components” in ⇒
Heating, Ventilation and Air Conditioning; Rep. Gr. 87 ; Re‐
moval and Installation .
Note
To prevent damage to the A/C condenser and also to the refrig‐

erant lines/hoses, ensure that the lines and hoses are not stretch‐
ed, kinked or bent.
– Tie up the A/C compressor with the refrigerant hoses still con‐
nected.
– Disconnect the connection from the generator and free up the
wiring harness.

Golf 2004 ➤ , Golf 2009 ➤
– Remove the 4 exhaust pipe with catalytic converter to exhaust

manifold nuts -2- and the suspended mount bolts -3-.
– Remove the exhaust pipe with catalytic converter -1- from the
manifold and tie up firmly to the side. Refer to
⇒ “4.3 Exhaust Pipe with Catalytic Converter”, page 189 .
Note
The coupling element in the exhaust pipe with catalytic converter

must not be bent more than 10°, otherwise it may be damaged.
– Remove the right drive axle and remove the left drive axle from
the transmission. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 40 ; Removal and Installation .
– Remove the pendulum support.
WARNING
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♦ The fuel supply line is under pressure. Always yV
olk wear pro‐ not
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tective eyewear and protective clothing ised to prevent injuries
b ara
nte
and fuel from coming in contact withut
h your skin. Before
or eo
loosening the fuel lines, place asscloth around the connec‐
a ra
c
tion point. Remove the hose connection carefully to re‐
ce
le
un
pt
lease the pressure.
an
d
itte
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erm
ab
ility
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wit
– Disconnect the ventilation line -1-, vacuum line -2- and fuel
is n
h re
supply line -3-. Press in the securing ring to disengage the
ole,
spec
lines.
t to the co
– Seal the lines so that the fuel system is not contaminated by
dirt, etc.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
– Remove the bolt -2- and move the windshield washer fluid
thi
te
sd
a
reservoir -1- toward the front.

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pr
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fo
– Remove the bolts -6- and disconnect the connector -3-.

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ng
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op
– Remove the bolts -5- and place the coolant expansion tank C py
ht. rig
-4- on top of the engine with the hoses connected. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Slightly loosen the bolts on the engine and transmission mounts

before lifting the vehicle.
– Disconnect the coolant lines at the radiator and heater core

(quick acting couplings).

Golf 2004 ➤ , Golf 2009 ➤
– Install the Engine Holder Bracket - T03000- as follows:

♦ Remove the Pin - T03000/3- from the bracket. . Volkswagen AG
gen AG does
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♦ Mount the Engine Holder Bracket - T03000- with the Pin - y Volk not
gu
T03000/4- to the cylinder block and tighten the bolts rised b ara
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-1 and 2- hand tight. ut
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♦ Then, install the pin - T03000/3- and tighten it to 20 Nm.
s
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♦ Then, tighten the bolts -1 and 2- to 25 Nm.
an
itte
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erm
ab
– Place the engine-/gearboxjack - VAG1383A- under the engine
ility
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holder bracket - T03000- and lift the engine/transmission as‐
wit
, is n
sembly slightly.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Remove the engine mount from above. To do this, remove the
nf
ercia
bolts -1, 2 and 3-.
orm
m
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om
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c
Note
or
thi
te
sd
iva
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Remove the rear bolt -2- through a hole in the wheel housing.
r
rp
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o
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f
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove the transmission mount to transmission mount brack‐

et bolts -arrows- from above.
Note
♦ Use the Step Ladder - VAS5085- to remove the mount bolts.

♦ The engine/transmission assembly must be guided with care
to prevent damage while lowering it.
– Lower the engine/transmission assembly carefully downward.
3.3 Engine and Transmission, Separating

⇒ “3.3.1 With a Automatic Transmission”, page 14
⇒ “3.3.2 With a Manual Transmission”, page 17
3.3.1 With a Automatic Transmission

♦ Shop Crane - Load Cap = 700-1200 KG - VAS6100-
♦ Shackle - 10-222A/12-
♦ Crankshaft Adapter - T03003-
♦ Socket SW15 - V/175-
♦ Hose Clamps up to 25 mm Dia. - 3094-

Golf 2004 ➤ , Golf 2009 ➤
♦ Hose Clamps up to 40 mm - 3093-

Conditions
• The engine and transmission assembly is removed and se‐
cured to the Engine Holder Bracket - T03000- .
Caution

nents.
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– Remove the bracket -1- from the starters upper
rised stud bolt ara
nte
-arrow-. ut
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– Remove the starter upper stud bolt. s
ce
le
un
pt
an
d
itte
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rm
ab
Note
pe
ility
ot
wit
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Mark the coolant hoses on the transmission fluid cooler to prevent
h re
mixing them up when installing them again later.
hole
spec
es, in part or in w
t to the co
rrectness of i
– Clamp off the coolant hoses to the transmission fluid cooler
using the Hose Clamps Up to 25 mm - 3094- and the Hose
l purpos
Clamps Up to 40 mm - 3093- .
– Open the spring clamps -A- and remove the coolant hoses
nform
ercia
-B and C- from the cooler.

m
a
com
ti
– Seal the coolant hoses and connections with plugs from the
on in
Engine Bung Set - VAS6122- .
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
cted agen
Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
– Remove the upper transmission to engine bolts -arrows- using

a 12 point swivel socket -A-.
– Turn the cap -1- in the direction of theG-arrow- and remove it.
. Volkswage A n AG d
agen oes
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y Vol gu
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ed nte
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th
au ra
c
ss
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e
nl
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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
– Remove the 6 torque converter nuts using the Socket SW15

- V/175- .
rrectness of i
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at
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ion
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or
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ate
do
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cum
for
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– Rotate the engine in engine rotation direction -arrow- an ad‐ Cop py
ditional 60° turn using the Crankshaft Adapter - T03003- .
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Note
♦ The torque converter will be pulled out when the transmission

is separated from the engine if all 6 nuts are not removed!
♦ Counter hold the vibration damper using the Crankshaft
Adapter - T03003- when loosening the nuts on the torque con‐
verter.

Golf 2004 ➤ , Golf 2009 ➤
– Remove the selector lever cable bracket from the transmis‐

sion.
– Support the transmission using the Shop Crane - Load Capge=n AG. Volkswagen AG d
700-1200 kg - VAS6100- and the Shackle - 10-222A/12-olks but
wa oes
not
do not lift it. byV gu
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– Remove the last transmission to engine bolt.
au
th ra
ss c
– Separate the transmission from the engine. Push the torque
ce
e
nl
pt
converter off of the engine drive plate at the same time.
du
an
itte
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erm
ab
ility
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Note
wit
, is n
h re
hole
Secure the torque converter from falling out.
spec
es, in part or in w
t to the co
Assembling
Assemble in reverse order of removal. Pay attention to the tight‐
rrectness of i
ening specifications:
l purpos
♦ Vehicles with an automatic transmission. Refer to ⇒ Auto‐

matic Transmission; Rep. Gr. 37 ; Removal and Installation .
nform
ercia
3.3.2 With a Manual Transmission

m
at
om
ion
c
in t

or
his
ate
♦ Shackle - 10-222A/12-
do
priv
cum
for

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ng
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op
♦ Torque Wrench (40-200 Nm) - VAG1332-
C py
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Conditions co Vo
by lksw
cted agen
Prote AG.
• The engine and transmission assembly is removed and se‐
cured to the Engine Holder Bracket - T03000- .
Caution

nents.

Golf 2004 ➤ , Golf 2009 ➤
Separating
– Remove the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.
27 ; Removal and Installation
– Disconnect all electrical connections from the transmission to
the engine and free them up.
– Support the transmission using the Shop Crane - Load Cap =
700-1200 KG - VAS6100- and the Shackles - 10-222a/12- but
do not lift it.
– Remove the upper transmission to engine bolts.
– Support the transmission using the Shop Crane - Load Cap =
700-1200 KG and remove the last bolts.
– Remove the lower bolts connecting the engine and transmis‐
sion.
. Volkswagen AG
– Separate the transmission from the engine; when doing this, kswagen AG does
not
guide the transmission. Vol gu
by ara
ed nte
ris
Assembling utho eo
ra
sa c
Assemble in reverse order of removal. Pay attentions to the tight‐
ce
le
ening specifications:
un
pt
an
d
itte
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♦ Vehicles with an manual transmission. Refer to ⇒ Manual
erm
ab
Transmission; Rep. Gr. 34 ; Removal and Installation .
ility
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wit
is n
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ole,
spec
3.4 Engine, Securing to the Engine and
t to the co
Transmission Holder - VAS6095-
rrectne
♦ Lifting Tackle - 3033-
s
s o
cial p
f i
♦ Engine and Transmission Holder - VAS6095-
nform
mer
♦ Engine Lateral Bracket - T03001-
atio
om
n
c
♦ Transport Arm - T03002-
i
or
n thi
te
sd
a
When performing work, secure the engine using the Engine Lat‐
iv
o
pr
eral Bracket - T03001- to the Engine and Transmission Holder -

um
r
fo
VAS6095- .
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ng
t.
yi Co
op
– Remove the transmission. Refer to one of the following:
C py
t. rig
gh ht
yri by
Refer to ⇒ Manual Transmission; Rep. Gr. 34 ; Removal and cop Vo
by lksw
cted
Installation .
agen
Prote AG.
Refer to ⇒ Automatic Transmission; Rep. Gr. 37 ; Removal

and Installation .
– Pull off the clip -1- for the electric wiring harness, remove the
bolts -3- and then remove the cover -2-.

Golf 2004 ➤ , Golf 2009 ➤
– Disconnect the harness connectors -1 and 2- and remove the

bolts -arrows- at the Secondary Air Injection (AIR) valve.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
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h
aut ra
ss c
ce
le
un
pt
– Install the Transport Arm - T03002- as shown.
an
d
itte
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erm
ab
The pin -1- engages in the cylinder block. Tighten the knurled
ility
ot p
thumb screw -2- hand tight.
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
– Install the Engine Lateral Bracket - T03001- . t. Cop py
rig
gh ht
Tighten the bolts -1 and 3 - to 40 Nm, and the bolt -2- to 25 yri
p by
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Nm. by c lksw
cted agen
Prote AG.
Note
♦ The bolts are designed so that they cannot be lost.

♦ When removing, the Engine Lateral Bracket - T03001- must
be held tensioned in the direction of withdrawal, otherwise the
bolt -1- cannot be unscrewed.
– Install the Lifting Tackle - 3033- as shown and lift using the
Shop Crane - Load Cap = 700-1200 KG - VAS6100- from the
Engine-/Gearbox Jack - VAG1383A- .
– Secure the engine to the Engine and Transmission Holder -
VAS6095- .

Golf 2004 ➤ , Golf 2009 ➤
3.5 Engine, Installing

Install in reverse order of removal. Note the following:
Caution

♦ To prevent damage to the lines, make sure there is suffi‐
cient clearance to all moving or hot components.

– Grease the splines of the input shaft lightly with Grease For
Clutch Plate Splines - G000100- .
– Install the clutch and the clutch mechanism.
– Secure the engine and transmission mounts to the engine,
shake the engine and transmission assembly to align it and
tighten the mount bolts.
AG. Volkswagen AG d
agen oes
olksw not
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ara
d
Note orise nte
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♦ For the engine and transmission mount tightening specifica‐ s
ce
le
tions. Refer to
un
pt
an
d
⇒ “1.1 Fastener Tightening Specifications”, page 7 .

itte
y li
erm
ab
♦ Electrical connections and routings. Refer to ⇒ Electrical
ility
ot p
Equipment; Rep. Gr. 97 .
wit
is n
h re
ole,
– Install the exhaust pipe with catalytic converter. Refer to
spec
t to the co
– Install the right drive axle and the left drive axle to the trans‐
mission. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.
40 ; Removal and Installation .
rrectne
– Install the pendulum support. Refer to ⇒ Suspension, Wheels,
s
Steering; Rep. Gr. 40 ; Specifications .

s o
cial p
f i
– Install the Air Conditioning (A/C) compressor. Refer to “Re‐

nform
frigerant Circuit Components” in ⇒ Heating, Ventilation and

mer
atio
Air Conditioning; Rep. Gr. 87 ; Removal and Installation .

om
n
c
– Install the ribbed belt. Refer to

or
n thi
e

t
sd
iva
o
pr
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

um
r
fo
en
ng
50 ; Description and Operation .

t.
yi Co
Cop py
With a Manual Transmission ht. rig
rig ht
py by
o Vo
– Install the shift mechanism and adjust if necessary. Refer to by c lksw
cted agen
⇒ Manual Transmission; Rep. Gr. 34 ; Removal and Instal‐ Prote AG.
lation .
– Install the clutch slave cylinder. Refer to ⇒ Manual Transmis‐
sion; Rep. Gr. 30 ; Removal and Installation .
– Install the selector lever cable and adjust if necessary. Refer
to ⇒ Automatic Transmission; Rep. Gr. 37 ; Removal and
Installation .

Golf 2004 ➤ , Golf 2009 ➤

– Fill the coolant. Refer to
– Install the Engine Control Module (ECM).
– Install the battery. Refer to ⇒ Electrical Equipment; Rep. Gr.
– Adapt the ECM. Refer to “Guided Functions” in the vehicle di‐
agnostic tester.
– Perform the vehicle system test. Refer to “Guided Fault Find‐
ing” in the vehicle diagnostic tester.
– Then, end “Guided Fault Finding”.
Observe the safety precautions that apply to road tests.
– Perform a road test.
– After that perform the vehicle system test again and repair any
occurring malfunctions.
Tightening Specification
Bolted Connections Tightening specification
Bolts and nuts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M12 60 Nm
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
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
4 Special Tools
AG. Volkswagen AG d
agen oes
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Special tools and workshop by
Vol not
gu
ara
equipment required rised
nte
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ut
♦ Hose Clip Pliers - ss a ra
c
VAS6340-
ce
e
nl
pt
du
an
♦ Hose Clip Pliers - itte
y li
VAS6362-
erm
ab
ility
ot p
♦ Engine-/Gearbox Jack -
wit
, is n
VAG1383A-
h re
hole
spec
♦ Tensioning Strap - T10038-
es, in part or in w
t to the co
♦ Step Ladder - VAS5085-
♦ Engine Holder Bracket -
T03000-
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.

Golf 2004 ➤ , Golf 2009 ➤
♦ Lifting Tackle - 3033-

♦ Shop Crane - Load Cap =
700-1200 KG - VAS6100-
♦ Engine and Transmission
Holder - VAS6095-
♦ Engine Lateral Bracket - n AG. Volkswagen AG do
swage es n
T03001- byV
olk ot g
ua
d ran
ir se
♦ Transport Arm - T03002- tho tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Special Tools 23
Golf 2004 ➤ , Golf 2009 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
♦ Socket SW15 - V/175-
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
rrectness of i
l purpos
nform
ercia
♦ Shackle - 10-222A/12-
m
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.


Golf 2004 ➤ , Golf 2009 ➤
13 – Crankshaft, Cylinder Block

. Volkswagen AG
do gen AG
⇒ “1.1 New Connecting Rod,
Vol
kswSeparating”, page 25 es not
a
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ara
ed
1.1 New
tho
riConnecting
s
Rod, Separating nte
eo
au ra
c
New connecting
ss rods may not be separated at the location where
ce
e
they should be. If the connecting rod bearing cap cannot be re‐
nl
pt
du
an
moved by hand, proceed as follows:
itte
y li
erm
ab
– Mark which cylinder the connecting rod belongs to.
ility
ot p
wit
– Lightly clamp the connecting rod in a vise equipped with alu‐
, is n
h re
minum protective jaw pads.
hole
spec
es, in part or in w
t to the co
Note
♦ Only clamp the connecting rod lightly to avoid damaging it.
rrectness of i
♦ Clamp the connecting rod below the dotted line.
l purpos
– Loosen both bolts -arrows- about five turns.
nform
mercia
at
om
ion
c
in t
or
– Carefully tap against the connecting rod bearing cap in the

his
ate
direction of the -arrow- with a plastic hammer until the cap is

do
riv
loose.
p
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.
Golf 2004 ➤ , Golf 2009 ➤

Engine Codes BGP and BGQ
⇒ “2.1 Ribbed Belt Overview”, page 26
Engine Codes CBTA and CBUA
⇒ “2.2 Ribbed Belt Drive Overview”, page 28
⇒ “2.3 Engine Overview, Rear”, page 30
⇒ “2.4 Engine Overview, Front/Side”, page 32
⇒ “2.5 Sealing Flange and Drive Plate/Flywheel Overview”, page
33
⇒ “2.6 Flywheel Overview”, page 34
⇒ “2.7 Crankshaft Overview”, page 35
⇒ “2.8 Crankshaft, Locking”, page 36
⇒ “2.9 Pistons and Connecting Rod Overview”, page 38
2.1 Ribbed Belt Overview
1 - Bolt
❑ 25 Nm
2 - Bolt
❑ 25 Nm
AG. Volkswagen AG d
3 - Generator lksw
agen oes
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Vo gu
❑ Removing and instal‐ d by ara
ling. Refer to ⇒ Electri‐ rise nte
tho eo
cal Equipment; Rep. Gr. s au ra
c
27 ; Removal and Instal‐ s
ce
le
lation .
un
pt
an
d
itte
❑ To make it easier to po‐

y li
erm
ab
sition the generator,

ility
ot p
drive the threaded bush‐

wit
is n
ing for the generator bolt

h re
ole,
back slightly.
spec
4 - Bolt
t to the co
❑ 25 Nm
5 - Lower Idler Pulley with
rrectne
Bracket
❑ For the Air Conditioning
ss
(A/C) compressor rib‐

o
cial p
bed belt.
inform
❑ Do not remove the pul‐

mer
ley.
atio
om
n
c
6 - Bolt
i
or
n thi
te
sd
❑ 25 Nm
iva
o
pr
cum
r
7 - A/C Compressor
fo
en
ng
t.
yi
❑ Removing and instal‐
Co
Cop py
ling. Refer to “Refriger‐
t. rig
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ant Circuit Compo‐ p by
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lksw
nents” in ⇒ Heating,
by
cted agen
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Ventilation and Air Con‐
AG.
ditioning; Rep. Gr. 87 ;

Removal and Installa‐
tion .
26 Rep. Gr.13 - Crankshaft, Cylinder Block

Golf 2004 ➤ , Golf 2009 ➤
8 - Bolt
❑ 25 Nm
9 - Coolant Pump
❑ In the cylinder block.
❑ Removing and installing. Refer to ⇒ “4.2 Coolant Pump”, page 135 .
10 - Ribbed Belt, Generator, Power Steering Pump and Coolant Pump
❑ Belt routing. Refer to ⇒ Fig. ““Belt Routing”“ , page 28 .
❑ Before removing, mark the rotation direction using chalk or a felt tip pen.
❑ Check for wear.wagen AG. Volkswagen AG doe
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❑ Do not kink. Vol t gu
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❑ Removing
thori and installing. Refer to ⇒ “5.1 Ribbed Belt”,
eo page 45 .
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11 - Ribbed
ss Belt, A/C Compressor c
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❑ Check for wear.
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❑ Do not kink.
h re
hole
❑ Removing and installing. Refer to ⇒ “5.1 Ribbed Belt”, page 45 .
spec
es, in part or in w
12 - Vibration Damper
t to the co
❑ To remove and install, lock the crankshaft. Refer to ⇒ “2.8 Crankshaft, Locking”, page 36 .
13 - Bolt
rrectness of i
❑ 50 Nm + an additional 90° (1/4 turn).
l purpos
❑ Always replace.
❑ Only use strength category 10.9 bolts.
nf
ercia
❑ Quantity: 5
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14 - Bushing
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❑ Quantity: 2
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15 - Ribber Belt Tensioner, A/C Compressor Belt

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❑ 35 Nm
en
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❑ Do not remove the tensioning roller, remove the entire tensioner. Refer to
C py
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⇒ “5.2 Ribbed Belt Tensioner, A/C Compressor”, page 46 .
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16 - Ribbed Belt Tensioner, Generator, Power Steering Pump and Coolant Pump Belt
cted agen
Prote AG.
❑ 35 Nm
⇒ “5.3 Ribbed Belt Tensioner, Generator, Power Steering Pump and Coolant Pump”, page 47 .
17 - Bolt
❑ 25 Nm
18 - Bolt
❑ 8 Nm
19 - Upper Idler Pulley with Bracket
❑ For the generator, power steering pump and coolant pump ribbed belt.
❑ Do not remove the pulley.
20 - Bolt
❑ 40 Nm + an additional 90° (1/4) turn.
21 - Engine Mount
22 - Bushing
❑ Quantity: 2
23 - Accessory Bracket
2. Description and Operation 27

Golf 2004 ➤ , Golf 2009 ➤
Belt Routing
1- Upper idler pulley
2- Generator
3- Lower idler pulley
4- Ribbed belt, generator, power steering pump and coolant
pump
5- A/C compressor
6- Ribbed belt, A/C compressor
7- Vibration damper
8- Belt tensioner, A/C compressor ribbed belt
9- Belt tensioner, generator, power steering pump and coolant
pump ribbed belt
10 - Coolant pump
2.2 Ribbed Belt Drive Overview

n AG. Volkswagen AG
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1 - Bolt tho eo
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❑ 25 Nm
ce
le
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2 - Bolt an
d
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❑ 25 Nm ab
ility
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3 - Generator
wit
is n
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ole,
spec
ling. Refer to ⇒ Electri‐

cal Equipment; Rep. Gr.

t to the co
27 ; Removal and Instal‐

lation .
❑ To make it easier to po‐
rrectne
sition the generator,

drive the threaded bush‐
ss
ing for the generator bolt

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cial p
back slightly.
inform
mer
4 - Bolt
atio
m
❑ 25 Nm
o
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c
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5 - Lower Idler Pulley with

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Bracket
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❑ For the Air Conditioning

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(A/C) compressor rib‐

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bed belt
C py
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❑ Do not remove the pul‐ py by
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ley.
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6 - Bolt
❑ 25 Nm
7 - A/C Compressor
ling. Refer to “Refriger‐
ant Circuit Compo‐
nents” in ⇒ Heating,
Ventilation and Air Con‐
ditioning; Rep. Gr. 87 ;
Removal and Installa‐
tion .

Golf 2004 ➤ , Golf 2009 ➤
8 - Bolt
❑ 25 Nm
9 - Coolant Pump
❑ In the cylinder block.
10 - Ribbed Belt, Generator, Power Steering Pump and Coolant Pump
❑ Check for wear.
❑ Do not kink.
11 - Ribbed Belt, A/C Compressor
❑ Check for wear.
❑ Do not kink.
❑ There are different versions
❑ To remove and install, lock secure the crankshaft. Refer to ⇒ “2.8 Crankshaft, Locking”, page 36 .
13 - Bolts
❑ Always replace.
❑ Use a strength category 10.9 bolt only.
❑ Quantity: 5
AG . Volkswagen AG
14 - Bushing ksw
agen does
not
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❑ Quantity: 2 ed by gu
ara
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15 - Belt Tensioner,
au
th A/C Compressor eo
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❑ 35 Nm s
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an
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⇒ “5.2 Ribbed Belt Tensioner, A/C Compressor”, page 46 .

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16 - Belt Tensioner, Generator, Power Steering Pump and Coolant Pump

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❑ 35 Nm
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hole
spec
⇒ “5.3 Ribbed Belt Tensioner, Generator, Power Steering Pump and Coolant Pump”, page 47 .
es, in part or in w
t to the co
17 - Bolt
❑ 25 Nm
rrectness of i
18 - Bolt
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❑ 8 Nm
19 - Upper Idler Pulley with Bracket
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❑ For the generator, power steering pump and coolant pump ribbed belt.
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❑ Do not remove the pulley.

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20 - Bolt
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21 - Engine Mount
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22 - Bushing
t. C rig
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❑ Quantity: 2 cop Vo
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cted agen
Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
Belt Routing
1- Upper idler pulley
2- Generator
3- Lower idler pulley
4- Ribbed belt, generator, power steering pump and coolant
pump
5- A/C compressor
6- Ribbed belt, A/C compressor
7- Vibration Damper
8- Belt tensioner, A/C compressor ribbed belt
9- Belt tensioner, generator, power steering pump and coolant
pump ribbed belt
10 - Coolant pump
AG. Volkswagen AG d
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2.3 Engine Overview, Rear
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1 - Cylinder Block s
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2 - Locking Bolt
an
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❑ 30 Nm
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❑ With a rolled seal.

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❑ The bore in the cylinder

ole,
block is used for locking

spec
the crankshaft using the

t to the co
Locking Pin - T40069- .

3 - Knock Sensor 1 - G61-
rrectne
❑ Note the installed posi‐

tion: The wire connec‐
tion points downward
ss
vertically.
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4 - Bolt
mer
atio
❑ 20 Nm
om
n
c
❑ Tightening specification
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the knock sensor.

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5 - Bolt
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❑ 10 Nm C py
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6 - Cover
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7 - Plug
Prote AG.
8 - Wire Clip
❑ Clipped to the cover
plate.
tion points 45° toward
the right on the outside.

Golf 2004 ➤ , Golf 2009 ➤
10 - Wire Bracket
❑ Bolted to the Secondary Air Injection (AIR) valve.
11 - Connector
❑ Green for knock sensor 1.
❑ Installed position. Refer to
⇒ Fig. ““Installed Position of the Knock Sensor Harness Connectors”“ , page 31 .
❑ Contacts are gold plated.
12 - Connector
❑ Gray for knock sensor 2.
❑ Installed position.agRefer toolkswagen AG do
en AG. V
⇒ Fig. ““Installed
Volksw Position of the Knock eSensor
s no
t gu Harness Connectors”“ , page 31 .
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❑ Contactsrised
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Installed Position of the Knock Sensor Harness Connectors
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1- Green for knock sensor 1
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2- Gray for knock sensor 2
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Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
2.4 Engine Overview, Front/Side
1 - Cylinder Block
2 - Gasket
❑ Always replace.
3 - Brake Booster Vacuum
Pump
❑ Do not open.
ling. Refer to
⇒ “4.3 Vacuum Pump”,
page 84 .
4 - Bracket
5 - Bolt
❑ 10 Nm
6 - Oil Filter Adapter
❑ Overview. Refer to
⇒ “2.2 Oil Filter Adapter
Overview”, page 104 .
7 - Bolt
❑ 25 Nm
8 - Nut
❑ 10 Nm
9 - Bolt
❑ 10 Nm
10 - Thermostat Housing
❑ With thermostat and
coolant pipe. AG. Volkswagen AG d
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11 - Bolt byV
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❑ 10 Nm horis nte
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12 - Intake Manifold Support ss c
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❑ Only for engines with a Secondary Air Injection (AIR) system.

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13 - Bolt
erm
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ility
❑ 25 Nm
ot p
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14 - Bolt
h re
hole
spec
❑ 10 Nm
es, in part or in w
t to the co
15 - Bolt
❑ 25 Nm
rrectness of i
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17 - Bolt
nf
ercia
18 - Engine Mount
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19 - Guide Tube
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❑ For the oil dipstick.

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20 - Bracket
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21 - Bolt
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❑ 25 Nm C py
ht. rig
rig ht
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32
cted agen
Prote AG.
Rep. Gr.13 - Crankshaft, Cylinder Block
Golf 2004 ➤ , Golf 2009 ➤
22 - Bolt
❑ 10 Nm
23 - Coolant Pump
2.5 Sealing Flange and Drive Plate/Flywheel Overview
❑ There are different ver‐
sions.
2 - Bolts
❑ 50 Nm + an additional
90° (1/4) turn. agen
AG. Volkswagen AG d
oes
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❑ Always replace. by Vo gu
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❑ Use a strength category rise nte
ho eo
10.9 bolt only. s aut ra
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❑ Quantity: 5
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3 - Bolt
itte
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❑ 10 Nm
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4 - Sealing Flange, Belt Pulley
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h re
Side
hole
spec
❑ With an integrated seal.
es, in part or in w
t to the co
ling. Refer to
⇒ “5.5 Sealing Flange,
rrectness of i
Belt Pulley Side”,
page 49 .
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5 - Cylinder Block
nform
ercia
6 - Bolt
m
at
om
i
90° (1/4) turn.
on
c
in t
or
❑ Always replace.
his
ate
do
riv
7 - Drive Plate/Flywheel
p
cum
for
en
g
♦ To remove, lock the crank‐

n
t.
yi Co
shaft using the Locking Pin Cop py
t. rig
- T40069- . opyri
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c lksw
♦ The flywheel must not be
by
cted agen
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pried out or the sealing
AG.
flange will be damaged.

❑ Drive plate removing and installing. Refer to ⇒ “5.7 Drive Plate”, page 53 .
❑ Flywheel removing and installing. Refer to ⇒ “5.8 Flywheel”, page 54 .
8 - Sensor Wheel
❑ For the engine speed sensor.
❑ With a position holder.
9 - Seal, Transmission Side
❑ Removing and installing. Refer to ⇒ “5.6 Seal, Transmission Side”, page 52 .
10 - Sealing Flange, Transmission Side
❑ Removing and installing. Refer to ⇒ “5.9 Sealing Flange, Transmission Side”, page 54 .
11 - O-Ring
❑ Always replace.

Golf 2004 ➤ , Golf 2009 ➤
12 - Bolt
❑ 25 Nm
13 - Alignment Sleeves
14 - Bolt
❑ 5 Nm
15 - Engine Speed Sensor - G28-
16 - Seal
❑ Always replace.
2.6 Flywheel Overview
Note
Servicing the clutch. Refer to ⇒ Manual Transmission; Rep. Gr.

30 .
1 - Flywheel
2 - Bolts
90° (1/4) turn. n AG. Volkswagen AG do
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❑ Always replace. yV
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ris tee
utho or
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spec
es, in part or in w
t to the co
rrectness of i
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at
om
ion
c
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or
his
ate
do
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cum
for
en
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Cop py
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Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
2.7 Crankshaft Overview
1 - Bolt
90° (1/4) turn.
❑ Tighten to 40 Nm (but
not the additional 90°) to
measure the radial play
in the crankshaft.
❑ Always replace.
❑ Fully threaded.
2 - Bearing Cap
❑ Bearing cap 1: Belt pul‐
ley side
❑ Retaining tabs on the
bearing shells and cylin‐
der block/bearing caps AG. Volkswagen AG d
must align with one an‐
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not
other. d byV
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3 - Bearing Shellufortho the Bear‐ or
ing Cap ss a ac
ce
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❑ Crankshaft bearing
nl
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shell, allocating. Refer

an
itte
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⇒ Fig. ““Allocation, Low‐ ab

ility
ot p
er Bearing Shells (Bear‐ wit

, is n
ing Cap)”“ , page 36 .

h re
hole
spec
❑ Without a lubricating
es, in part or in w
groove.
t to the co
❑ Do not interchange
used bearing shells
(mark them).
rrectness of i
4 - Crankshaft
l purpos
❑ Axial play, checking.

Refer to
nf
ercia
⇒ “4.1 Crankshaft Axial

orm
Clearance, Checking”,
m
atio
m
page 42 .
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❑ Radial clearance, checking. Refer to ⇒ “4.2 Crankshaft Radial Clearance, Checking”, page 42 .
thi
te
sd
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❑ Crankshaft dimensions. Refer to ⇒ “3.1 Crankshaft Dimensions”, page 41 .

iv
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❑ Locking the crankshaft. Refer to ⇒ “2.8 Crankshaft, Locking”, page 36 .

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5 - Thrust Washers Cop py
ht. rig
❑ For bearing 3.
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❑ The side lubricating grooves face outward. Prote
cted AG.
agen
6 - Bearing Shell for the Cylinder Block

❑ With a lubricating groove.
❑ Crankshaft bearing shell, allocating. Refer to
⇒ Fig. ““Allocation, Upper Bearing Shells (Cylinder Block)”“ , page 36 .
❑ Do not interchange used bearing shells (mark them).
7 - Cylinder Block

Golf 2004 ➤ , Golf 2009 ➤
Allocation, Upper Bearing Shells (Cylinder Block)

From the factory, the upper bearing shells are allocated to the
cylinder block with the correct thickness. Colored dots serve to
identify the bearing thicknesses.
The letters marked on the lower sealing surface of the cylinder
block identify which bearing thickness must be installed in which
location.
Letter on Cylinder Block Colored Dot on the Bearing
Shell
G= Yellow
B= Blue
R = Red
Note
♦ The -arrow- points in the direction of travel.

♦ If the colored dot is not visible, use the blue bearing shell.
Allocation, Lower Bearing Shells (Bearing Cap)

♦ From the factory, the lower bearing shells are allocated to the agen AG. Volkswagen AG do
bearing cap with the correct thickness. Colored dots on theVolksw es n
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sides of the bearing shells serve to identify bearing shell dthick‐
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♦ The allocation of the bearing shells for the bearing
ss cap is iden‐ c
ce
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tified by a series of letters on the vibration damper. The first

un
pt
letter in the row of letters represents bearing “1”, the second
an
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letter is for bearing “2”, etc.
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ility
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Letter on Vibration Damper Colored Dot
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R = Red
hole
spec
G = Yellow
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t to the co
B = Blue
W = White
rrectness of i
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Note
nform
ercia
The -arrow- points in the direction of travel.

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tion in
2.8 Crankshaft, Locking

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♦ Crankshaft Adapter - T03003- t. C rig
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♦ Locking Pin - T40069-
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Prote AG.
Procedure
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50 ; Description and Operation .
– Remove the front section of the right wheel housing liner. Re‐

Golf 2004 ➤ , Golf 2009 ➤
– Install the Crankshaft Adapter - T03003- onto the bolts of the

vibration damper.
The Crankshaft Adapter - T03003- can only be installed cor‐
rectly in one position.
– Rotate the crankshaft in engine rotation direction until the ar‐
row -A- on the Crankshaft Adapter - T03003- faces
olkswadownward
vertically in comparison to the enginew en AG. V
axis.
ag
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does
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This position corresponds rapproximately
ise
db to the Top Dead ran
tee
Center (TDC) position ofut the crankshaft at cylinder 5.
ho
or
a ac
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pt
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– Remove the locking bolt -1- from the rear of the cylinder block.
ility
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– Look through the threaded hole and check whether the bore
wit
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-2- in the crankshaft aligns with the threaded hole.
h re
hole
spec
Use a mirror to do so, if necessary.
es, in part or in w
t to the co
– Rotate the crankshaft slightly if necessary.
– If the bore and the hole align, install the Locking Pin - T40069-
rrectness of i
completely into the threaded hole and tighten it to 10 Nm.
l purpos
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t.
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Note Prote
cted AG.
agen
With the engine removed, the TDC mark can also be seen on the
vibration damper and sealing flange. The notches -A and B- must
align.
– Check whether the crankshaft can be rotated.

After Disassembly and Assembly Work

Golf 2004 ➤ , Golf 2009 ➤
– Remove the Locking Pin - T40069- and install the locking bolt
-1- .
The rest of the installation follows the reverse of the removal pro‐
cedure.
Tightening Specifications
Component Nm
Locking bolt to rear of cylinder block 30 Nm
AG. Volkswagen AG d
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2.9 Pistons and Connecting Rod Overview
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Note
hole
spec
es, in part or in w
The engine is to be secured to the Engine Lateral Bracket -
t to the co
T03001- when performing assembly work.
rrectness of i
l purpos
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mercia
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tion in
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Cop py
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by
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Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
1 - Bolt
90° (1/4) turn.
❑ Tighten to 30 Nm to
measure radial play, do
not tighten the addition‐
al 90° turn.
❑ Always replace.
❑ Lubricate the threads
and contact surface.
2 - Pressure Relief Valve
❑ 27 Nm
❑ Opening pressure: 1.3
to 1.6 bar (18.85 to 23.2
psi) excess pressure.
3 - Oil Spray Jet
❑ For piston cooling.
4 - Connecting Rod Bearing
Cap
❑ Pay attention to the in‐
stalled position.
❑ Due to the separation
procedure (cracking) for
the connecting rod, the
connecting rod bearing
cap only fits in one posi‐ n AG. Volkswagen AG do
tion and only on the ap‐ olkswage es n
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propriate connecting d byV ua
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❑ Mark which cylinder the ss
au ac
cap belongs to.
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❑ Installed position: the
an
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marks -A- point to the
rm
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belt pulley side.
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ility
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5 - Bearing Shell
, is n
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hole
❑ Note the installed position. Refer to ⇒ Fig. ““Bearing Shell Installed Position”“ , page 40 .
spec
es, in part or in w
❑ Do not interchange used bearing shells (mark them).
t to the co
❑ Axial play:
New: 0.10 to 0.35 mm rrectness of i
Wear limit: 0.4 mm

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❑ Measure radial clearance using Plastigage®:

nform
ercia
New: 0.02 to 0.06 mm

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Wear limit: 0.09 mm

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Do not rotate the crankshaft when measuring radial play.

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6 - Connecting Rod
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en
ng
t.
❑ With a cracked bearing cap.
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❑ Separating new connecting rods. Refer to ⇒ “1.1 New Connecting Rod, Separating”, page 25 .
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❑ Always replace as a set.
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❑ Mark which cylinder the connecting rod belongs to.
AG.
❑ Installed position: The marks -A- point to the belt pulley side.

Golf 2004 ➤ , Golf 2009 ➤
7 - Circlip
8 - Piston Pin
❑ If difficult to move, heat the piston to 60 °C (140 °F).
❑ Remove and install using a Pilot Drift - VW 222 A- .
9 - Piston
❑ Checking. Refer to ⇒ Fig. ““Piston, Checking”“ , page 44 .
❑ Mark the installed position and cylinder allocation.
❑ The arrow on the piston face points toward the belt pulley side.
❑ Install using a piston ring compressor.
❑ Piston and cylinder bore, checking. Refer to ⇒ “4.3 Pistons and Cylinder Bore, Checking”, page 43 .
10 - Piston Rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers for removal and installation.
❑ Marks face toward the piston crown.
❑ Checking the ring gap. Refer to ⇒ Fig. ““Piston Ring Gap, Checking”“ , page 43 .
❑ Checking the piston ring groove clearance. Refer to
⇒ Fig. ““Piston Ring Groove Clearance, Checking”“ , page 43 .
Bearing Shell Installed Position

Bearing shell -1- with a connecting rod oil bore -arrow-.
Bearing shell -2- without a oil bore for the connecting rod cap.
– Place the bearing shells centrally into the connecting rod and
connecting rod bearing cap.
Dimension -a- must be the same on the left and right.
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Rep. Gr.13 - Crankshaft, Cylinder Block
Golf 2004 ➤ , Golf 2009 ➤
3 Specifications
⇒ “3.1 Crankshaft Dimensions”, page 41
3.1 Crankshaft Dimensions

(Dimensions are in mm)
Honing Dimen‐ Crankshaft Bearing Connecting Rod Bear‐
sion Pin Diameter ing
Pin Diameter
Basic dimen‐ 58.00 -0.022 47.80 -0.022
sion -0.042 -0.042
1st oversize 57.75 -0.022 47.55 -0.022
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2nd oversize 57.50 -0.022 47.30 -0.022
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3. Specifications 41
Golf 2004 ➤ , Golf 2009 ➤

⇒ “4.1 Crankshaft Axial Clearance, Checking”, page 42
⇒ “4.2 Crankshaft Radial Clearance, Checking”, page 42
⇒ “4.3 Pistons and Cylinder Bore, Checking”, page 43
4.1 Crankshaft Axial Clearance, Checking

♦ Dial Gauge Holder - VW387-
♦ Dial Gauge 0-10 mm - VAS6079-
Procedure
– Install the Dial Gauge - VAS6079- with the Dial Gauge Holder
- VW387- onto the cylinder block as shown in the illustration.
– Place the dial gauge against the crankshaft counterweight.
– Press the crankshaft against the dial gauge by hand and set
the gauge to “0”.
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– Press the crankshaft off the dial gauge and read the meas‐ ksw
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Wear limit: 0.30 mm
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4.2 Crankshaft Radial Clearance, Checking
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♦ Plastigage®
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Procedure
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Note
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♦ Marked the used bearing for installation later, but not on the
running surface.
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♦ Replace bearing shells that are worn down to the base layer.
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– Remove the bearing cap.

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– Clean the bearing cap and bearing journals.

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– Place the Plastigage® over the entire width of the bearing

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– Install the bearing cap and tighten the bolts to 40 Nm without Prote AG.
rotating the crankshaft.

– Remove the bearing cap.
– Compare the width of the Plastigage® with the calibrated
scale.
Radial clearance:
New: 0.023 to 0.043 mm
Wear limit: 0.07 mm

Golf 2004 ➤ , Golf 2009 ➤
4.3 Pistons and Cylinder Bore, Checking

Piston Ring Gap, Checking

♦ Feeler Gauge
– Insert the ring at a right angle from above, to the lower end of
cylinder approximately 15 mm from the cylinder edge.
Piston Ring Gap
New Wear limit
Compression rings mm 0.20 0.8
through
0.40
Oil scraping ring mm 0.25 0.8
through
0.50
Piston Ring Groove Clearance, Checking
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♦ Feeler Gauge
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– Clean the groove in the ring before checking.

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Piston Ring Ring to Groove Clearance

New Wear limit
rrectne
Compression rings mm 0.06 0.20

through
0.09
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Oil scraping ring mm 0.03 0.15

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4. Diagnosis and Testing 43

Golf 2004 ➤ , Golf 2009 ➤
Piston, Checking
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♦ Micrometer 75-100 mm - VAS6071-
rrectness of i
– Take the measurement approximately 10 mm from the lower
edge of the piston skirt and offset 90° to the piston axis.
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Deviation from nominal dimension: Max. 0.04 mm
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Cylinder Bore, Checking

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Note
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The cylinder bore must not be measured if the cylinder block is

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secured to the engine stand with the Engine Lateral Bracket -

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T03001- , or else results may be incorrect.
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♦ Cylinder Gauge - VAS6078-
– Measure diagonally at 3 positions transversely -A- and longi‐
tudinally -B-.
Deviation from nominal size: Max. 0.08 mm.
Piston and Cylinder Reconditioning Dimension
Honing Dimen‐ Piston Diameter Cylinder Bore
sion Diameter
Basic dimension mm 82.465 1 82.51
♦ 1The measurement does not include the graphite coating,

which is 0.02 mm thick. The graphite coating wears off.

Golf 2004 ➤ , Golf 2009 ➤

⇒ “5.1 Ribbed Belt”, page 45
⇒ “5.2 Ribbed Belt Tensioner, A/C Compressor”, page 46
⇒ “5.3 Ribbed Belt Tensioner, Generator, Power Steering Pump
and Coolant Pump”, page 47
⇒ “5.4 Vibration Damper”, page 47
⇒ “5.5 Sealing Flange, Belt Pulley Side”, page 49
⇒ “5.6 Seal, Transmission Side”, page 52
⇒ “5.7 Drive Plate”, page 53
⇒ “5.8 Flywheel”, page 54
⇒ “5.9 Sealing Flange, Transmission Side”, page 54
⇒ “5.10 Piston”, page 57 wage
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Special tools and workshop equipment required ss
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♦ Locking Pin - T10060A-

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Removing the Air Conditioning (A/C) Compressor Ribbed Belt
– Mark the rotation direction on the ribbed belt.
rrectness of i
– Rotate the belt tensioner -1- in the -direction of the arrow- us‐
l purpos
ing a 15 mm box end wrench -A- as illustrated, and then lock

it into place using the Locking Pin - T10060A- .
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– Remove the A/C compressor ribbed belt.
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Removing Generator, Power Steering Pump and Coolant Pump

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Ribbed Belt
or
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– Relieve the tension on the belt tensioner -1- for the A/C com‐
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pressor ribbed belt (remove the Locking Pin - T10060A- ).
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pump and coolant pump ribbed belt.
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– Insert the Locking Pin - T10060A- into the belt tensioner -2-.
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– Rotate the belt tensioner -2- in the direction of the -arrow- us‐
ing a 15 mm box end wrench -A- and then lock it into place
using the Locking Pin - T10060A- .
– Remove the generator, power steering pump and coolant
pump ribbed belt.
Installing

Golf 2004 ➤ , Golf 2009 ➤
– Place the generator, power steering pump and coolant pump

belt around the pulleys, then lastly around the idler pulley -3-.
– Rotate the A/C compressor pulley before tensioning the gen‐
erator, power steering pump and coolant pump ribbed belt.
Make sure the ribbed belt is seated correctly on the pulleys.
– Before installing the A/C compressor ribbed belt, secure the
belt tensioner using the Locking Pin - T10060A- .
Note
When installing the ribbed belt, note the rotation direction of the
belt and be sure that it is seated correctly on the pulley.
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– Start the engine and check the belt running direction.
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– Loosen the bolt -2- for the belt tensioner -1- and remove the
on in
tensioner.
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– Install in reverse order of removal. Note the following:

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Belt tensioner to accessory bracket 35
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Golf 2004 ➤ , Golf 2009 ➤
5.3 Ribbed Belt Tensioner, Generator, Pow‐

er Steering Pump and Coolant Pump
Caution
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Note the following whenever
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– Loosen the bolt -2- for the belt tensioner -1- and remove the
tensioner.
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– Install in reverse order of removal. Note the following:
rrectne
Component Nm
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5.4 Vibration Damper

Caution

nents.
Procedure
– Remove the right front wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Removal and Installation .

Golf 2004 ➤ , Golf 2009 ➤
– Install the Crankshaft Adapter - T03003- onto the bolts for the
vibration damper.
– Rotate the crankshaft in engine rotation in direction of
-arrow- far enough the until arrow -A- on the Crankshaft Adapt‐
er - T03003- points downward vertically, relative to engine
axis.
This position corresponds approximately to the Top Dead
Center (TDC) position of the crankshaft at cylinder 5.
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With the engine removed, The TDC mark can also be seen on the
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vibration damper and sealing flange. The notches -A and B- must d
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align.
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rrectness of i
– Remove the locking bolt -1- from the back of the cylinder block.
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– Look through the threaded hole. Make sure the bore -2- in the
crankshaft is lined up wit the threaded hole.
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ercia
Use a mirror for this, if necessary

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– Rotate the crankshaft slightly, if necessary.
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tion in
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– When the bore and hole line up, install the Locking Pin -
te o
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s
T40069- all the way into the threaded hole and tighten it to 10
iva
do
r
Nm. Make sure the crankshaft cannot be rotated.

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– Remove the Air Conditioning (A/C) compressor ribbed belt.

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Refer to ⇒ “5.1 Ribbed Belt”, page 45 . C py
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– Loosen the bolts for the vibration damper and remove the vi‐ cop Vo
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Prote AG.
• Replace the bolts

• Use strength category 10.9 bolts only
• 50 Nm + an additional 90° (1/4) l turn

Golf 2004 ➤ , Golf 2009 ➤
-1-.
cedure.
Component Nm
Locking bolt to rear of cylinder block 30
5.5 Sealing Flange, Belt Pulley Side

♦ Trim Removal Wedge - 3409-
♦ Oil Seal Guide Sleeve - T03004- agen
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♦ Silicone Sealant - D174003A2-
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– Remove the Air Conditioning (A/C) compressor ribbed belt.
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Refer to ⇒ “5.1 Ribbed Belt”, page 45 .
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– Lock the crankshaft. Refer to
hole
spec
⇒ “2.8 Crankshaft, Locking”, page 36 .
es, in part or in w
t to the co
– Remove the vibration damper.
– Remove the belt tensioner -1-.
rrectness of i
– Remove the bolts -2-.
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Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
– Beginning at the alignment bushings -arrows-, pry off the seal‐

ing flange -1- using a suitable screwdriver -A-.
– Use the Trim Removal Wedge - 3409- to support the screw‐ AG. Volkswagen AG d
driver in order to prevent damage to the sealing surface
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The sealing flange is damaged while removing.
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– Pry off the sealing flange completely.
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Note
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After removing the sealing flange, clean the Trim Removal Wedge
h re
- 3409- which is intended for the removal of interior equipment
hole
spec
parts.
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t to the co
Installing
rrectness of i
WARNING
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To prevent injuries from shavings, wear protective goggles and

protective clothing.
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– Remove the remainder of the sealant from the cylinder block,

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using a rotating plastic brush, for example.
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Caution
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Make sure that no sealant residue enters the engine.
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– Clean the sealing surfaces on the cylinder block and crank‐
AG.
shaft journal. They must be free of oil and grease.
Note
♦ Do not additionally oil or grease the sealing lip of the sealing

flange!
♦ The following steps must be followed so that the sealing lip of
the sealing flange does not roll itself up when installing.
– Widen the sealing lip of the new sealing flange as shown using
the Oil Seal Guide Sleeve - T03004- .
The surface -A- is the outer side.

Golf 2004 ➤ , Golf 2009 ➤
– After a short time, remove the Oil Seal Guide Sleeve - T03004-
and slide it rotated 180° into the seal.
the Oil Seal Guide Sleeve - T03004- must stand out approxi‐
mately 3 mm on the inner side -B-.
The surface -A- is the outer side.
The surface -B- is the inner side (sealing surface).
– Cut the sealant tube nozzle at the front mark (nozzle diameter:
approximately 2 mm).
Note
The sealing flange must be installed within 5 minutes after appli‐

cation of the sealant.
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– Apply the sealant bead -A- as shown into the groove in the
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sealing flange.
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♦ Width of sealant bead: 2.5 to 3.0 mm
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♦ Height of sealant bead above the sealing surface: approxi‐
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mately 1.0 mm
hole
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es, in part or in w
t to the co
rrectness of i
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– Insert the sealing flange using the Oil Seal Guide Sleeve -
nform
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T03004- on the crankshaft journal and press the sealing flange

uniformly onto the cylinder block.
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– Tighten the bolts -A- uniformly in a diagonal sequence.

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cedures. Note the following:

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♦ Remove the Locking Pin - T40069- from the cylinder block and
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install the plug. C py
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Component Nm
Vibration damper to crankshaft 50 Nm + an
additional 90°
(1/4) turn
(replace the
bolts)
Sealing flange to cylinder block 10

Golf 2004 ➤ , Golf 2009 ➤
Engine Mechanical, Fuel Injection
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5.6 Seal, Transmission Side ed
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Special tools and workshop
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♦ Assembly Tool - T10122-
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♦ Pulling Hook - T20143-
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Removing
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– Remove the transmission. Refer to one of the following:
hole
spec
es, in part or in w
⇒ Manual Transmission; Rep. Gr. 34 ; Removaland Installa‐
t to the co
tion .
⇒ Automatic Transmission; Rep. Gr. 37 ; Removal and In‐
rrectness of i
stallation .
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– Remove the flywheel or drive plate and remove the sensor
or
wheel for the Engine Speed Sensor - G28- from the crank‐
m
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atio
shaft.
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– Pull out the seal using the Pulling Hook - T20143/2- .
thi
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Be careful not to damage the sealing surface on the crank‐
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shaft.
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Installing t. Cop py
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Note
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Do not lubricate or grease the sealing lip on the seal.
– Clean the sealing surfaces. They must be free of oil and

grease.
– Before installing, remove any remaining oil from the crankshaft
journal with a clean cloth.
– Insert the Assembly Device - T10122/1- onto the Pull Sleeve

- T10122/2- and slide the seal -A- onto the pull sleeve.
– Remove the Assembly Device - T10122/1- .

Golf 2004 ➤ , Golf 2009 ➤
– Install the Pull Sleeve - T10122/2- with the seal -A- onto the
crankshaft.
– Press in the seal all around evenly and flush using the Pres‐
sure Sleeve - T10122/3- .
cedure. Note the following:
install the plug.
Component Nm
Flywheel/drive plate to crankshaft 60 + an addi‐
♦ Replace bolts tional 90° (1/4)
turn
5.7 Drive Plate

♦ Depth Gauge
Removing
– Remove the transmission. Refer to ⇒ Automatic Transmis‐
sion; Rep. Gr. 37 ; Removal and Installation .
⇒ “2.8 Crankshaft, Locking”, page 36 and remove the drive
plate. wage
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– Install the drive plateautonly using the washer with openings ra
-1- and without a shim
ss -2-. c
ce
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un
pt
– Insert the new bolts -3- and tighten them to 30 Nm.

an
d
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erm
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ility
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ole,
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t to the co
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– Check the dimension -a- an three points and calculate the

ss
average value.
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cial p
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Specified value: 18.8 to 20.4 mm

form
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om
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Note
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Measure through the drive plate hole to the surface of sealing

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flange.
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If the specification is not obtained:
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Golf 2004 ➤ , Golf 2009 ➤
AG. Volkswagen AG d
agen oes
– Remove the drive plate and install the shimVo-2-.
lksw Tighten the not
gu
y
bolts -3- to 30 Nm again and repeat the
se
dmeasurement.
b ara
nte
ri
ho eo
If the specified value is OK: aut ra
c
ss
– Tighten the bolts to 60 Nm + an additional 90° (1/4) turn (the
ce
le
un
pt
additional 90° turn may occur in several stages).
an
d
itte
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erm
ab
ility
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ole,
install the plug (30 Nm).
spec
t to the co
5.8 Flywheel
rrectne
ss
o
cial p
f inform
mer
atio
om
n
c
i
or
n
Removing
thi
te
sd
va
– Remove the transmission. Refer to ⇒ Manual Transmission;

i
o
pr
cum
r

fo
en
ng
t.
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– Lock the crankshaft. Refer to Cop py
. rig
ht ht
rig by
copy Vo
– Mark the flywheel to the engine.
by lksw
cted agen
Prote AG.
– Remove the bolts and the flywheel.
Installing
Tightening specification. Refer to
⇒ “2.6 Flywheel Overview”, page 34 .
– Use new bolts.
5.9 Sealing Flange, Transmission Side

♦ Hand Drill with Plastic Brush Attachment
♦ Protective Eyewear
Caution

nents.

Golf 2004 ➤ , Golf 2009 ➤
Removing
• The engine is removed, and the transmission
n AGis
. Voseparated
lkswagen AG
from the engine. lkswage does
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– Remove the timing chain cover.
ris Refer to
e nte
utho page 86 .
⇒ “4.4 Timing Chain Cover”, eo
ra
a c
ss
– Remove the flywheel or drive plate and then remove the sen‐
ce
e
nl
pt
sor wheel for the Engine Speed Sensor - G28- from the du
an
itte
crankshaft.
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erm
ab
ility
– Remove the cylinder head. Refer to
ot p
wit
⇒ “4.2 Cylinder Head”, page 80 .
, is n
h re
hole
– Disengage the wiring harness -arrow- and remove the engine
spec
speed sensor -1- and vacuum pump -2-.
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.

Golf 2004 ➤ , Golf 2009 ➤
– Remove the sealing flange -1- from the cylinder block -2- and
from the lower oil pan -3- at the upper and lower marked lo‐
cations using a screwdriver -A- .
Start near the alignment sleeves -arrows-.
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Be careful not to damage the sealing surfaces.utho
or
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ss
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– Remove the seal from the removed sealing flange.
un
pt
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d
itte
Installing
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ility
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WARNING
is n
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ole,
spec
t to the co
– Remove the sealant residue from the cylinder block, upper oil
rrectne
pan and sealing flange using a rotating plastic brush.
ss o
Caution
cial p
f inform
mer
Make sure that no sealant residue gets into the engine.
atio
om
n
c
i
or
n thi
e
– Clean the sealing surfaces on the cylinder block, the upper oil
t
sd
va
pan and on the sealing flange. There must not be any oil or
i
o
pr
cum
r
grease on them.
fo
en
ng
t.
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op py
– Replace the seals -1 and 2-.
t. C rig
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pyri by
Vo
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by
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Prote AG.
Note
The sealing flange must be installed within 5 minutes after appli‐


Golf 2004 ➤ , Golf 2009 ➤
– Apply the sealant bead -A- to the sealing flange as shown.

♦ The sealant bead must be 1.5 to 2.0 mm thick.
♦ Pay special attention to the course of the sealant bead in the
area of the -arrow-.
– Install the sealing flange so that the alignment sleeve fit into
the holes in the cylinder block.
– Install the bolts hand tight.
AG. Volkswagen AG d
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du
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ab
ility
ot p
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– Install the bolts -3- in the cylinder block and in the upper oil
hole
spec
pan and tighten them to 10 Nm.
es, in part or in w
t to the co
– Tighten the bolts in the cylinder block and upper oil pan to 25
Nm.
– Wipe off any sealant that leaks out.
rrectness of i
– Install the alignment sleeves all the way.
l purpos
– Install a new seal. Refer to

⇒ “5.6 Seal, Transmission Side”, page 52 .
nform
ercia
m
at
om

on
c
in t
or
♦ Install the brake booster vacuum pump. Refer to

his
ate
do
⇒ “4.3 Vacuum Pump”, page 84 .

priv
cum
for
♦ Install the cylinder head. Refer to

en
ng
t.
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Co
Cop py
t. rig
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♦ Install the drive plate. Refer to ⇒ “5.7 Drive Plate”, page 53 .
ht
pyri by
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cted
♦ Or, install the flywheel. Refer to ⇒ “5.8 Flywheel”, page 54 .
agen
Prote AG.
install the plug.
♦ Fill the coolant. Refer to
Component Nm
Flywheel/drive plate to crankshaft 60 + an addi‐
♦ Replace bolts tional 90° (1/4)
turn
5.10 Piston
♦ Drip Tray - VAG1306- or Drip Tray for VAS6100 - VAS6208-

Golf 2004 ➤ , Golf 2009 ➤
♦ Spring Type Clip Pliers - VAS5024A-

♦ Polydrive Bit and Drive Socket - T10070-
♦ Ignition Coil Puller - T40039-
Removing
– Remove the engine. Refer to
⇒ “3.2 Engine, Removing”, page 9 .
– Separate the engine and transmission. Refer to
⇒ “3.3 Engine and Transmission, Separating”, page 14
– Secure the engine to the engine and transmission holder. Re‐
fer to agen
AG. Volkswagen AG d
oes
⇒ “3.4 Engine, Securing to the Engine and Transmission Hold‐olksw not
yV gu
er VAS6095 ”, page 18 . sed b ara
n ri tee
ho
– Remove the cylinder head. Refer to aut or
ac
⇒ “4.2 Cylinder Head”, page 80 . ss
ce
e
nl
pt
du
– Remove the upper oil pan. Refer to
an
itte
y li
⇒ “4.2 Upper Oil Pan”, page 109 .
erm
ab
ility
ot p
– Mark the installed position and cylinder allocation on the piston
wit
to be removed.
, is n
h re
hole
– Remove the connecting rod bearing cap and pull the piston
spec
and connecting rod upward.
es, in part or in w
t to the co
Note
rrectness of i
Heat the piston to approximately 60 °C (140 °F) if it is difficult to
l purpos
move the piston pin.
nform
ercia
– Remove the circlip from the eye of the piston pin.

m
at
om
– Remove the piston pin using a Pilot Drift - VW222A- .
ion
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in t
or
Installing
his
ate
do
riv
Installation is performed in the reverse order of removal.

p
cum
for
en
g
– Tightening specification. Refer to

n
t.
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⇒ “2.9 Pistons and Connecting Rod Overview”, page 38 . Cop py
t. rig
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pyri by
Vo
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cted
Note
agen
Prote AG.
♦ Replace the bolts which have been tightened to a torque an‐

gle.
♦ The arrow on the piston face points toward the belt pulley side.
♦ Offset the piston ring gap by 120° .
– Coat the contact surfaces on the bearing shells with oil.

– Install the piston with a piston ring compressor. Pay attention
to the installed position.
– Install the connecting rod bearing cap. Pay attention to the in‐
stalled position.
– Install the upper oil pan. Refer to
– Install the cylinder head. Refer to

Golf 2004 ➤ , Golf 2009 ➤
– Install the transmission to the engine. Refer to

⇒ “3.3 Engine and Transmission, Separating”, page 14 .
– Install the engine. Refer to
⇒ “3.5 Engine, Installing”, page 20 .
lkswage es n
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tho
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an
d
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
6 Special Tools
♦ Micrometer 75-100 mm - VAS6071-
♦ Cylinder Gauge - VAS6078-
Volkswagen AG
♦ Locking Pin - T40069- swagen AG. does
k not
Vol gu
♦ Dial Gauge Holder by
ed - VW387- ara
ris nte
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hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Dial Gauge 0-10 mm - VAS6079-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
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fo
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ng
t.
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Cop py
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pyri by
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co lksw
by
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♦ Locking Pin - T10060A- Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
♦ Oil Seal Guide Sleeve - T03004-
♦ Assembly Tool - T10122- olkswage es n
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spec
♦ Pulling Hook - T20143- 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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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Special Tools 61
Golf 2004 ➤ , Golf 2009 ➤
♦ Drip Tray - VAG1306- or

Drip Tray for VAS6100 -
VAS6208-
♦ Torque Wrench (5-50 Nm) -
VAG1331-
♦ Torque Wrench (40-200
Nm) - VAG1332-
♦ Spring Type Clip Pliers -
VAS5024A-
♦ Polydrive Bit and Drive
Socket - T10070-
♦ Ignition Coil Puller -
T40039-
AG. Volkswagen AG d
agen oes
olksw not
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spec
es, in part or in w
t to the co
rrectness of i
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mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
15 – Cylinder Head, Valvetrain

AG. Volkswagen AG d
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1 Description and Operation ed byV
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ara
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⇒ “1.1 Cylinder Head Overview”, page
aut 63
ho eo
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⇒ “1.2 Timing Chain Routing Overview”, page 65
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nl
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⇒ “1.3 Camshaft Timing Chain Overview”, page 66
itte
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⇒ “1.4 Oil Pump Timing Chain Overview”, page 67
ility
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⇒ “1.5 Valvetrain Overview”, page 68
h re
hole
spec
1.1 Cylinder Head Overview
es, in part or in w
t to the co
1 - Bolt
rrectness of i
❑ 10 Nm
l purpos
2 - Cylinder Head Cover

❑ With the pressure regu‐
lator valve for the crank‐
nform
ercia
shaft housing ventila‐

m
tion.
at
om
ion
❑ Tightening sequence.
c
in t
or
Refer to
his
ate
⇒ Fig. ““Cylinder Head
do
priv
c
Cover Bolt Tightening
um
for
Sequence”“ ,
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ng
t.
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page 64 . . Cop py
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❑ Removing and instal‐ rig ht
py by
ling. Refer to
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cted
⇒ “4.1 Cylinder Head
agen
Prote AG.
Cover”, page 79 .
3 - Cylinder Head Cover Gas‐
ket
❑ Replace if damaged or
leaking.
4 - Crankcase Ventilation Hose
❑ To the intake manifold.
5 - Cap
6 - Gasket
❑ Replace if damaged or
leaking.
7 - Bolt
❑ 10 Nm
8 - Wire Bracket
9 - Seal
ling. Refer to ⇒ “4.5 Timing Chain Cover Seal”, page 88 .
10 - Wire Bracket
11 - Timing Chain Cover
❑ Removing and installing. Refer to ⇒ “4.4 Timing Chain Cover”, page 86 .
12 - Bolt
❑ 2 Nm

Golf 2004 ➤ , Golf 2009 ➤
13 - Camshaft Adjustment Valve 1 - N205-

❑ Check using the vehicle diagnostic tester.
14 - O-Ring
❑ Replace if damaged.
15 - Bolt
❑ 10 Nm
16 - Camshaft Position Sensor - G40-
17 - Transport Strap
18 - Bolt
❑ 25 Nm
19 - Cylinder Head Gasket n AG. Volkswagen AG do
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❑ Always replace. byV
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ed ran
❑ After replacing, replace
hor the entire amount of coolant.
is tee
t or
au ac
20 - Cylinder Head ss
ce
le
❑ Removing and installing. Refer to ⇒ “4.2 Cylinder Head”, page 80 .

un
pt
an
d
itte
❑ Checking the cylinder head for warpage. Refer to
y li
erm
ab
⇒ Fig. ““Checking the Cylinder Head for Distortion”“ , page 65 .
ility
ot p
❑ It is not permitted to rework the sealing surface.
wit
is n
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❑ With the coolant pipe connection pressed in.
ole,
spec
– If necessary, remove any coolant deposits with a brass wire brush or with a fine sandpaper (minimum
t to the co
100 grit).
– If the pipe connection is worn, replace it using Liquid Locking Fluid - D000600A2- .
21 - Cap rrectnes
❑ Only on engines with Secondary Air Injection (AIR).

s o
cial p
❑ AIR system overview. Refer to ⇒ “1.1 Secondary Air Injection System Overview”, page 177 .
inform
mer
22 - Gasket
atio
m
❑ Always replace.
o
n
c
i
or
n thi
23 - Bolt
te
sd
va
❑ 40 Nm + an additional 180° (1/2) additional turn.

i
o
pr
cum
r
fo
❑ Always replace.
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ng
t.
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op
❑ Follow the loosening and tightening sequence. Refer to ⇒ “4.2 Cylinder Head”, page 80 . C py
t. rig
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yri
24 - Wire Bracket
p by
co Vo
by lksw
cted
❑ For the Heated Oxygen Sensor - G39- .
agen
Prote AG.
Cylinder Head Cover Bolt Tightening Sequence
64 Rep. Gr.15 - Cylinder Head, Valvetrain

Golf 2004 ➤ , Golf 2009 ➤
Checking the Cylinder Head for Distortion

– Check the cylinder head at multiple points for distortion, using
a straight edge and feeler gauges.
♦ Maximum permissible distortion: 0.05 mm
If this value is exceeded, the cylinder head must be replaced. It
is not permissible to rework the sealing surface.
1.2 Timing Chain Routing Overview
1 - Exhaust Camshaft Sprock‐

et
2 - Camshaft Timing Chain,
Chain Tensioner
❑ At the top, with a sliding
insert.
3 - Camshaft Timing Chain
4 - Camshaft Timing Chain
Tensioning Rail agen
AG. Volkswagen AG d
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❑ For the chain tensioner d byV gu
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for the timing chain. orise nte
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❑ Secured to the cylinder ss a ra
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block.
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an
5 - Oil Pump Timing Chain,
d
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Chain Tensioner
rm
ab
pe
❑ With the tensioning rail. ility

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6 - Crankshaft Sprocket
hole
spec
❑ Component of the
es, in part or in w
crankshaft.
t to the co
7 - Oil Pump Timing Chain

Guide Rail
rrectness of i
❑ Secured to the upper oil

pan.
l purpos
8 - Oil Pump Sprocket

nform
ercia

ling. Refer to one of the
m
a
com
following:
ion in
r
te o
Engine codes BGP and

thi
s
iva
BGQ. Refer to
do
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rp
⇒ “4.3 Oil Pump”,

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fo
page 112 .
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ng
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Cop py
Engine codes CBTA and ht. rig
rig ht
CBUA. Refer to ⇒ “4.4 Oil Pump”, page 115 . py by
co Vo
by lksw
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Prote
9 - Oil Pump Timing Chain Guide Rail
AG.

❑ From MY 2008 the roller chain has been changed to a toothed chain.

Golf 2004 ➤ , Golf 2009 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition
AG. V07.2014
olkswagen A
n G do
wage es n
Volks ot g
11 - Camshaft and Oil Pump Timing Chains Double
ed
by Sprocket ua
ran
oris tee
12 - Camshaft Timing Chain Guide Rail auth or
ac
ss
13 - Intake Camshaft Adjuster
ce
le
un
pt
❑ With a chain sprocket.
an
d
itte
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ab
pe
ility
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1.3 Camshaft Timing Chain Overview
h re
hole
spec
es, in part or in w
t to the co
1 - Intake Camshaft Adjuster
❑ With the chain sprocket.
❑ Do not disassemble.
rrectness of i
l purpos
et
❑ Not pressed on the cam‐
nform
ercia
shaft.
m
❑ When removing, pry off
a
com
tio
lightly, if necessary.
n in
r
te o
thi
3 - Cylinder Head
s
iva
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rp
c
4 - Tensioning Rail
um
fo
en
ng
❑ For the chain tensioner

t.
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for the camshaft timing
C py
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chain. rig ht
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❑ Secured to the cylinder
by
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block.
AG.
❑ Oil before installing on

the pin.
5 - Double Sprocket
❑ Securing. Refer to
⇒ “1.4 Oil Pump Timing
Chain Overview”,
page 67 .
6 - Timing Chain
❑ Removing:
– Follow the procedure for
the “valve timing, adjust‐
ing”. Refer to
⇒ “3.3 Valve Timing, Ad‐
justing”, page 75 .
– Remove the vacuum

pump. Refer to
⇒ “4.3 Vacuum Pump”,
page 84 .
– Mark the direction of travel.

❑ Note when installing:
– Install in the original direction of rotation.
– The chain must lie correctly in the tensioning and guide rails.
– Adjust the valve timing. Refer to ⇒ “3.3 Valve Timing, Adjusting”, page 75 .
7 - Strainer
❑ Always replace.

Golf 2004 ➤ , Golf 2009 ➤
8 - Bolt
❑ 10 Nm
9 - Chain Tensioner
❑ Secure using a Locking Pin - T03006- .
10 - Gasket
❑ Always replace.
11 - Guide Rail n AG. Volkswagen AG do
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❑ Oil before
y V installing on the pin.
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12 - Boltthoris tee
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❑ ss 60 Nm + an additional 90° (1/4) additional turn. ac
a
ce
le
❑ Always replace.
un
pt
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itte
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13 - Bolt
rm
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pe
ility
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❑ Always replace.
h re
hole
spec
es, in part or in w
t to the co
1.4 Oil Pump Timing Chain Overview
rrectness of i
1 - Cylinder Block
l purpos
2 - Guide Rail
❑ Secured to the upper oil
nform
ercia
pan.
m
❑ Oil before installing on

a
com
ti
the pin.
on in
r
te o
thi
3 - Chain Tensioner
s
iva
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❑ Secure using a Locking

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Pin - T10115- .
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4 - Bolt C py
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❑ 10 Nm yri
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cted
5 - Oil Pump Sprocket
agen
Prote AG.

following:
BGQ. Refer to
page 112 .
Engine codes CBTA and

CBUA. Refer to
page 115 .

❑ From MY 2008 the roller
chain has been
changed to a toothed
chain.
❑ Removing:
– Remove the engine.
– Remove sealing flange,

transmission side.

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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Golf 2004 ➤ , Golf 2009 ➤ autho eo
ra
Engine Mechanical, Fuel Injection and Ignition - Edition 07.2014 ss c
ce
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nl
pt
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an
– Remove the timing chain.
itte
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– Remove the chain tensioner -3-.
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– Mark the direction of travel.
hole
spec
❑ Note when installing:
es, in part or in w
t to the co
– Install in the original direction of rotation.
– The chain must lie correctly in the tensioning and guide rails.
rrectness of i
– Adjust the valve timing. Refer to ⇒ “3.3 Valve Timing, Adjusting”, page 75 .
7 - Bolt l purpos
nf
ercia
orm
m
atio
❑ Always replace.
om
n in
c
8 - Guide Rail
or
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te
sd
a
❑ Oil before installing on the pin.

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9 - Bolt
f
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ng
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❑ 10 Nm t. Cop py
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10 - Axial Bearing Disc yri
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❑ Engages in the groove in the double sprocket -12-. cted agen
Prote AG.
11 - Bolt
❑ 60 Nm + 90° (1/4) additional turn.
❑ Always replace.
12 - Camshaft and Oil Pump Timing Chains Double Sprocket
❑ Oil the journal before installing.
❑ Lubricate the axial bearing disc groove.
13 - Gear Shaft
14 - Threaded Pin
❑ 40 Nm
❑ For the camshaft timing chain tensioning rail.
1.5 Valvetrain Overview
Note
♦ Cylinder heads with cracks between the valve seats, or be‐

tween the valve seat and the spark plug threads, can continue
to be used without reducing the service life, as long as the
cracks have a Max. width of 0.3 mm, or only the first 4 threads
of the spark plug threads are cracked.
♦ The cylinder head and guide frame must be replaced together.
♦ Do not grind the valve seats in the cylinder head. Only hand
lapping the valves is permitted.
♦ Do not start the engine for approximately 30 minutes after in‐
stalling the camshafts. The hydraulic lash adjusters must seat
themselves (otherwise the valves will crash into the pistons).
♦ After working on the valvetrain and adjusters, carefully rotate
the crankshaft by hand at least 2 full revolutions before starting
to be sure that the valves do not strike the pistons.
♦ Always replace the gaskets and seals.

Golf 2004 ➤ , Golf 2009 ➤
1 - Bolt
❑ 8 Nm + an additional 90°
(1/4) additional turn. agen
AG. Volkswagen AG d
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❑ Always replace. by Vo gu
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2 - Guide Frame uthor eo
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❑ Removing and instal‐ ss c
ling. Refer to
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⇒ “4.6 Camshaft”,
an
itte
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page 89 .
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ility
❑ With integrated cam‐
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shaft bearings.
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❑ Clean the sealing sur‐
hole
spec
face, reworking is not
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❑ Remove any old sealant
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❑ For the camshaft adjust‐

er.
tion. Refer to
⇒ “4.6 Camshaft”, page 89 .
8 - Timing Chain
❑ Removing from the sprockets. Refer to ⇒ “3.3 Valve Timing, Adjusting”, page 75 .
9 - Cylinder Head
❑ Do not grind the valve seats, only hand lapping is permitted.
10 - Roller Rocker Arm with Hydraulic Lash Adjuster
❑ Do not interchange.
❑ Lubricate the contact surface.
11 - Valve Retainers
12 - Upper Spring Seat
13 - Valve Spring
14 - Valve Stem Seal
❑ Removing and installing. Refer to ⇒ “4.7 Valve Shaft Seals”, page 92 .
15 - Valve Guide
❑ Checking. Refer to ⇒ “3.4 Valve Guide, Checking”, page 78 .
16 - Intake Valve
❑ Do not grind, only hand lapping is permitted.
❑ Valve dimensions. Refer to ⇒ “2.1 Valve Dimensions”, page 71 .

Golf 2004 ➤ , Golf 2009 ➤
❑ Valve guide, checking. Refer to ⇒ “3.4 Valve Guide, Checking”, page 78 .
17 - Exhaust Valve
❑ Do not grind, only hand lapping is permitted.
❑ Valve dimensions. Refer to ⇒ “2.1 Valve Dimensions”, page 71 .
❑ Valve guide, checking. Refer to ⇒ “3.4 Valve Guide, Checking”, page 78 .
18 - Sealing Plug
❑ Always replace.
❑ Installing. Refer to ⇒ “4.6 Camshaft”, page 89 .
19 - Intake Camshaft
❑ Removing and installing. Refer to ⇒ “4.6 Camshaft”, page 89 .
❑ Check the radial clearance using Plastigage® (roller rocker arm is removed).
Wear limit: 0.1 mm
Run out: maximum 0.035 mm
Axial clearance: maximum 0.17 mm
20 - Exhaust Camshaft
❑ Removing and installing. Refer to ⇒ “4.6 Camshaft”, page 89 .
❑ Check the radial clearance using Plastigage® (roller rocker arm is removed).
Wear limit: 0.1 mm
Run out: maximum 0.035 mm
Axial clearance: maximum 0.17 mm

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Golf 2004 ➤ , Golf 2009 ➤
2 Specifications
⇒ “2.1 Valve Dimensions”, page 71
2.1 Valve Dimensions
Note
Intake and exhaust valves must not be refaced by grinding. Only

hand lapping is permitted.
Dimension Intake Valve Exhaust Valve

Diameter mm 32.25 to 32.45 27.90 to 28.10
a
Diameter mm 5.97 to 5.99 5.93 to 5.95
b
c mm 103.90 to 104.00 101.85 to 101.90
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– Then tighten bolts -13- to 10 Nm.
Golf 2004 ➤ , Golf 2009 ➤

⇒ “3.1 Compression Pressure, Checking”, page 72
⇒ “3.2 Valve Timing, Checking”, page 73
⇒ “3.3 Valve Timing, Adjusting”, page 75
⇒ “3.4 Valve Guide, Checking”, page 78
3.1 Compression Pressure, Checking

♦ Spark Plug Removal Tool - 3122B-
♦ Compression Tester - VAG1763-
♦ Adapter - VAG1381/5A-
Test Conditions
• The engine oil temperature must be at least 30 °C (86 °F).
• The voltage supply is OK.
⇒ “5.1 Engine Cover with Air Filter”, page 159 . agen
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– Remove the spark plugs using the Spark Plug Removal Tool
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– Check the compression using the Compression Tester -
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Using the compression tester. Refer to the operating instructions.

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– Operate the starter until the tester no longer indicates that the
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Compression Pressure
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New Wear Limit Difference Between

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By disconnecting the connectors, Diagnostic Trouble Codes
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(DTCs) are stored to memory. After the test, check the DTC
memory and erase, if necessary.
– Read the Engine Control Module (ECM) DTC memory. Refer

to the vehicle diagnostic tester.

Golf 2004 ➤ , Golf 2009 ➤
3.2 Valve Timing, Checking

♦ Camshaft Clamp - T40070-
Procedure
– Remove the cylinder head cover. Refer to
⇒ “4.1 Cylinder Head Cover”, page 79 .
– Install the Crankshaft Adapter - T03003- onto the vibration
damper bolts.
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If the threaded holes in the camshafts -arrows- do not point up‐

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rotation direction.
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Golf 2004 ➤ , Golf 2009 ➤
– Remove the locking bolt -1- from the rear of the cylinder block.
– Look the through threaded hole and check whether the bore
-2- in the crankshaft aligns with the threaded hole.
Use a mirror to do so.
– If he hole and bore align, install the Locking Pin - T40069-
completely into the threaded hole and tighten it to 10 Nm.
If the crankshaft was rotated out past the TDC mark:
– Rotate the crankshaft back 45° in the opposite direction of en‐
gine rotation.
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-A and B- must align.
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– Check whether the crankshaft can be rotated.
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The valve timing is correct when the Camshaft Clamp - T40070-
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also correct. Possibly the crankshaft was not secured correctly.
If the Camshaft Clamp - T40070- Cannot Be Installed
The valve timing is incorrect when the Camshaft Clamp - T40070-
bolts cannot be installed easily into the ends of the camshafts
despite the tensioned chain.
♦ In this case, the valve timing must be adjusted. Refer to
⇒ “3.3 Valve Timing, Adjusting”, page 75 .

Golf 2004 ➤ , Golf 2009 ➤
-1- to the rear of the cylinder block.
cedure.
Component Nm
Locking bolt to rear of cylinder block 30 Nm
3.3 Valve Timing, Adjusting

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– Secure the completely pressed in piston using the Locking Pin

- T03006- . the pin must be inserted until it stops.
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– Rotate the crankshaft so that the Camshaft Clamp - T40070-
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can be installed easily onto the camshafts as shown.

– Tighten bolts for the Camshaft Clamp - T40070- to 20 Nm.
Remove the Camshaft Sprocket or Adjuster

Golf 2004 ➤ , Golf 2009 ➤
– Relieve the tension on the timing chain. To do so, insert a

screwdriver of appropriate size between the piston of the chain
tensioner and tensioning rail and press the screwdriver in the
direction of the -arrow-.
– Secure the completely pressed in piston using the Locking Pin
- T03006- . The pin must be inserted until it stops.
– Remove the bolts -1 and 4- using the Multipoint Socket -
T10035- and remove the actuator -2- and the sprocket -3-.
If necessary, the sprocket -3- must be pryed off lightly using a
screwdriver.
Note
Lock the crankshaft. Refer to

⇒ “2.8 Crankshaft, Locking”, page 36 if not yet locked. The crank‐
shaft must only be rotated slightly around the TDC point for this.
Otherwise there is a risk the valves will rest on the pistons.
Adjusting the Timing

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• The camshafts are secured by the Camshaft Clamp - T40070-
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camshaft sprocket -4-.
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Note
When applying the additional 90° torque angle, the timing chain
must no longer be held at preload.

Golf 2004 ➤ , Golf 2009 ➤
– Remove the Camshaft Clamp - T40070- .
– Remove the Locking Pin - T40069- for securing the crankshaft.

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exhaust valve guides.
– Determine the tilt clearance.
Wear limit: 0.8 mm
If the tilt clearance is exceeded:
– Replace the cylinder head.

Golf 2004 ➤ , Golf 2009 ➤

⇒ “4.1 Cylinder Head Cover”, page 79
⇒ “4.2 Cylinder Head”, page 80
⇒ “4.3 Vacuum Pump”, page 84
⇒ “4.4 Timing Chain Cover”, page 86
⇒ “4.5 Timing Chain Cover Seal”, page 88
⇒ “4.6 Camshaft”, page 89
⇒ “4.7 Valve Shaft Seals”, page 92
4.1 Cylinder Head Cover

♦ Torque Wrench - VAG1331-
Removing
– Disconnect crankcase ventilation hose -arrow-.
– Remove the Secondary Air Injection (AIR) pipe -A-, if equip‐
ped.
– Remove the ignition coils -1 through 5-. Refer to
⇒ “3.1 Ignition Coil with Power Output Stage”, page 199 .
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Replace the cylinder head cover if damaged or leaking.
– Clean the sealing surfaces so they are completely free of any

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Golf 2004 ➤ , Golf 2009 ➤
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valves immediately before fitting the cylinder head.
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♦ When replacing the cylinder head or cylinder head gasket, the
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♦ Drip Tray for VAS6100 - VAS6208-

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♦ Make sure there is enough clearance to moving or hot
components to prevent damage to the lines.
Removing
Gr. 27 ; Removal and Installation .

Golf 2004 ➤ , Golf 2009 ➤
– Remove the bolts -arrows- and remove the battery tray from
the vehicle.
WARNING
– Remove the intake manifold. Refer to

⇒ “5.3 Intake Manifold”, page 161 .
– Install the transport strap back onto the cylinder head in order
to better hold the cylinder head during removal.
– Secure the camshafts and remove the adjuster and sprocket
from the camshafts. Refer to
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– Remove the wire bracketau-3-tho bolts -arrows- at the Secondary or
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– Remove the cylinder head bolts in the specified sequence.
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– Carefully remove the cylinder head. Prote
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Installing
Note
♦ There must be no oil or coolant in the blind holes for the cyl‐
inder head bolts in the cylinder block.
♦ Only remove the new cylinder head gasket from its packaging
immediately before installing.
♦ Handle the new gasket with extreme care. Damaging will lead
to leaks.
♦ Replace the cylinder head bolts.
– Insert clean cloths into the cylinder bores and chain compart‐
ment so that no dirt or abrasive powder can penetrate between
the cylinder wall and piston and into the chain compartment.
– Do not allow dirt or abrasive powder to get into the coolant
either.
– Carefully clean the cylinder head and cylinder block sealing
surfaces. Avoid scratching or scoring (do not use sandpaper
with grit below 100).
– Carefully remove any metal particles, emery remains and the
cloths.

Golf 2004 ➤ , Golf 2009 ➤
Note the shelf life date.
– Apply a bead of sealant -1- (front and rear) on the clean sealing
surfaces as shown.
– Install the new cylinder head gasket -2-.
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The cylinder head must be installed within 5 minutes of being ap‐

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– Install the cylinder head.

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– Guide the timing chain over the coolant pipe connection.

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– Insert the cylinder head bolts and tighten them hand tight.
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Golf 2004 ➤ , Golf 2009 ➤
– Then, tighten the cylinder head bolts -1 through 12- in se‐

quence as shown:
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♦ Replace and fill the coolant. Refer to

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♦ Install the battery. Refer to ⇒ Electrical Equipment; Rep. Gr.
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4.3 Vacuum Pump
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Due to installation conditions, the transmission must be removed

on vehicles with a automatic transmission.
Removing
– Remove the bolts -arrows- and remove the battery tray.

Golf 2004 ➤ , Golf 2009 ➤
– Remove intake air duct bolts -arrows- and duct from the lock
carrier.
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– Disconnect the wiring harness from the bracket -2-.
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– Remove the bolt -3- for the coolant pipe.

– Disconnect the vacuum hose -1-.
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– Remove the 3 bolts -arrows- and the vacuum pump.

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– Place the new gasket -2- on the vacuum pump.

– Position the vacuum pump coupling plate -3- so it engages in
the symmetrical groove on the double sprocket -1- when in‐
stalling the vacuum pump -arrows-.
– Install and tighten vacuum pump bolts.
cedure.
Component Nm
Vacuum pump to sealing flange, transmission 10
side
Coolant pipe to bracket 10

Golf 2004 ➤ , Golf 2009 ➤
4.4 Timing Chain Cover

♦ Torque Wrench (5-50 Nm) - VAG1331- agen
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– Remove the coolant pipe at the coolant thermostat housing
and the bracket on the vacuum pump.
– Pull out the retaining clip -arrow- and remove the coolant pipe
-A-.

Golf 2004 ➤ , Golf 2009 ➤
– Disconnect the connectors -1 and 3-.

– Disconnect the connecting pipe -2- from the Secondary Air In‐
jection (AIR) valve.
– Remove the rear coolant pipe -4-.
– Disconnect the vacuum hose -6- from the vacuum pump and
disconnect the connector -7-.
– Remove the brackets -8 and 9- and lay aside the wiring har‐
ness with the pressure pipe.
– Press the bracket for the knock sensor wiring harness at the
AIR valve slightly toward the rear.
– Remove the flange -5- and set it aside with the coolant hoses
connected.
– Remove the timing chain cover bolts.
– Pry off the timing chain cover -1- from the cylinder head -2-
uniformly at the top and bottom recesses.
Note
♦ The sealing surfaces must not be damaged under any circum‐

stances. If necessary, use the Trim Removal Wedge - 3409- .
♦ After removing the timing chain cover, clean the Trim Removal
Wedge - 3409- which is intended for the removal of interior
equipment parts.
Installing
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– Remove the remainder of sealant from the timing chain cover
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and from the cylinder head, using for example, a rotating plas‐
pt
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– Clean the coolant pipe connection on the cylinder head. If

necessary, remove any coolant deposits with a copper wire
rrectness of i
brush or fine sandpaper (minimum 100 grit). If the pipe con‐

nection is worn, replace it using Liquid Locking Fluid -
l purpos
D000600A2- .
– Replace the seal in the timing chain cover. Refer to
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⇒ “4.5 Timing Chain Cover Seal”, page 88 .

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– Replace the seal in the coolant flange.

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Golf 2004 ➤ , Golf 2009 ➤
Note
The timing chain cover must be installed within 5 minutes after

application of the sealant.
AG. Volkswagen A
– Apply the sealant bead -A- as shown waonto
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– Coat the seal for the timing
s
chain cover lightly with engine oil
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– Install all the bolts and tighten them in a diagonal sequence.
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– Fill the coolant. Refer to
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Component Nm
Timing chain cover to cylinder head 10
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Flange to the timing chain cover 10

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♦ Tube 60 mm Dia. - VW415A-

♦ Fitting Sleeve - 3241/4-
Driving Out the Seal

Golf 2004 ➤ , Golf 2009 ➤
Driving in the Seal

– Support the timing chain cover with supports -arrows- on a firm
surface and press in the new seal until it is seated.
4.6 Camshaft
♦ Sealant - D154103A1-
Removing
Note
♦ The sealing surfaces on the bottom of thewguide

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Golf 2004 ➤ , Golfut 2009 ➤
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Engine Mechanical,
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– Then, remove the Camshaft Clamp - T40070- .
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Installing
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– Remove the remainder of the sealant from the guide frame
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– Clean the sealing surfaces, they must be free of oil and grease.
– Oil the journal surfaces of the camshafts.
– Place the guide frame on a soft surface.
– Insert the camshafts correctly into the guide frame.

♦ The intake camshaft with the sensor wheel -2- faces toward
the Camshaft Position Sensor - G40- -1-.
♦ The camshafts must lie exactly in the axial bearings -3- of the
guide frame.
♦ The ends of the seals -4 and 5- must face up or down. They
must not face to the side.
– Turn over the guide frame slightly with the camshafts installed,
hold the camshafts firmly in place in the guide frame while do‐
ing this.
– Rotate the camshafts until the threaded holes -arrows- point

upward.
– Check whether the camshafts still lie exactly in the axial bear‐
ings of the guide frame.

Golf 2004 ➤ , Golf 2009 ➤
– Install the Camshaft Clamp - T40070- as shown to the cam‐

shafts and tighten the bolts to 20 Nm.
– Turn over the guide frame again.
– Lightly apply an even bead of sealant into the clean grooves

of the guide frame -1 through 8-.G. Volkswage
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♦ Installing and securing the guide frame should be performed

without interruption because the sealant begins to harden im‐
mediately as soon as it contacts the sealing surfaces.
rrectness of i
♦ Note the expiration date of the sealant.

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– Place the guide frame onto the cylinder head immediately.

nform
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– Gently tighten the bolts working from the inside toward the
outside in several stages.
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Engine Mechanical,
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– Then, tighten the bolts to 8 Nm in the sequence indicated.
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– The sealant must squeeze out slightly, even in the chain com‐
or
partment area -arrows-.
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– Wipe off the excess sealant on the sealing surface facing the
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– Carefully press in the sealing plugs -A- until they reach the end
of the chamfer -arrows-.
Note
If a sealing plug was pressed in too far, it must be pressed through

and pressed in again up to the mark.
block and install the locking bolt (30 Nm).
4.7 Valve Shaft Seals

(With the cylinder head installed)
♦ Spark Plug Removal Tool - 3122B-
♦ Valve Seal Removal Tool - 3364-
♦ Valve Stem Seal Driver - 3365-
♦ Adapter - T40012-
♦ Valve Cotters Asm/Disasm Device - VAS5161-
♦ Guide Plate for FSI Engine - VAS5161/19B-
Removing
To remove the valve stem seals on some valves, the following
components must be removed:

Golf 2004 ➤ , Golf 2009 ➤
♦ For the intake valves in cylinder 1: The transport strap

♦ For the intake valves in cylinder 5: The Camshaft Adjustment
Valve 1 - N205-
♦ For the exhaust valves in cylinder 5: The Secondary Air Injec‐
tion Solenoid Valve - N112-
– Remove the camshafts. Refer to ⇒ “4.6 Camshaft”, page 89 .
– Remove the roller gerocker
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– Remove
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tee
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Tool
-s3122B- .
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– Install the Guide Plate for FSI Engine - VAS5161/19B- to the

un
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cylinder head using the Knurled Thumb Screws M6 -
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– Adjust the piston of the respective cylinder to the Bottom Dead
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– Install the Adapter - T40012- into the spark plug threads and
connect the compressed air hose (minimum 6 bar (87 psi)).
t to the co
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– Loosen any stuck valve retainers using the Punch -

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VAS5161/3- and a plastic mallet.

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– Install the Retainer - VAS5161/6- with the Guide Forks M6/M8

with Threaded Studs - VAS5161/5- into the Guide Plate for FSI
Engine - VAS5161/19B- .
– Insert the Assembly Cartridge - VAS5161/8- into the Guide
Plate for FSI Engine - VAS5161/19B- .
– Engage the Pressure Fork with Lever for Assembly Cartridge
- VAS5161/2- on the retainer - VAS5161/6- .

Golf 2004 ➤ , Golf 2009 ➤
Note
The Pressure Fork with Lever for Assembly Cartridge -

VAS5161/2- must engage on the exhaust side as illustrated.
– Press down the Assembly Cartridge - VAS5161/8- . At the

same time, turn the knurled thumb screw on the Assembly
Cartridge - VAS5161/8- clockwise until the points engage in
the valve retainers.
– Lightly move the knurled thumb screw on the assembly car‐ AG. Volkswagen
tridge back and forth, this causes the valve retainers lto wbe
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– Release the Pressure fork with Lever for Assembly
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– Remove the Assembly Cartridge - VAS5161/8- , valve spring
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Tool - 3364- .
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Tool - 3364- , drive the roll pin -arrow- out using a drift and
AG.
remove the impact attachment.

– Place the lower part of the Valve Seal Removal Tool - 3364-
onto the valve stem seal.
– Insert the drift -1- into the bore in the lower part of the removal
tool.

Golf 2004 ➤ , Golf 2009 ➤
– Using the drift as a lever, pull out the valve stem seal in the
direction of the -arrow-.
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– Place the plastic sleeve -A- on the valve stem to prevent dam‐
t to the co
age to the new valve stem seal -B-.
– Oil the sealing lip of the valve stem seal -B-, insert it into the
Valve Stem Seal Driver - 3365- and carefully slide it onto the
rrectne
valve guide.
s
– Remove the plastic sleeve -A-.
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– Insert the valve spring and valve spring retainers.
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– Install the Valve Cotters Asm/Disasm Device - VAS5161-
atio
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components as illustrated.
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Exhaust Side

Golf 2004 ➤ , Golf 2009 ➤
Engine Mechanical, Fuel Injection and. V
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Ignition
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AG d 07.2014
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♦ If the valve retainers were removed from the assembly car‐
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insertion device from above and take up the valve retainers.
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– Press the Assembly Cartridge - VAS5161/8- with the Pressure
t to the co
Fork With Lever For Assembly Cartridge - VAS5161/2- down.
Tap lightly against the lower area of the assembly cartridge.
Rotate the knurled thumb screw on the assembly cartridge
rrectness of i
back and forth and pull it upward.
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– Release the Pressure Fork with Lever for Assembly Cartridge

- VAS5161/2- with the knurled thumb screw pulled.
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– Remove the Valve Cotters Asm/Disasm Device - VAS5161-

components.
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Golf 2004 ➤ , Golf 2009 ➤
5 Special Tools
♦ Universal Dial Gauge Mount - MP3-447-
♦ Locking Pins - T03006-
♦ Multipoint Socket - T10035-
♦ Spring Type Clip Pliers - VAS6499-
♦ Valve Seal Removal Tool - 3364-
♦ Valve Stem Seal Driver - 3365- lkswage es n
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♦ Adapter - T40012- ir se
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♦ Valve Cotters Asm/Disasm Device
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♦ Guide Plate for FSI Engine - VAS5161/19B-

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5. Special Tools 97
Golf 2004 ➤ , Golf 2009 ➤
♦ Spark Plug Removal Tool -

3122B-
♦ Ignition Coil Puller -
T40039-
VAG1331-
♦ Compression Tester -
VAG1763-
♦ Adapter - VAG1381/5A-
AG. Volkswagen AG d
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Golf 2004 ➤ , Golf 2009 ➤
♦ Arbor - VW195-
♦ Tube 60 mm Dia. -
VW415A-
♦ Fitting Sleeve - 3241/4-
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5. Special Tools 99
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Engine Mechanical, Fuel Injection and dIgnition
by - Edition 07.2014 ua
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17 – Lubrication
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⇒ “1.1 Engine Oil”, page 100
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⇒ “1.2 Oil Filter Housing, Draining”, page 100 es, in part or in w
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1.1 Engine Oil
Oil Capacity
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For the engine oil capacity. Refer to the Fluid Capacity Tables,
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Rep. Gr. 03.

Viscosity Class and Oil Specification
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For the viscosity class and specification. Refer to the Fluid Ca‐
m
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pacity Tables, Rep. Gr. 03.
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Oil Dipstick Marks
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1 - MAX. mark
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2 - MIN. mark
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a - Oil level in area of the MAX mark: Do not add engine oil.
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b - Oil level in the center area: Oil can be added.
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c - Oil level in area of the MIN. mark: Add approximately 0.5 liter
(0.52 quart) of engine oil.
1.2 Oil Filter Housing, Draining
Note
When installing the Oil Drain Adapter - T40057- , a valve in the

oil filter housing is opened. If the oil drain adapter - T40057- is
removed, the valve is closed again.

♦ Oil Drain Adapter - T40057-
– Remove the cap -arrow- from the oil filter housing.
100 Rep. Gr.17 - Lubrication

Golf 2004 ➤ , Golf 2009 ➤
– Hold the Oil Drain Adapter - T40057- hose in a drip tray and
install the Oil Drain Adapter - T40057- all the way onto the oil
filter housing -2-.
– Allow the engine oil to drain.
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Golf 2004 ➤ , Golf 2009 ➤

⇒ “2.1 Oil Pan and Oil Pump Overview”, page 102
⇒ “2.2 Oil Filter Adapter Overview”, page 104
2.1 Oil Pan and Oil Pump Overview
Note
♦ If large quantities of metal particles or abraded material are

detected during engine repairs, it may mean the crankshaft or
rod bearings are damaged. To prevent further damage, per‐
form the following steps after the repair:
♦ Clean the oil passages carefully.
♦ Replace the oil spray jets.
♦ Replace the engine oil cooler.
♦ Replace the oil filter element.
1 - Cylinder Block n AG. Volkswagen AG do

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2 - Oil Pump Timing Chain d byV
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❑ Beginning with MY 2008 tho tee
or
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ce
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chain.
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3 - Bolt
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90° (1/4) turn.
is n
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❑ Always replace.
spec
4 - Bolt
t to the co
❑ 25 Nm
rrectne
⇒ “2.2 Oil Filter Adapter
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6 - Oil Pump Sprocket f inform

mer

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page 112 . Cop py
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Engine codes CBTA and cop Vo
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CBUA. Refer to
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page 115 .
❑ Lettering points out‐
ward.
❑ With an anti-twist mech‐
anism.
7 - Oil Pump
❑ Removing and installing. Refer to one of the following:

Golf 2004 ➤ , Golf 2009 ➤
Engine codes BGP and BGQ. Refer to ⇒ “4.3 Oil Pump”, page 112 .
Engine codes CBTA and CBUA. Refer to ⇒ “4.4 Oil Pump”, page 115 .
8 - Bolt wage
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❑ 25 Nm d byV
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9 - Oil Dipstick utho
or
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❑ The oil level must not be above the MAX. mark!
ss
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10 - Retaining Ring
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❑ Clipped in at the intake manifold.
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11 - Guide Tube
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12 - Intake Manifold Support
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spec
❑ Only for engines with a Secondary Air Injection (AIR) system.
es, in part or in w
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13 - Bolt
❑ 25 Nm
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14 - O-Ring
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❑ Always replace.
15 - Seal
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❑ Always replace.
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16 - Bracket
ion in
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17 - Bolt
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❑ 10 Nm
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18 - Lower Oil Pan

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❑ Removing and installing. Refer to ⇒ “4.1 Lower Oil Pan”, page 108 .
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19 - Bolt cop Vo
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❑ 10 Nm Prote AG.
20 - Oil Pan Drain Plug

❑ 30 Nm
❑ Always replace.
21 - Coupling Element
❑ Bolt - 10 Nm
22 - Oil Intake Pipe
23 - Bolt
❑ 25 Nm
24 - Upper Oil Pan
❑ Removing and installing. Refer to ⇒ “4.2 Upper Oil Pan”, page 109 .
25 - O-Ring
❑ Always replace.

Golf 2004 ➤ , Golf 2009 ➤
Engine Mechanical, Fuel Injection and Ignition n AG. Volk07.2014
ag-eEdition
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2.2 Oil Filter Adapter Overview
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1 - Bolt
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❑ 25 Nm
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❑ Removing:
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– Drain the coolant. Refer
es, in part or in w
to
t to the co
⇒ “1.1 Coolant, Draining
and Filling”, page 121 .
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– Remove the intake
manifold. Refer to
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⇒ “5.3 Intake Manifold”,

page 161 .
nf
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– Unscrew connection for
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thermostat.
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– Disconnect the coolant
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remove it.
– Loosen the intake mani‐

fold support, if necessa‐
ry.
– Remove the oil filter

adapter bolts, the vent
hose -item 6- remains
connected.
3 - Gasket
❑ Always replace.
4 - Oil Pressure Switch - F1-
❑ 20 Nm
❑ 1.4 bar (20.30 psi), black connector.
❑ Checking. Refer to ⇒ “3.1 Oil Pressure and Oil Pressure Switch, Checking”, page 106 .
5 - From the Intake Tube
❑ -3- refer to ⇒ “2.2 Engine Cover with Air Filter Overview”, page 150 .
6 - Vent Hose
❑ Because of the 4 pin retainer, disconnect only when the oil filter is removed.
7 - Cap
8 - Oil Filter Housing
❑ 25 Nm
❑ Remove and install using the Oil Filter Wrench - 3417- .
❑ Draining. Refer to ⇒ “1.2 Oil Filter Housing, Draining”, page 100 .
9 - Seal
❑ Always replace.
❑ Insert when lubricated.
❑ Installed position: Service flag upward.

Golf 2004 ➤ , Golf 2009 ➤
10 - Oil Filter Element

❑ Drain the oil filter housing before removing. Refer to ⇒ “1.2 Oil Filter Housing, Draining”, page 100 .
❑ Replacing. Refer to “Engine Oil, Draining or Extracting, Changing Oil Filter and Filling Oil” Maintenance
Procedures, Rep. Gr. 03, Maintenance Procedures.
11 - Gasket
❑ Always replace.
12 - Engine Oil Cooler
❑ See the note. Refer to ⇒ “2.1 Oil Pan and Oil Pump Overview”, page 102 .
❑ Make sure there is enough space to the surrounding components.
❑ Coolant hose connection diagram. Refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 124 .
13 - Bolt
❑ 25 Nm
14 - To the Thermostat Housing
15 - Gasket
❑ Always replace.
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Golf 2004 ➤ , Golf 2009 ➤

⇒ “3.1 Oil Pressure and Oil Pressure Switch, Checking”,
page 106
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Special tools and workshop equipment
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♦ Oil Pressure Gauge - VAG1342-
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♦ Voltage Tester - VAG1527B-
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♦ Socket 24 mm and Jointed Extension - T40175-
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• The engine oil level is OK
t to the co
• The engine oil temperature at least 80 °C (176 °F) (the coolant
fan must start up once).
rrectness of i
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Note
nform
ercia
For the function test and servicing the optical and acoustic oil
pressure indicator. Refer to the wiring diagrams and to “Function
m
a
and Component Selection” in the vehicle diagnostic tester.
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Golf 2004 ➤ , Golf 2009 ➤
– Remove the Oil Pressure Switch - F1- and install it in the pres‐
sure gauge.
– Thread the oil pressure gauge into the oil filter adapter, in place
of the oil pressure switch.
– Connect the brown wire on the gauge to ground (-).
– Connect the Voltage Tester - VAG1527B- using an adapter
cable from the connector test set - VAG1594C- to battery pos‐
itive (B+) and the oil pressure switch. The Light Emitting Diode
(LED) must not light up. gen AG
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– If the LED lights up, replace
d b the oil pressure switch.
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If the LED does not light uup:
tho eo
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– Start the engine and increase the engine speed: The LED
ce
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nl
must illuminate at 1.2 to 1.6 bar (17.4 to 23.2 psi). Replace the
pt
du
an
oil pressure switch if it does not.
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– Increase the engine speed further. At 2000 RPM and an oil
ility
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temperature of 80 °C (176 °F), the oil pressure must be be‐
wit
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tween 2.7 and 4.5 bar (39.16 to 65.26 psi).
h re
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spec
At higher engine speeds the oil pressure must not exceed 7.0 bar
es, in part or in w
(101.52 psi)
t to the co
If the specification is not obtained:
rrectness of i
– Check the screen in the oil intake pipe for contamination.
l purpos
Note
nform
ercia
Also, mechanical damage, for example, bearing damage can also

m
at
be the cause of too low oil pressure.
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If no malfunction can be found:

at
do
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– Replace the oil pump. Refer to one of the following:

um
for
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Engine codes BGP and BGQ. Refer to
Co
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⇒ “4.3 Oil Pump”, page 112 .
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Engine codes CBTA and CBUA. Refer to
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⇒ “4.4 Oil Pump”, page 115 . Prote AG.
If the specification is exceeded:

– Check the oil passages.
– If necessary, replace the oil filter adapter with pressure relief
valve.

Golf 2004 ➤ , Golf 2009 ➤

⇒ “4.1 Lower Oil Pan”, page 108
⇒ “4.2 Upper Oil Pan”, page 109
n AG . Volkswage
Engine Codes BGP andksBGQ
wage ⇒ “4.3 Oil Pump”,
n AG d
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sn 112
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Engine Codes CBTA sed b and CBUA ⇒ “4.4 Oil Pump”, page
ara 115
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4.1 ss
a Lower Oil Pan ac
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Removing
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– Drain the engine oil.
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Note
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Observe disposal regulations!

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– Remove the oil pan bolts.

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– Press the lower oil pan at the tabs -arrows- on the upper oil
n
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pan. Be careful not to damage the sealing surfaces in the
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– Replace the lower oil pan lower if damaged.
by
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Installing
WARNING

– Remove any sealant residue on the cylinder block and the up‐
per oil pan using for example, a rotating plastic brush.
Caution

oil or grease.

Golf 2004 ➤ , Golf 2009 ➤
Note n AG. Volkswagen AG do

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The lower oil pan must be installed
ir se
d b
within 5 minutes after appli‐ arant
cation of the sealant. uth o ee
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pt
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– With the engine removed, apply a sealant bead -A- to the clean
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sealing surface on the upper oil pan as illustrated.
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Note
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♦ With the engine installed, apply the sealant to the lower oil pan
the same way.
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♦ The sealant bead must be routed on the inside of the bolt

holes.
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– Install all the bolts and tighten them in a diagonal sequence.
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♦ After installing the lower oil pan, the sealant must dry for ap‐
o
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f
en
ng
proximately 30 minutes. Only after then may the engine oil be

t.
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Component Nm
AG.
Lower oil pan to upper oil pan 10
4.2 Upper Oil Pan

♦ Adapter Plates - 2036/1-
♦ 3 M8 x 20 Bolts and 3 Washers
Removing
– Remove the adjuster and sprocket from the camshafts. Refer
to ⇒ “3.3 Valve Timing, Adjusting”, page 75 .
– Remove the sealing flange, transmission side. Refer to
⇒ “5.9 Sealing Flange, Transmission Side”, page 54 .

Golf 2004 ➤ , Golf 2009 ➤
– Tension the chain tensioner -1- and secure it using the Locking
Pin - T10115- .
– Remove the guide rail -2-.
– Remove the sealing flange, belt pulley side. Refer to
⇒ “5.5 Sealing Flange, Belt Pulley Side”, page 49 .
– Remove the lower oil pan. Refer to
⇒ “4.1 Lower Oil Pan”, page 108 . AG. Volkswagen AG d
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– Remove the bolts -2 and 4- and remove the oil intake pipe.
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es, in part or in w
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– Pry the upper oil pan from the cylinder block using a suitable
m
at
screwdriver -A- at the areas shown.
om
ion
c
in t
r
B - Crankshaft bearing cap 6

o
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ate
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C - Crankshaft bearing cap 1

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Installing
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Cop py
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WARNING py by
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– Remove any sealant residue from the cylinder block using for
example, a rotating plastic brush.
Caution

oil or grease.

Golf 2004 ➤ , Golf 2009 ➤
Note
The upper oil pan must be installed within 5 minutes after appli‐
– Apply sealant beads -1, 2 and 3- to the clean sealing surfaces

of the upper oil pan as shown.
♦ The sealant beads must be 1.5 to 2.0 mm thick.
– Position the upper oil pan on the cylinder block and align it on
the transmission side.
– Install 2 bolts each, at the front and rear hand tight.
– Wipe off any excess sealant in the area of the -arrows-.

G. Volkswage nA n AG d
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– Loosen the bolts again slightly. Volks not
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– Install the Adapter Plates - 2036/1- onto
thoris the cylinder block as nte
eo
shown. au ra
c
ss
ce
– Press the upper oil pan tightly against the Adapter Plates -
le
un
pt
2036/1- and tighten the bolts hand tight.
an
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ab
– Install the remaining upper oil pan bolts and tighten them hand
ility
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tight.
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Make sure that upper oil pan makes contact with the Adapter
ole,
Plates - 2036/1- .
spec
t to the co
– Tighten all the upper oil pan bolts in a diagonal sequence

working from the inside toward the outside.
rrectne
– Install a new seal -5- into the oil pump -6-.

– Secure the oil intake pipe -1- and the bracket -4- with the bolts
ss
-2 and 3-.
o
cial p
f inform
mer
atio
om
n
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or
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Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
– Install the guide rail -2-, relieve tension on the chain tensioner
-1- and pull out the Locking Pin - T10115- .
– Adjust the valve timing. Refer to
♦ After installing the oil pan, allow the sealant to dry for approx‐
imately 30 minutes. Only after then may the engine oil be
added.
Tightening Specifications AG. Volkswagen AG d
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Upper oil pan to cylinder blockthor
25 eo
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Oil intake pipe to oil pump ss 10 c
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Oil intake tube to upper oil pan 10
pt
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4.3 Oil Pump
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♦ Oil Pump Align Plate - T03005-
Removing rrectnes

s o
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f inform
mer
– Tension the chain tensioner -1-, secure it using the Locking

atio
Pin - T10115- and remove the chain tensioner.

om
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– Remove the sprocket bolt -1-.

Hold the sprocket -2- in place using the Counterhold Tool -
T10172- .
– Remove the sprocket from the oil pump and remove the oil
pump.
Installing
• The crankshaft is secured

Golf 2004 ➤ , Golf 2009 ➤
– Replace the O-ring -25-. Refer to

⇒ “2.1 Oil Pan and Oil Pump Overview”, page 102 and tighten
the oil pump to the cylinder block bolts hand tight.
– Position the sprocket on the oil pump with the writing facing
outward. Secure it with a new bolt -1-. The drive chain is not
installed yet.
Tightening specification: 20 Nm + an additional 90° (1/4) turn.
– Loosen the oil pump bolts -2 through 4-. The oil pump must be
able to slide easily.
– Check the Oil Pump Align Plate - T03005- . If there are still
protective shields on the magnets, remove them.
– Check that there are no shavings on the oil pump align plate
magnets . The contact surfaces on the crankshaft, the align
plate and the sprocket must be clean.
– Place the Oil Pump Align Plate - T03005- onto the crankshaft
and secure it with 2 vibration damper bolts -1-.
Tightening specification: 30 Nm wagen AG. Volkswagen AG doe
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The oil pump is activated byedthe
by magnets. ara
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Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
– Remove the Locking Pin - T40069- .
– Press the crankshaft in the axial bearing play toward the belt
drive -arrow 1- and secure it with a -shim- as shown in the
illustration.
– Press the oil pump lightly toward the chain drive -arrow 2-.
Note
This step is important in order to guarantee correct position of the

sprockets to each other.
AG. Volkswagen AG d
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– In this condition,
aut first tighten the bolts -2 and 3- and then tight‐ or a
h
en the bolt -4-
s to 25 Nm.
s c
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– Install the Locking Pin - T40069- again. The crankshaft must

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only be rotated slightly around the Top Dead Center (TDC)

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– Remove the Oil Pump Align Plate - T03005- .

ole,
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– If a new oil pump is installed, fill the oil pump with some engine
t to the co
oil via the intake passage and rotate the oil pump several times
through.
– Place the chain onto the oil pump sprocket.
rrectne

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Golf 2004 ➤ , Golf 2009 ➤
– Install the guide rail -2-, relieve tension on the chain tensioner
-1- and pull out the Locking Pin - T10115- .
Note
Make sure that the chain lies correctly in the guide rail -4- and in
the tensioning rail -3-.
– Adjust the valve timing. Refer to

4.4 Oil Pump

AG. Volkswagen AG d
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In MY 2008, the oil pump timing chain was changed
hor from a roller eo
ut
chain to a toothed chain. The gears are now
s a wider and the Oil ra
c
Pump Shim - T03005/1- must also be used when securing the oil
s
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⇒ “4.2 Upper Oil Pan”, page 109 . nf
ercia
– Tension the chain tensioner -1-, secure it using the Locking

or
Pin - T10115- and remove the chain tensioner.

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Golf 2004 ➤ , Golf 2009 ➤
– Remove the sprocket bolt -1-.

Hold the sprocket -2- in place using the Counterhold Tool -
T10172- .
– Remove the sprocket from the oil pump and remove the oil
pump.
Installing
• The crankshaft is secured
– Replace the O-ring item -25-. Refer to

⇒ “2.1 Oil Pan and Oil Pump Overview”, page 102 and tighten
the oil pump to cylinder block bolts hand tight.
olksw
– Position the sprocket onto theswoil
agpump
en AG. Vwith the writing
agen AG
doesfacing
outward. Secure it with a bnew
yV
olk
bolt -1-. The chain is not installed
not
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Tightening specification:
sa
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– Loosen the oil pump bolts -2 through 4-. The oil pump must be
spec
able to slide easily. t to the co
– Check the Oil Pump Align Plate - T03005- . If there are still
protective shields on the magnets, remove them.
rrectne
– Check that there are no shavings on the oil pump align plate
magnets. The contact surfaces on the crankshaft, the oil pump
align plate and the sprocket must be clean.
ss o
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f inform
mer
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– Place the Oil Pump Shim - T03005/1- and the Oil Pump Align
i
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pr
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Plate - T03005- on the crankshaft and secure both with the 2

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vibration damper bolts -1-.

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The oil pump is activated by the magnets.
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Golf 2004 ➤ , Golf 2009 ➤
– Remove the Locking Pin - T40069- .
– Press the crankshaft in the axial bearing play toward the belt
drive -arrow 1- and secure it with a -shim- as shown in the
illustration.
– Press the oil pump lightly toward the chain drive -arrow 2-.
Note
This step is important in order to guarantee correct position of the

sprockets to each other.
lkswage es n
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– In this condition, first
ir se tighten the bolts -2 and 3- and then tight‐
d b ran
tee
en the bolt -4- to uth25 Nm.
o
or
s a ac
– Install the Locking Pin - T40069- again. The crankshaft must
s
ce
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nl
only be rotated slightly around the Top Dead Center (TDC)

pt
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point for this. Otherwise there is a risk the valves will rest on
itte
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the pistons.
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– Remove the Oil Pump Align Plate - T03005- and the Oil Pump
wit
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Shim - T03005/1- .
h re
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– If a new oil pump is installed, fill the oil pump with some engine
es, in part or in w
oil via the intake passage and rotate the oil pump several times
t to the co
through.
– Place the chain onto the oil pump sprocket.
rrectness of i

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Golf 2004 ➤ , Golf 2009 ➤
– Install the guide rail -2-, relieve the tension on the chain ten‐
sioner -1- and pull out the Locking Pin - T10115- .
Note
Make sure that the chain lies correctly in the guide rail -4- and in
the tensioning rail -3-. . Volkswag
AG en AG
agen does
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– Adjust the valve etiming.
db
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Refer to gu
ara
⇒ “3.3 Valve hTiming,
oris Adjusting”, page 75 . nte
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The rest of the
s installation follows the reverse of the removal pro‐c
s
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Golf 2004 ➤ , Golf 2009 ➤
5 Special Tools
♦ Oil Pump Shim - T03005/1-
♦ Oil Drain Adapter - T40057-
♦ Oil Pressure Gauge -

VAG1342-
♦ Voltage Tester -
VAG1527B-
♦ Connector Test Set -
VAG1594C- AG. Volkswagen AG d
agen oes
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♦ Socket 24 mm and Jointed by Vol not
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Extension - T40175- rise
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5. Special Tools 119

Golf 2004 ➤ , Golf 2009 ➤
♦ Adapter Plates - 2036/1-

VAG1331-
AG. Volkswagen AG d
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Golf 2004 ➤ , Golf 2009 ➤
19 – CoolingolkSystem
swa
gen AG
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does
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⇒ “1.1 Coolant, Draining and Filling”, page 121
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1.1 Coolant, Draining and Filling

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♦ Adapter - VAG1274/8-
h re
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spec
♦ Shop Crane - Drip Tray - VAS6208-
t to the co
♦ Cooling System Charge Unit - VAS6096-
rrectne
♦ Refractometer - T10007A-
s
Draining
s o
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f inform
mer
Note
atio
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Follow disposal regulations.
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damage to eyes and scalding. Cover the cap with a cloth and cted agen
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– Open the cap on the coolant expansion tank.

– Place the Drip Try for VAS6100 - VAS6208- below.
– Open the spring clamp -1- and remove the coolant hose -2-.
Note
If the quick acting coupling on the lower radiator connection is

pulled off, a large amount of coolant flows onto the bumper.
Filling
Caution
Only mix distilled water with coolant additives. Using distilled

water provides optimum corrosion protection.

Golf 2004 ➤ , Golf 2009 ➤
Note
♦ The water portion of the coolant influences the effectiveness

of the coolant. Based on the contents, gen Athe
G. Vcountry
olkswagenorAGeven
does the
swa
region specific quality can be y Vdifferent.
olk Use distilled water. nFor
ot g
this reason, we recommend ed b using distilled water when addinguara
nte
ris
coolant or filling coolant
ut
ho for the first time. eo
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sa ac
♦ Use only coolant additives
s listed in the Parts Catalog. Other
ce
e
coolant additives may above all reduce the corrosion protec‐

nl
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tion effect significantly. The damage resulting from this may
itte
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lead to loss of coolant and consequently to severe engine
erm
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damage.
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♦ Coolant with the correct mixture ratio prevents freezing and
h re
corrosion damage and calcium deposits. The boiling point will
hole
spec
be raised. The cooling system must be filled with coolant ad‐
es, in part or in w
ditive year-round.
t to the co
♦ Because of its high boiling point, the coolant contributes to
engine reliability under heavy loads, particularly in countries
rrectness of i
with tropical climates.
l purpos
♦ The Refractometer - T10007A- MUST be used to determine

the freeze protection value.
nf
ercia
♦ Protection against frost must be assured down to minimum -25
orm
°C (-13 °F) (in arctic climatic countries down to approximately
m
atio
m
-36 °C (-32.8 °F)). When stronger freeze protection is needed

o
n in
c
due to the climate, the freeze protection may be increased. But

or
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only down to -48 °C (-54 °F), otherwise the effectiveness of

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ter even in warmer seasons and in warmer countries. The frost Cop py
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♦ Read the freeze protection value on the scale for the coolant
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additive that has been added.
AG.
♦ The temperature on the Refractometer - T10007A- corre‐

sponds to the »freezing point«. At this temperature, ice crys‐
tals may begin to form in the coolant.
♦ Do not reuse used coolant.
♦ Only use water/coolant additive to lubricate the coolant hoses.
Recommended mixture ratios:

Frost Protection Anti-Freeze Coolant Ad‐ Water 1)
to ditive 1)
-25 °C 40 % 3.6L 5.4L
-35 °C 50 % 4.5L 4.5L
♦ 1 The quantity of coolant can vary depending upon the vehicle
equipment.
122 Rep. Gr.19 - Cooling System

Golf 2004 ➤ , Golf 2009 ➤
– Connect the coolant hose -2- to the radiator and secure it with
the spring clamp -1-.
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Description and Operation .
Filling Using the Cooling System Charge Unit - VAS6096-
– Install the Adapter - VAG1274/8- onto the expansion tank.
– Fill the coolant circuit using the Cooling System Charge Unit -
VAS 6096- . Refer to operating instructions for the cooling
system charge unit.
Filling Without Using the Cooling System Charge Unit - VAS
6096- wage
es
ks not
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d by ara
– Slowly fill the expansion tank up to the toporimark
se in the shaded nte
eo
area -arrow-. auth
ra
ss c
– Install the coolant expansion tank cap.
ce
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un
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an
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– Turn off the heater and Air Conditioning (A/C).

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– Start the engine and maintain an engine speed of about 2000
ility
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RPM for approximately 3 minutes.
wit
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– Let the engine run until the fan starts up.
spec
t to the co
WARNING
rrectne
s
s o
cial p
f inform
mer
– Check the coolant level and fill as necessary.
atio
om
n
c
i
or
n
♦ With the engine at operating temperature, the coolant level
thi
te
sd
must align with the top mark of the hatched area.
iva
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cum
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♦ When the engine is cold, the coolant level should be in the

fo
en
ng
middle of the shaded area.

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Golf 2004 ➤ , Golf 2009 ➤

⇒ “2.1 Coolant Hose Connection Diagram”, page 124
⇒ “2.2 Coolant Pump and Thermostat Overview”, page 125
⇒ “2.3 Radiator and Fan Overview”, page 130
2.1 Coolant Hose Connection Diagram
1 - Radiator
❑ Removing and instal‐ agen
AG. Volkswagen AG d
oes
ling. Refer to Volksw not
gu
⇒ “4.4 Radiator”, d by ara
ise nte
page 139 . hor eo
aut ra
❑ Replace the coolant af‐ ss c
ter replacing.
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2 - Coolant Pipe
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3 - Intake Manifold
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4 - Coolant Pump and Coolant
h re
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Thermostat
spec
es, in part or in w
❑ Coolant pump removing
t to the co
and installing. Refer to
⇒ “4.2 Coolant Pump”,
page 135 .
rrectness of i
❑ Thermostat removing
and installing. Refer to
l purpos
⇒ “4.1 Coolant Thermo‐

stat”, page 134 .
nform
ercia
❑ Checking the coolant

m
thermostat, see item

a
com
ti
-17-. Refer to Part 1 of on in
the
r
te o
thi
⇒ “2.2 Coolant Pump

s
iva
do
and Thermostat Over‐

r
rp
cum
view”, page 125 .

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5 - Front Coolant Pipe Cop py
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❑ Secured to the accesso‐
ht
pyri by
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ry bracket. by c lksw
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6 - Right Coolant Pipe
❑ Secured to the engine
mount.
7 - Expansion Tank
❑ With a cap.
❑ Checking the pressure relief valve in the cap. Refer to ⇒ page 132 .
8 - Rear Coolant Pipe
9 - Cylinder Head/Cylinder Block
❑ Replace the coolant after replacing.
10 - Coolant Flange
11 - Quick-Release Coupling
❑ Lower connection.
12 - Heater Core
❑ Replace the coolant after replacing.

Golf 2004 ➤ , Golf 2009 ➤
❑ Upper connection.
14 - Bypass Thermostat
❑ Only for vehicles with a automatic transmission.
❑ Overview. Refer to ⇒ Fig. ““Bypass Thermostat Overview”“ , page 129 .
❑ Checking. Refer to ⇒ page 129 .
15 - Automatic Transmission Fluid Cooler
17 - Coolant Hose
2 versions:
❑ Without a engine pre-warmer
AG. Volkswagen AG d
❑ With a engine pre-warmer agen oes
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18 - Pre-Warmer orise nte
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❑ Only on vehicles with as engine pre-warmer.
au ra
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19 - Throttle Valve Control Module - J338-

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❑ Connection only for a coolant heated throttle valve control module.
itte
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20 - Coolant Hoses
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❑ Only for a throttle valve control module heated by coolant.
, is n
h re
hole
spec
es, in part or in w
❑ Upper connection.
t to the co
❑ Lower connection.
rrectness of i
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2.2 Coolant Pump and Thermostat Over‐ nf

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Caution
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♦ Route all lines and wires in their original locations. C py
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components to prevent damage to the lines. cted agen
Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
Note
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary release the pressure before beginning nany
AG. Volkswagen AG d
wage oes
repair work. yV
olks not
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ed ran
♦ Secure all hose connections with clamps, hallocation.
or
is Refer to tee
the Parts Catalog. au
t or
ac
ss
♦ The Hose Clip Pliers - VAG1921- or -VAS6362- are recom‐
ce
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mended for installing spring clamps.
an
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♦ Always replace gaskets and seals.
ab
ility
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♦ The arrows on coolant pipes and coolant hoses must line up
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across from each other.
h re
hole
spec
es, in part or in w
Part 1: Belt Pulley Side
t to the co
Part 2: transmission side. Refer to ⇒ page 127 .
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1 - Cylinder Block
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3 - Bolt
orm
❑ 25 Nm
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4 - Bolt/Nut
or
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❑ 10 Nm
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5 - To the Heater Core Lower
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Connection
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6 - Retaining Clip
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7 - O-Ring
c by lksw
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❑ Always replace.
8 - Front Coolant Pipe
9 - Connecting Hose
10 - O-Ring
❑ Always replace.
11 - Coolant Pipe
12 - Connecting Hose
13 - Cover
14 - To the Radiator Lower
Connection
15 - Bolt
❑ 5 Nm
16 - O-Ring
❑ Always replace.
17 - Coolant Thermostat
ling. Refer to
⇒ “4.1 Coolant Thermostat”, page 134 .
❑ Note the installed position: the valve must be at the top.
❑ Checking (coolant thermostat installed): Refer to the “Function and Component Selection” in the vehicle
diagnostic tester.
❑ Checking (coolant thermostat removed):

Golf 2004 ➤ , Golf 2009 ➤
Heat the thermostat in water.
Starts to open: approximately 87 ℃ (188.6 °F)

Opening ends: approximately 102 ℃ (215.6 °F)
Open distance: at least 7 mm
18 - Seal
❑ Always replace.
19 - Bolt
❑ 25 Nm
20 - Coolant Thermostat Housing
21 - Seal
❑ Always replace.
23 - Bolt
❑ 10 Nm
24 - Coolant Pump
❑ With an integrated silicone seal for sealing to the cylinder block.
25 - Right Coolant Pipe
❑ Secured to the engine mount.
26 - To the Expansion Tank Lower Connection
Part 2: Transmission Side
AG. Volkswagen AG d
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Prote AG.

Golf 2004 ➤ , Golf 2009 ➤
1 - Coolant Connection
❑ Pressed in the cylinder
head.
❑ Clean before installing
the coolant flange -17-
– If necessary, remove
any coolant deposits
with a brass wire brush
or with a fine sandpaper
(minimum 100 grit).
❑ If the pipe connection is
worn, replace it using
Liquid Locking Fluid - D
000 600 A2- .
2 - Thrust Ring
3 - Seal
❑ Replace after removing
the coolant flange -17-.
4 - To the Expansion Tank Up‐
per Connection
5 - Rear Coolant Pipe
6 - Bolt/Nut
❑ 10 Nm
7 - Heat Shield
8 - To the Heater Core Upper
Connection
9 - Supply Hose AG. Volkswagen AG d
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10 - Bypass Thermostat d by Vo gu
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❑ Only for vehicles with a rise nte
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⇒ Fig. ““Bypass Thermostat Overview”“ , page 129 .

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11 - To the Automatic Transmission Fluid Cooler

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12 - To the Heater Core Lower Connection

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13 - From the Automatic Transmission Fluid Cooler

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14 - Return Hose
15 - Coolant Pipe
ss o
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❑ Bolted to the coolant flange -17-

f inform
mer
16 - To the Coolant Thermostat Housing

atio
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17 - Flange
o
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18 - Supply Hose
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19 - To the Radiator Upper Connection

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20 - Coolant Hoses
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❑ Only for a throttle valve control module heated by coolant.
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Golf 2004 ➤ , Golf 2009 ➤

22 - Engine Coolant Temperature Sensor - G62-
23 - O-Ring
❑ Always replace.
24 - Retaining Clip
Bypass Thermostat Overview

1 - Spring bracket
2 - Lower part of housing
- Note the installed position: The arrow points toward the auto‐
matic transmission fluid cooler
3 - Operating element
4 - Spring
5 - O-ring
6 - Upper part of housing
Checking the Bypass Thermostat:
– Remove the operating element -3- and heat in a hot water
bath.
Starts to open: approximately 75 ℃ (167 °F)
Stops at: approximately 85 °C (185 °F)
. Volkswagen AG
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Opening lift: approximatelyVo5lkmm not
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1 - Upper Coolant Hose
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❑ From the coolant ther‐
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2 - O-Ring
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3 - Radiator
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⇒ “4.4 Radiator”,
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page 139 .
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4 - Gasket
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to 1.6 bar (20.30 to

23.20 psi).
6 - Connector
7 - Bolt
❑ 3 Nm
8 - Expansion Tank
❑ Perform a leak test on
the cooling system us‐
ing the Cooling System
Tester - VAG1274B-
and the Adapter - VAG1274/8- . Refer to ⇒ “3.1 Cooling System, Checking for Leaks”, page 132 .
9 - Bracket
❑ For the radiator.
10 - Bolt
❑ 5 Nm
11 - Spacer Piece
❑ For the refrigerant line bracket.
12 - Support
❑ Insert in the lock carrier.
13 - Nut
❑ 5 Nm
14 - Fan Shroud
15 - Bolt
❑ 5 Nm
16 - Coolant Fan 2 - V177-
❑ Removing and installing. Refer to ⇒ “4.3 Fan Shroud and Fan”, page 138 .

Golf 2004 ➤ , Golf 2009 ➤
17 - Connector
18 - Connector
19 - Coolant Fan - V7-
❑ Removing and installing. Refer to ⇒ “4.3 Fan Shroud and Fan”, page 138 .
❑ With the Coolant Fan Control Module - J293- .
20 - Lower Coolant Hose
❑ From the connection for the coolant flange.
21 - Retaining Clip
22 - Engine Coolant Temperature Sensor on Radiator Outlet - G83-
23 - O-Ring
❑ Always replace.
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Golf 2004 ➤ , Golf 2009 ➤

⇒ “3.1 Cooling System, Checking for Leaks”, page 132
3.1 Cooling System, Checking for Leaks

♦ Cooling System Tester - VAG1274B-
Test Conditions
• The engine is at operating temperature
Test Sequence
WARNING
Steam can be released when the cap is removed from the ex‐
pansion tank. Cover the cap with a cloth and open carefully. AG. Volkswagen AG d
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– Open the cap on the coolant expansion tank. horis nte
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tank.
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– Clamp the Connecting Piece - VAG1274B/1- on the Adapter -
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VAG1274/8- .
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– Connect the Connector Piece - VAG1274B/1- to the Cooling
, is n
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System Tester - VAG1274B- using the connecting hose.
hole
spec
– Generate a positive pressure of approximately 1.0 bar (14.5
es, in part or in w
t to the co
psi) using the tester hand pump.
DANGER!
rrectness of i
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Risk of scalding! Reduce the pressure before disconnecting

the Cooling System Tester - VAG1274B- from the connecting
hose or Connector Piece - VAG1274B/1- . To do this, press the
nf
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pressure release valve on the Cooling System Tester -

VAG1274B- until the pressure gauge displays 0. orm
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– Clamp the Connecting Piece - VAG1274B/1- on the Adapter - Prote AG.
VAG1274/9- .

Golf 2004 ➤ , Golf 2009 ➤
– Connect the Connector Piece - VAG1274B/1- to the Cooling

System Tester - VAG1274B- using the connecting hose.
– Actuate the hand pump.
• The pressure release valve must open at 1.4 to 1.6 bar (20.30
to 23.20 psi).
AG. Volkswagen AG d
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Golf 2004 ➤ , Golf 2009 ➤

⇒ “4.1 Coolant Thermostat”, page 134
⇒ “4.2 Coolant Pump”, page 135
⇒ “4.3 Fan Shroud and Fan”, page 138
AG. Volkswagen AG d
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⇒ “4.4 Radiator”, page 139 Volksw
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Checking the coolant thermostat, see item -17- in Part 1. Refer to
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♦ Shop Crane - Drip Tray - VAS6208-
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♦ Refractometer - T10007-
f inform
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Removing
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– Reinsert the oil dipstick guide tube in the cylinder block. Tight‐
en the bolt to prevent coolant from leaking into the engine.
– Place a suitable container under the coolant thermostat hous‐
ing to catch any coolant leaking out.
– Remove the bolts -arrows-, the cover -A- and the thermostat.
Installing

Golf 2004 ➤ , Golf 2009 ➤
♦ Replace the O-ring and seal, see items -16 and 18- in Part 1.
Refer to
⇒ “2.2 Coolant Pump and Thermostat Overview”, page 125 .
♦ Note the installed position of the thermostat -1-. The valve
-2- must point upward.
Component Nm
Cover to coolant thermostat housing 5
4.2 Coolant Pump

♦ Engine Support Bridge - 10-222A-
♦ Engine Support Adapter - 10-222A/3-
♦ Engine Support Feet - 10-222A/8-
♦ Shackle - 10-222A/12-
♦ Torque Wrench (40-200 Nm) - VAG1332- AG. Volkswagen AG d
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Golf 2004 ➤ , Golf 2009 ➤
WARNING

– Remove the connecting pipe -4-. To do so, disconnect the

Secondary Air Injection (AIR) connecting pipe -1-, if equipped
and the vent tube -2- and reposition the spring clamp -3-.
– Remove the right front wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Removal and Installation .
– Remove the generator, gpower
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pump ribbed belt.
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manifold and tie up firmly to the side. Refer to

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Note
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nf
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– Remove the pendulum support. Refer to ⇒ Suspension,

m
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atio
Wheels, Steering; Rep. Gr. 40 ; Description and Operation .

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– Remove the shift mechanism from the transmission. Refer to

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⇒ Manual Transmission; Rep. Gr. 34 ; Removal and Instal‐

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– Remove the selector lever cable from the transmission. Refer
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to ⇒ Automatic Transmission; Rep. Gr. 37 ; Removal and
AG.
Installation .
Installing the Engine Support Bridge - 10-222A- , Rabbit, from MY
2006 through 2009

Golf 2004 ➤ , Golf 2009 ➤
– Position the Engine Support Bridge - 10-222A- with the Engine

Support Feet - 10-222A/8- . Support the engine and transmis‐
sion assembly in the installed position using the Engine Sup‐
port Adapter - 10-222A/3- and the Shackle - 10-222A/12- .
Note
♦ The illustration shows the arrangement with a automatic trans‐

mission.
♦ In vehicles with a manual transmission, the spindle -A- is to be
located toward the rear and secured to the reinforcement
brace of the transmission.
Installing the Engine Support Bridge - 10-222A- , Golf, from MY

2010
– Position the Engine Support Bridge - 10-222A- with the Engine
Support Feet - 10-222A/8- . Support the engine and transmis‐
sion assembly in the installed position as illustrated.
Note the following:
• The panel -A- must not be bent.
• Secure the Shackle - 10-222A/12- on the reinforcing brace in
vehicles with a manual transmissions and at the transport eye
in vehicles with a automatic transmissions.
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– Remove the bolt -2- and move the windshield washer
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– Remove the bolts -6- and disconnect the connector -3-.
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– Remove the bolts -5- and place the coolant expansion tank on
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top of the engine with the hoses connected.
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– Remove the bolts -1, 2 and 3- and remove the engine mount.
nf
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Note
rm
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n in
Remove the single, lower rear bolt -2- through a hole in the wheel
or c
housing.
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Golf 2004 ➤ , Golf 2009 ➤ ut
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un
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– Remove the transmission mount to transmission mount brack‐
an
d
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et bolts -arrows-.
rm
ab
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– Slide the engine as far as possible toward the front and to the
ot
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left.
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es, in part or in w
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rrectness of i
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– Remove the 3 coolant pump bolts and swivel the coolant pump
-A- out as shown.
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Installing
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♦ Note the installed position of the coolant pump. The sealing
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⇒ “1.1 Coolant, Draining and Filling”, page 121 . copy Vo
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♦ Install the battery. Refer to ⇒ Electrical Equipment; Rep. Gr.
AG.

Component Nm
Engine and transmission mount bolts Refer to
⇒ “1.1 Fasten‐
er Tightening
Specifica‐
tions”,
page 7 .
Coolant pump to cylinder block 10
4.3 Fan Shroud and Fan

Removing
– Remove the fan shroud upper bolts -arrows-.
– Unclip the lower coolant hose from the fan shroud.
– Disconnect the electrical connector -1- and remove the fan
shroud lower bolts -arrows-.
– Remove the fan shroud downward.

Golf 2004 ➤ , Golf 2009 ➤
– Disconnect the electrical connector -1- and lay the wire free.
Installed position of the connector deviates from the illustra‐
tion.
– Remove the coolant fan nuts -arrows- and remove the fans.
Installing
Component Nm
Coolant fan to fan shroud 5
Fan shroud to radiator 5
4.4 Radiator
Removing
– Remove the front bumper cover. Refer to ⇒ Body Exterior;
AG. Volkswagen AG d
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– Remove the fan shroud and fans. Refer to Volksw
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– Drain the coolant. Refer to auth
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⇒ “1.1 Coolant, Draining and Filling”, page 121 . ss c
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un
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– Remove the coolant hoses from the radiator.
an
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Caution
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To prevent damage to the Air Conditioning (A/C) condenser
hole
spec
and the refrigerant lines, do not stretch, kink or bend the lines
es, in part or in w
and hoses.
t to the co
– Remove the lock carrier to radiator bracket bolts -arrows-. rrectness of i
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Golf 2004 ➤ , Golf 2009 ➤
– Move the radiator and A/C condenser toward the rear and out
of the lower mount. While doing this, pull the lock carrier on
the left mount -1- slightly downward.
– Remove the bolts for the refrigerant lines on the right side of
the radiator -arrow-.
– Remove the A/C condenser bolts. Secure the A/C condenser
on the lock carrier using cable ties, for example.
– Remove the radiator downward.
Installing
– Install the radiator from below and secure it to the A/C con‐
denser.
– Install the radiator and A/C condenser in the lower mounts.
– Place the radiator upper bracket on the radiator and secure it

to the lock carrier -arrows-. n AG. Volkswagen AG age does
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– Install the front bumper cover . Refer y Vto ⇒ Body Exterior; Rep.
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Gr. 63 ; Removal and Installation ed .b ara
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– Install the fan shroud and sfans.
sa
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Refer to ra
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⇒ “4.3 Fan Shroud and Fan”, page 138 .
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Further installation is performed in reverse order of removal. Note

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♦ Replace the coolant if a new radiator was installed.

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Component Nm
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Lock carrier to radiator bracket 5

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A/C condenser to radiator 5

Fan shroud to radiator 5
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Golf 2004 ➤ , Golf 2009 ➤
5 Special Tools
♦ Cooling System Tester - VAG1274B-
AG. Volkswagen AG d
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Golf 2004 ➤ , Golf 2009 ➤
♦ Shop Crane - Drip Tray -
VAS6208-
♦ Hose Clip Pliers -
VAS6362-
♦ Cooling System Charge
Unit - VAS6096-
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Golf 2004 ➤ , Golf 2009 ➤
. Volkswagen AG
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Golf 2004 ➤ , Golf 2009 ➤
24 – Multiport Fuel Injection

⇒ “1.1 Fuel System, Filling and Bleeding”, page 144
wage
1.1 Fuel System, Filling
Vol and Bleeding
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Special tools and workshop ut
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♦ Suction Pump - VAS5226-
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Note
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♦ If the fuel supply system was opened, it must always be bled
before starting the engine.
rrectness of i
♦ If the fuel supply system is not bled, the catalytic converter will
be damaged.
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♦ Pay attention to the rules of cleanliness. Refer to

⇒ “1.2 Clean Working Conditions”, page 3 .
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Procedure
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– Remove the cap -arrow- for the bleed valve.
144 Rep. Gr.24 - Multiport Fuel Injection

Golf 2004 ➤ , Golf 2009 ➤
– Turn the valve on the T-piece counterclockwise until it is com‐

pletely open.
– Install Adapter - VAG1318/20-1- onto the Adapter for K-Jet‐
ronic Test Device - VAG1318/20- .
– Install the Adapter - VAG1318/20- hand tight onto the bleed
valve.
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– Connect the hose from the Suction Pump - VAS5226- as
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– Check the adapter and hose connections for leaks.
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Connect the vehicle diagnostic tester as follows:
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– Connect the diagnostic cable connector -2- to the diagnostic
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OBD
OBD ►
Engine electronics ►
Output diagnostic test ►
– Press the arrow button ► repeatedly until the Fuel Pump Relay
- J17- is activated. This activates the fuel pump. Let the diag‐
nosis run until fuel flows out of the bleed valve without bubbles.
Then end the output diagnostic test mode.
Note
If the output diagnostic test mode is interrupted, the engine must

be started for a short time before the mode can be accessed
again. The output diagnostic test mode is automatically cancelled
after 60 seconds.

Golf 2004 ➤ , Golf 2009 ➤
AG. Volkswagen AG d
– Turn the valve at the T-piece counterclockwise until it is lcom‐
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Hose Clamp Up to 25 mm - 3094- and disconnect
ss
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Adapter - VAG1318/20-1- .
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pt
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an
– Remove the Adapter for K-jetronic Test Device - VAG1318/20-
itte
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from the bleed valve.
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– Install the cap -arrow- on the bleed valve.
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Golf 2004 ➤ , Golf 2009 ➤

⇒ “2.1 Fuel Injection System Component Location Overview”,
page 147
⇒ “2.2 Engine Cover with Air Filter Overview”, page 150
Engine Codes BGP and BGQ
⇒ “2.3 Intake Manifold Overview”, page 152
⇒ “2.4 Fuel Rail and Injectors Overview”, page 153
Engine Codes CBTA and CBUA
⇒ “2.5 Intake Manifold Overview”, page 154
⇒ “2.6 Fuel Rail and Injectors Overview”, page 155
2.1 Fuel Injection System Component Lo‐

cation Overview
Note
The Mass Airflow Sensor - G70- is no longer installed from MY

2009. The Intake Air Temperature Sensor - G42- is installed on
the intake manifold with the Manifold AbsoluteePressure
n AG. VolkswSensor
agen AG
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The Following Components Are thNot
or
Displayed in the Overview: eo
s au ra
c
Manifold Absolute Pressure s(MAP) sensor
ce
le
un
Accelerator Pedal Position Sensor - G79- / Accelerator Pedal Po‐ pt

an
d
itte
sition Sensor 2 - G185- y li

rm
ab
pe
ility
Leak Detection Pump - V144-
ot
wit
, is n
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Clutch Position Sensor - G476-
hole
spec
es, in part or in w
t to the co
rrectness of i
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tion in
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Golf 2004 ➤ , Golf 2009 ➤
1 - Fuel Injectors - N30, N31,

N32, N33, N83-
ling. Refer to
⇒ “5.4 Fuel Injectors”,
page 164 .
2 - Camshaft Position Sensor -
G40-
3 - 81 Pin Connector
❑ Disconnect and connect
the connector with the
ignition turned off.
❑ Release to disconnect.
4 - Engine Control Module -
J623-
❑ Installed location: In the
plenum chamber.
5 - 40 Pin Connector
❑ Disconnect and connect
the connector with the
ignition turned off.
❑ Release to disconnect.
6 - Secondary Air Injection Sol‐
enoid Valve - N112-
❑ For Secondary Air Injec‐
tion (AIR).
❑ Checking. Refer to
⇒ “3.1 Secondary Air In‐ . Volkswagen AG
jection Solenoid Valve, kswagen AG does
not
l
Checking”, page 186 by .
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ise
7 - Engine Coolant uTempera‐
tho
r tee
or
ture Sensor - G62-
ss
a ac
❑ If necessary release
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pt
du
pressure in the cooling

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system before removing.

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8 - EVAP Canister Purge Regulator Valve 1 - N80-

wit
, is n
❑ Installed position: The arrow points in the direction of flow.

h re
hole
spec
9 - Ignition Coil with Power Output Stage - N70, N127, N291, N292, N323-
es, in part or in w
t to the co
❑ Removing and installing. Refer to ⇒ “3.1 Ignition Coil with Power Output Stage”, page 199 .
10 - MAF Sensor
rrectness of i
❑ The MAF sensor is no longer installed from MY 2009. The IAT sensor is installed on the intake manifold
with the Manifold Absolute Pressure (MAP) sensor.
l purpos
11 - E-Box, in Engine Compartment, Left Side

nform
ercia
Component location of:

m
❑ Secondary Air Injection Pump Relay - J299- . Refer to

at
om
io
⇒ Fig. ““Secondary Air Injection Pump Relay”“ , page 150 .

n
c
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or
❑ Fuel pump relay. Refer to ⇒ Fig. ““Fuel Pump Relay”“ , page 150 .
his
ate
do
riv
❑ Terminal 30 Power Supply Relay - J317- . Refer to

p
cum
or
⇒ Fig. ““Terminal 30 Power Supply Relay”“ , page 150 .

f
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ng
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❑ Terminal 15 Power Supply Relay - J329- . Refer to
Co
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⇒ Fig. ““Terminal 15 Power Supply Relay”“ , page 150 .
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❑ Fasteners cop Vo
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Golf 2004 ➤ , Golf 2009 ➤
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rised Engine
b
Mechanical, Fuel Injection and
ara Ignition - Edition 07.2014
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12 - Engine Speed Sensor -ssG28- c
ce
le
❑ Secured to sealing flange, transmission side.
un
pt
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erm
ab
ility
❑ Removing and installing. Refer to ⇒ “5.2 Throttle Valve Control Module J338 ”, page 159 .
ot p
wit
14 - Camshaft Adjustment Valve 1 - N205- is n
h re
ole,
spec
15 - Secondary Air Injection Pump Motor - V101-
t to the co
❑ Removing and installing. Refer to ⇒ “4.1 Secondary Air Injection Pump Motor V101 ”, page 187 .
rrectne
❑ Component location. Refer to ⇒ “2.3 Engine Overview, Rear”, page 30 .
ss
❑ Component location. Refer to ⇒ “2.3 Engine Overview, Rear”, page 30 .
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18 - 6 Pin Harness Connector
mer
atio
om
n
c
❑ Black
i
or
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❑ For the heated oxygen sensor before the catalytic converter and the Oxygen Sensor Heater - Z19- .
t
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❑ Installed location: Secured to the left plenum chamber bulkhead.
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19 - Heated Oxygen Sensor - G39-
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❑ 55 Nm
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❑ Installed location: in the exhaust manifold
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❑ Only use hot bolt paste to grease the threads, do not let the paste get onto the slits of the oxygen sensor
AG.
body.
❑ Only with engine codes BGQ and CBUA.
❑ Black
❑ For the oxygen sensor in bank 1 center three way catalytic converter and the Heater For Oxygen Sensor
Center Catalytic Converter - Z59- .
❑ Component location. Refer to ⇒ “4.3 Exhaust Pipe with Catalytic Converter”, page 189 .
21 - Oxygen Sensor in Bank 1 Center Three Way Catalytic Converter - G465-
❑ 55 Nm
❑ Only with engine codes BGQ and CBUA.
❑ Installed location: in the center catalytic converter.
body.
❑ Brown
❑ For the oxygen sensor after three way catalytic converter and Heater For Oxygen Sensor 1 After Catalytic
Converter - Z29- .
❑ Component location. Refer to ⇒ “4.3 Exhaust Pipe with Catalytic Converter”, page 189 .
23 - Oxygen Sensor After Three Way Catalytic Converter - G130-
❑ 55 Nm
❑ Installed location: in the rear catalytic converter.
body.

Golf 2004 ➤ , Golf 2009 ➤
Secondary Air Injection Pump Relay

♦ In the E-box in the engine compartment, at the lower right
-1-
Terminal 30 Power Supply Relay

♦ In the E-box in the engine compartment -1-
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Fuel Pump Relay
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♦ In the E-box in the engine compartment -2-
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Terminal 15 Power Supply Relay

com
tion in
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♦ In the E-box in the engine compartment -3-.

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2.2 Engine Cover with Air Filter Overview

The upper air filter housing is also the engine cover.
Engine cover with air filter, removal and installation. Refer to

Golf 2004 ➤ , Golf 2009 ➤
1 - To the Throttle Valve Con‐

trol Module - J338-
2 - Spring Type Clamp
3 - Connection
❑ For the vent hose from
the oil filter adapter.
4 - Connection
❑ For the connecting pipe
from the Secondary Air
Injection (AIR) pump.
5 - Connecting Pipe
❑ To the throttle valve
control module.
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6 - Mass Airflow Sensor - G70- olksw not
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with Intake Air Temperature ised b ara
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Sensor - G42- ut
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❑ The Mass Airflow (MAF) ss c
sensor is no longer in‐
ce
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un
pt
stalled from MY 2009.
an
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The Intake Air Temper‐
erm
ab
ature (IAT) sensor is in‐
ility
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stalled on the intake
wit
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manifold with the Mani‐
h re
ole,
fold Absolute Pressure
spec
Sensor - G71- .
t to the co
7 - Bolt
❑ 3 Nm
rrectne
8 - From the Air Duct on the
Lock Carrier
ss o
9 - Bolt
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❑ 1.5 Nm
form
mer
atio
10 - Intake Air Duct
om
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c
❑ To the air filter.
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11 - Upper Air Filter Housing/Engine Cover

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12 - Rubber Bushing
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❑ Do not use lubricant. ht. Cop py
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13 - Filter Element py by
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14 - Lower Air Filter Housing Prote AG.
❑ The warm air intake has been discontinued with engine codes CBTA and CBUA.
15 - Bolt
❑ 2 Nm
❑ Follow the tightening sequence. Refer to
⇒ Fig. ““Lower Air Filter Housing Bolt Tightening Sequence”“ , page 152 .

Golf 2004 ➤ , Golf 2009 ➤
Lower Air Filter Housing Bolt Tightening Sequence

– Tighten the bolts, as shown, in sequence -1 through 5- to 2
Nm.
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2.3 Intake Manifold Overview
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1 - Vent Hose
ole,
spec
❑ From the cylinder head

cover.
t to the co
2 - Ventilation Hose
rrectne
3 - EVAP Canister Purge Reg‐
ulator Valve 1 - N80-
ss
4 - Vacuum Hose
o
cial p
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❑ From the Leak Detec‐
nform
tion Pump - V144- .
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atio
m
5 - Bolt
o
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❑ 9 Nm
thi
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6 - Fuel Rail
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ng
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⇒ “2.4 Fuel Rail and In‐ Cop py
jectors Overview”,
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page 153 .
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7 - Fuel Supply Line
Prote AG.
8 - Gasket
❑ Always replace.
tion:
Casting mark points up‐
ward.
9 - Intake Manifold
ling. Refer to
⇒ “5.3 Intake Manifold”,
page 161 .
10 - Rubber Bushing
12 - Bolt
❑ 25 Nm
13 - Nut
❑ 20 Nm
14 - O-Ring

Golf 2004 ➤ , Golf 2009 ➤
15 - Manifold Absolute Pressure Sensor - G71-

16 - Bolt
❑ 3.5 Nm
17 - Coolant Connections
❑ Phased-in introduction of a throttle valve control module without coolant heating.
18 - Bolt
❑ 6.5 Nm
❑ With Epc Throttle Drive - G186- , EPC Throttle Drive Angle Sensor 1 - G187- and EPC Throttle Drive
Angle Sensor 2 - G188- .
❑ When replacing, erase the adaptation values and adapt the Engine Control Module (ECM) to the throttle
valve control module. Refer to “Guided Functions” in the vehicle diagnostic tester.
20 - Gasket
2.4 Fuel Rail and Injectors Overview
1 - Bolt
❑ 3.5 Nm
2 - Fuel Rail
4 - O-Ring
❑ Always replace.
❑ Lubricate with clean en‐
gine oil. gen AG
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5 - Retaining Clip d by Vo gu
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❑ Make sure tho
ris clip is cor‐ eo
rectlys aseated on the fuel
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injector
s
and fuel rail.
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6 - Fuel Injector - N30, N31,

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N32, N33, N83-

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ility

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spec
page 164 .
es, in part or in w
t to the co
7 - Intake Manifold
8 - Cap
rrectness of i
9 - Bleed Valve
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Golf 2004 ➤ , Golf 2009 ➤
2.5 Intake Manifold Overview
1 - Connecting Hose
❑ For crankcase ventila‐
tion. AG. Volkswagen AG d
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❑ From the cylinder head olksw not
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2 - Ventilation Hose s aut ra
c
s
3 - EVAP Canister Purge Reg‐
ce
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ulator Valve 1 - N80-
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ab
4 - Vacuum Hose
ility
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❑ From the Leak Detec‐
wit
, is n
tion Pump - V144-
h re
hole
spec
❑ Vehicle through MY
es, in part or in w
2009 only.
t to the co
❑ From MY 10, the vac‐
uum connection is on
the vacuum line to the
rrectness of i
brake booster.
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5 - Bolt
❑ 9 Nm
nf
ercia
or
6 - Fuel Rail
m
m
atio
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o
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c
⇒ “2.4 Fuel Rail and In‐

or
thi
e
jectors Overview”,
t
sd
iva
page 153 . o
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rp
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7 - Fuel Supply Line yi

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8 - Gasket
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❑ Always replace.
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❑ Note the installed posi‐ Prote AG.
tion:
Casting mark points up‐
ward.
9 - Intake Manifold
❑ Removing and installing. Refer to ⇒ “5.3 Intake Manifold”, page 161 .
❑ Not installed on all vehicles.
11 - Bolt
❑ 25 Nm
12 - Bolt
❑ 16 Nm
13 - O-Ring
14 - Manifold Absolute Pressure Sensor - G71-
❑ From MY 2009 with the Intake Air Temperature Sensor - G42- .
15 - Bolt
❑ 3.5 Nm
16 - Coolant Connections
❑ Phased-in introduction of a throttle valve control module without coolant heating.

Golf 2004 ➤ , Golf 2009 ➤
17 - Bolt
❑ 6.5 Nm
❑ With EPC Throttle Drive - G186- , EPC Throttle Drive Angle Sensor 1 - G187- and EPC Throttle Drive
Angle Sensor 2 - G188- .
. Volkswagen AG
gen AG does
❑ When replacing,
Vol
kswa erase the adaptation values
not and adapt the Engine Control Module (ECM) to the throttle
valveedcontrol
by module. Refer to “Guided Functions”
gu
ara in the vehicle diagnostic tester.
is nte
or
19 - Gasket
au
th eo
ra
s c
❑ s Replace if damaged.
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le
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pt
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2.6 Fuel Rail and Injectors Overview
pe
ility
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1 - Bolt
spec
es, in part or in w
❑ 3.5 Nm
t to the co
2 - Fuel Rail
rrectness of i
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4 - O-Ring
❑ Always replace.
nform
ercia
❑ Lubricate with clean en‐

gine oil.
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com
tio
5 - Retaining Clip
n in
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❑ Make sure the clip is

s
iva
correctly seated on the

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rp
fuel injector and fuel rail.

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6 - Fuel Injector - N30, N31,
Co
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N32, N33, N83-
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ling. Refer to
cted agen
Prote AG.
page 164 .
7 - Intake Manifold
8 - Cap
9 - Bleed Valve

Golf 2004 ➤ , Golf 2009 ➤
3 Specifications

Lower Air Filter Housing Bolt Tightening Sequence and Specifi‐
cation
– Tighten the bolts, in sequence -1 through 5- to 2 Nm.
AG. Volkswagen AG d
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ility
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es, in part or in w
t to the co
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Golf 2004 ➤ , Golf 2009 ➤
AG. Volkswagen G d
Engine Mechanical,
lkswFuel
agenInjection and A
Ignition
oes - Edition 07.2014
n o ot g
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e
⇒ “4.1 Fuel Injector, Checking”, page 157
nl
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4.1 Fuel Injector, Checking
erm
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ility
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♦ Remote Control - VAG1348/3A-
hole
spec
es, in part or in w
♦ Adapter Cable - VAG1348/3-2-
t to the co
♦ Injector Rate Tester - VAG1602-
rrectness of i
♦ Test Instrument Adapter/DSO (5-pin) - VAS5565-
l purpos
Checking for Leaks
nform
ercia
• The fuel pressure must be OK. Refer to ⇒ Fuel Supply Sys‐

tem; Rep. Gr. 20 ; Diagnosis and Testing .
m
at
om
ion
– Remove the fuel rail -2- with the fuel injectors installed. Refer
c
in t
or
to ⇒ “5.4 Fuel Injectors”, page 164 and place it on a clean
his
ate
cloth.
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priv
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or
Do not disconnect the battery and do not disconnect the fuel

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supply line at the quick acting coupling or at the fuel rail.
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• The connectors must be disconnected from the fuel injectors.
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– Remove the rear seat bench. Refer to “Rear Seats” in ⇒ Body cted agen
Prote AG.
Interior; Rep. Gr. 72 ; Removal and Installation .
– Remove the cover from the fuel delivery unit.
– First, pull on the connector -arrow- without pressing the re‐

tainer to make sure it is connected securely. If the connector
was not connected correctly, it could cause a fault.
– Disconnect the connector.
– Check the contacts on the connector and the fuel delivery unit
for damage.

Golf 2004 ➤ , Golf 2009 ➤
– Install the Test Instrument Adapter/DSO (5-pin) - VAS5565-

between the connectors on the fuel delivery unit and cover.
– Connect the Remote Control - VAG1348/3A- to the Test In‐
strument Adapter/Dso (5-Pin) - VAS5565- and to battery pos‐
itive (+). . Volkswage AG n AG d
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Note rise nte
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This step allows the fuel pump to run when
s the engine is not run‐
ce
le
ning.
un
pt
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rm
ab
– Operate the Remote Control - VAG1348/3A- and look for leaks
pe
ility
in the fuel injectors. Only 1 to 2 drops per minute may emit
ot
wit
, is n
from each injector when the fuel pump is running.
h re
hole
If the fuel loss is greater:
spec
es, in part or in w
t to the co
– Disconnect the connection to battery positive (+) and replace
the leaking fuel injector. Refer to
⇒ “5.4 Fuel Injectors”, page 164 .
rrectness of i
Checking the Injection Quantity
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• The fuel pressure must be OK. Refer to ⇒ Fuel Supply Sys‐

tem; Rep. Gr. 20 ; Diagnosis and Testing .
nform
ercia
• The fuel rail is removed.

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t
• The fuel injectors are installed in the fuel rail and the fuel line
ion in
connected.
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s
iva
• The Remote Control - VAG1348/3A- is connected to the fuel
do
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rp
c
delivery unit.
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– Place a fuel injector to be tested into a graduated measuring
yi Co
op
glass from the Injector Rate Tester - VAG1602- .
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– Using an adapter cable from the Connector Test Set - Prote
cted AG.
agen
VAG1594C- , connect the cable to a terminal on the fuel
injector to be checked and to engine ground (-).
– Using Adapter Cable - VAG1348/3-2- , connect it to the second
terminal of the fuel injector and to the Remote Control -
VAG1348/3 A- .
– Connect the alligator clip to battery positive (B+).
– Operate the Remote Control - VAG1348/3A- for 30 seconds.
– Repeat the check on the other injectors. Use new graduated
measuring glasses for this.
– After all the fuel injectors have been activated, place the grad‐
uated measuring glasses on a level surface and compare the
quantity of injected fuel.
Specified value: 85 to 105 ml (2.87 to 3.55 oz) per injector
While checking the injection quantity, the spray pattern should
also be checked. The spray pattern must be the same for all the
fuel injectors.
If the measured value of one or more fuel injectors is below or
above the indicated specified value:
– Replace the faulty fuel injector. Refer to

Golf 2004 ➤ , Golf 2009 ➤
olkswagen AG
en AG. V
5 Removal
yV
olksand Installation s not g
wag doe
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ed
⇒ “5.1 Engine Cover
ho
ris with Air Filter”, page 159 nte
e
t or
au ac
⇒ “5.2 Throttle
ss Valve Control Module J338 ”, page 159
ce
e
nl
pt
⇒ “5.3 Intake Manifold”, page 161
du
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⇒ “5.4 Fuel Injectors”, page 164
erm
ab
ility
ot p
Rabbit, from MY 2006 through 2009
wit
, is n
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⇒ “5.5 Engine Control Module, without Anti-Theft Protection”,
hole
spec
page 166
es, in part or in w
t to the co
⇒ “5.6 Engine Control Module. with Anti-Theft Protection”,
page 167
rrectness of i
Golf, from MY 2010
l purpos
⇒ “5.7 Engine Control Module, without Anti-Theft Protection”,

page 169
nf
ercia
⇒ “5.8 Engine Control Module, with Anti-Theft Protection”,
or
page 170
m
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atio
m
5.1 Engine Cover with Air Filter

o
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or c
thi
te
sd
Removing
iva
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rp
– Disconnect the connector -1-, if equipped, reposition the cu

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f
en
ng
clamp -2- and disconnect the connecting pipe.

t.
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– Remove the screws -3- and disconnect intake air duct.
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– Pull the engine cover up, with a jerking motion off of the
mounts, first at the front in direction of -arrow 1-, then at the
right rear in direction of -arrow 2- and finally at the left rear in
direction of -arrow 3-.
– Carefully swivel the engine cover out of the rear area.
Installing
Note
The rubber bushings must not be treated with lubricant, neither

for assembly to the cover or for assembly to the engine.
– Position the engine cover correctly on the mounts and press

down by hand.
cedure.
5.2 Throttle Valve Control Module - J338-


Golf 2004 ➤ , Golf 2009 ➤
Removing
Note
Pay attention to the rules of cleanliness. Refer to


– Remove the connecting pipe -4-. To do so, disconnect the
Secondary Air Injection (AIR) connecting pipe -1-, if equipped,
and the vent tube -2- and reposition the spring clamp -3-.
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– Disconnect the connector lkswand the vent hose -2-. es not
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Seal the intake passage in the intake manifold using a clean cloth.
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– Clamp off the coolant hoses using Hose Clamps Up to 25 mm

rrectness of i
dia. - 3094- and disconnect them from the throttle valve control
module connections -arrows-, if equipped.
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Golf 2004 ➤ , Golf 2009 ➤
♦ Replace the gasket for the throttle valve control module, if

damaged.
♦ Connection for coolant hoses.
♦ Make sure the connecting pipe -1-, if equipped and the vent
tube -2- are fitted securely.
♦ When replacing, erase the adaptation values and adapt the
Engine Control Module (ECM) to the throttle valve control
module. Refer to “Guided Functions” in the vehicle diagnostic
tester.
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5.3 Intake Manifold
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♦ Socket and Extended Bit - T10107A-
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♦ Observe the safety precautions. Refer to
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⇒ “1.1 Safety Precautions”, page 1 .

♦ Follow the guidelines for clean working conditions. Refer to
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– See if a coded radio is installed. If so, obtain the anti-theft code.
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– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
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♦ The fuel supply line is under pressure. Always wear pro‐

tective eyewear and protective clothing to prevent injuries
and fuel from coming in contact with your skin. Before
loosening the fuel lines, place a cloth around the connec‐
lease the pressure.
– Disconnect the vent line -1-, the vacuum line -2- and the fuel
supply line -3-. To release the lines -1 and 2- , press the circlip
in. With the line -3-, the retainer must be pressed upward into
the housing.

Golf 2004 ➤ , Golf 2009 ➤
– Disconnect the connectors -1, 2 and 6-.

– Remove the wiring harness -3- from the transport strap.
– Pull the clips -4- and retaining ring -5- out of the locking mech‐
anism.
– Remove the bolts -7- and remove the transport strap.
– Remove the Throttle Valve Control Module - J338- . Refer to
⇒ “5.2 Throttle Valve Control Module J338 ”, page 159 . The
coolant hoses remain attached, if equipped.
– Disconnect the Manifold Absolute Pressure Sensor - G71-
connector.
– Disconnect the connector -1- and crankcase ventilation hose

-3-.
– Remove the wiring harness -2-. To do so, carefully pry out the
clips -arrows-.
– Pull the oil dipstick out -1- and press the retaining ring -4-
downward. agen
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– Remove the noise insulation. Refer to ⇒ Body Exterior;d by VRep. gu
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Gr. 50 ; Description and Operation . orise nte
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– Loosen the bolts or nuts -1- on the bottom side of the intake
manifold.
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Golf 2004 ➤ , Golf 2009 ➤
– Loosen the bolt -arrow- for the intake manifold support and
guide pipe.
– Lay the guide pipe -arrows- aside.
– Open the clip -arrow- on the Leak Detection Pump - V144-

vacuum hose.
– Loosen the intake manifold bolts -arrows- using the Socket
And Extended Bit - T10107A- .
The bolts remain in the intake manifold.
– Remove the intake manifold upward at an angle.
Make sure that no bolts fall out. AG. Volkswagen AG d
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– Seal the intake passages in the cylinder
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– Remove the fuel rail with injectors. Refer to

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– Disconnect the vacuum hose for the leak detection pump.

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5. Removal and Installation
Golf 2004 ➤ , Golf 2009 ➤
– Remove the Manifold Absolute Pressure (MAP) sensor.

Installing
♦ Replace the seals between the intake manifold and cylinder
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– Connect the battery. Refer to ⇒ Electrical Equipment; Rep.
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– Bleed the fuel supply system. Refer to
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Intake manifold to cylinder head 9
Intake manifold support to intake manifold, en‐ 20
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Intake manifold support to intake manifold, en‐ 16

gine codes CBTA and CBUA
Intake manifold support to cylinder block 25
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Transport strap to cylinder head 25

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Oil dipstick guide tube to cylinder block 25
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Note
♦ Observe the safety precautions. Refer to

⇒ “1.1 Safety Precautions”, page 1 .
♦ Follow the guidelines for clean working conditions. Refer to
– See if a coded radio is installed. If so, obtain the anti-theft code.

– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
WARNING
♦ The fuel supply line is under pressure. Always wear pro‐

tective eyewear and protective clothing to prevent injuries
and fuel from coming in contact with your skin. Before
loosening the fuel lines, place a cloth around the connec‐
lease the pressure.

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– Disconnect the vent line -1- and the fuel supply line -3-. To
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release the line -1-, press the circlip in. With line -3-, the re‐
ab
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tainer must be pressed upward into the housing.
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– Disconnect the connectors -1, 2 and 6-.mercia
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– Remove the wiring harness -3- from the transport strap.
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– Pull the clip -4- and retaining ring -5- out of the locking mech‐
s
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– Remove the bolts -7- and remove the transport strap.
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– Remove the bolts -1- and pull the fuel rail with the injectors
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– Seal or cover the openings in the intake manifold.
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– Pull off the retaining clips -3- and then the fuel injectors.
Installing
– Install new O-rings for the fuel injectors and coat them lightly
with clean engine oil.

Golf 2004 ➤ , Golf 2009 ➤
– Press the fuel injectors into the fuel rail so that the tabs
-1 and 2- align.
– Slide the retaining clip -3- as shown into the groove in the fuel
injector. The collar -4- must be located correctly in the cutout
of the retaining clip on both sides.
– After assembling, check all the fuel injectors for correct fitting.
– Attach the fuel rail with secured fuel injectors onto the intake
manifold and press it in uniformly.
– Bolt the fuel rail to the intake manifold.
– Connect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Removal and Installation
– Bleed the fuel supply system. Refer to
⇒ “1.1 Fuel System, Filling and Bleeding”, page 144 .
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5.5 Engine Control Module, without Anti-

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If the Engine Control Module (ECM) will be replaced, connect the

t to the co
vehicle diagnostic tester and perform the “Replacing Engine Con‐

trol Module” guided function.
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– Turn off the ignition.

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– Remove the wiper arms and plenum chamber cover. Refer to

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⇒ Electrical Equipment; Rep. Gr. 92 ; Removal and Installa‐

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Installing
– Connect and lock the rear connector to the ECM.
– Slide the ECM onto the retaining plate.
– Connect and lock the front connector to the ECM.
– Install the plenum chamber bulkhead. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 50 ; Description and Operation .
– Install the plenum chamber cover and the wiper arms. Refer
to ⇒ Electrical Equipment; Rep. Gr. 92 ; Removal and Instal‐
lation .

Golf 2004 ➤ , Golf 2009 ➤
5.6 Engine Control Module. with Anti-Theft

Protection
♦ Locking Pliers
♦ Window Cutter - VAG1561A-
♦ Saw Set - VAG1561/14-
♦ Heat Gun - VAS1978/14A-
Note wage
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If the Engine Control Module (ECM) will be replaced, oconnect
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vehicle diagnostic tester and perform the “Replacing u Engine Con‐
th or
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The threads of the shear bolts are equipped with locking com‐
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pound. By heating the shear bolts using a hot air gun, the inhibi‐
or
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ECM to prevent them from being burned.
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Perform the adjustments on the hot air gun -4- as shown: Prote
cted AG.
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– Turn the potentiometer for temperature adjustment -2- to max‐

imum heat output (600 °C (1112 °F)).
– Move the two stage switch for air quantity -3- to position 3.
WARNING
By heating the shear bolts, parts of the protective housing are

heated intensely. Wear protective gloves to prevent injuries.
– Guide the nozzle of the hot air gun onto the shear bolts.
– Turn the heat gun on and heat the bolts.
– Remove the bolts using locking pliers.

Golf 2004 ➤ , Golf 2009 ➤
AG. Volkswagen AG d
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If the bolts cannot be removed, cut into the head so two parallel
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lines are formed -arrows- and then remove them.
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– Insert a screwdriver -A- between the protective housing and
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– Pry the protective housing upward using the screwdriver -A-
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– Disconnect the front connector -1- from the ECM.

– Pry up the locking mechanism -2- slightly.
– Then slide the ECM out of the retainer -arrow-.
– Disconnect the rear connector from the ECM.

Installing
– Connect and lock the rear connector to the ECM.
– Slide the ECM onto the retaining plate.
– Connect and lock the front connector to the ECM.
– Slide the protective housing onto the retaining plate.

Golf 2004 ➤ , Golf 2009 ➤
– Tighten the shear bolts -1- uniformly until the bolt heads shear
off.
lation .
5.7 Engine Control Module, without Anti-

Theft Protection
Note
If the Engine Control Module (ECM) will be replaced, connect the

vehicle diagnostic tester and perform the “Replacing Engine Con‐
Removing
tion .
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– Push the retaining frame in the direction of the -arrow-
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– Push the retainers in the direction of the -arrow- and discon‐

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– Connect the connector to the ECM and push the retainers all
pt
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the way in, in the direction of the -arrow-.
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– Mount the ECM into the retaining frame and push it in, in the
direction of the -arrow- upward.
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5.8 Engine Control Module, with Anti-Theft

Protection
Note
♦ If the Engine Control Module (ECM) will be replaced, connect

the vehicle diagnostic tester and perform the “Replacing En‐
gine Control Module” guided function.
♦ The threads on the shear bolts may have locking compound
on them. Heat the shear bolts using the Hot Air Gun -
VAS1978/14- so they are easier to remove. When doing this
be careful not to damage any wires, connectors or compo‐
nents nearby.
Removing
tion .

Golf 2004 ➤ , Golf 2009 ➤
– Push the retaining frame in the direction of the -arrow- down‐

ward and remove the ECM.
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– Remove the shear bolts -arrows-.
t to the co
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– Slide a screwdriver between both locking plates in direction of
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– Bend the locking bracket -1- in the direction of the -arrow- until
it can be removed from the connectors.

Golf 2004 ➤ , Golf 2009 ➤
– Push the retainers in the direction of the -arrow- and discon‐

nect the connector.
Installing
– Connect the connector to the ECM and push the retainers all
the way in, in the direction of the -arrow-.
– Place the locking bracket -1- on the connectors and press it

in, in the direction of the -arrow-.
– Install the bolts -2- all the way into the hole on the ECM hous‐
ing.
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– Secure the locking bracket to the ECM -arrows- with new

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shear bolts.
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Rep. Gr.24 - Multiport Fuel Injection
Golf 2004 ➤ , Golf 2009 ➤
– Mount the ECM into the retaining frame and push it in, in the
direction of the -arrow- upward.
lation .
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Golf 2004 ➤ , Golf 2009 ➤
Engine Mechanical, Fuel Injection
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6 Special Tools ris nte
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♦ Window Cutter - VAG1561A-
itte
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♦ Suction Pump - VAS5226-
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♦ Vehicle Diagnostic, Testing, and Information System -

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♦ Hose Clamps up to 25 mm Dia. - 3094-

Golf 2004 ➤ , Golf 2009 ➤
♦ Socket and Extended Bit - T10107A-
♦ Saw Set - VAG1561/14-
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♦ Heat Gun - VAS1978/14A- rise d
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♦ Adapter for K-jetronic Test Device - VAG1318/20-

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Golf 2004 ➤ , Golf 2009 ➤
♦ Remote Control -
VAG1348/3A-
♦ Adapter Cable -
VAG1348/3-2-
♦ Injector Rate Tester -
VAG1602-
♦ Connector Test Set -
VAG1594C-
♦ Test Instrument Adapter/
DSO (5-pin) - VAS5565-
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Golf 2004 ➤ , Golf 2009 ➤
26 – Exhaust System, Emission Controls

⇒ “1.1 Secondary Air Injection System Overview”, page w177
agen
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⇒ “1.2 Exhaust Manifold Overview”, page 179 yV gu
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ris nte
Engine Codes BGP and CBTA tho eo
au ra
⇒ “1.3 Exhaust Pipe with Catalytic Converter
ss Overview”, c
ce
le
page 180
un
pt
an
d
itte
Engine Codes BGQ and CBUA
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erm
ab
⇒ “1.4 Exhaust Pipe with Catalytic Converter Overview”,
ility
ot p
page 182
wit
is n
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⇒ “1.5 Muffler Overview”, page 184
ole,
spec
1.1 Secondary Air Injection System Over‐
t to the co
view
rrectne
Note
ss o
The Secondary Air Injection (AIR) system is not installed on all
cial p
f in
engines.
form
mer
atio
om
n
c
i
or
n thi
te
sd
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Golf 2004 ➤ , Golf 2009 ➤
1 - Bolt
❑ 10 Nm
2 - Secondary Air Injection
(AIR) Pipe
❑ Follow the tightening se‐
quence. Refer to AG. Volkswagen AG d
⇒ Fig. ““AIR Pipe Bolt agen oes
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Tightening Sequence”“ , d by V gu
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page 179 . rise nte
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3 - Connector ss c
ce
e
❑ For the AIR solenoid

nl
pt
du
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valve.
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4 - Secondary Air Injection Sol‐
ility
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enoid Valve - N112-
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❑ Do not disassemble.
hole
spec
❑ Checking. Refer to
es, in part or in w
⇒ “3.1 Secondary Air In‐
t to the co
jection Solenoid Valve,
Checking”, page 186 .
rrectness of i
ling. Refer to
l purpos
⇒ “4.2 Secondary Air In‐

jection Solenoid Valve
N112 ”, page 188 .
nf
ercia
orm
5 - Connecting Pipe
m
atio
m
❑ Make sure it is secure

o
n in
or c
❑ To disengage, squeeze
thi
te
sd
a
together the securing

iv
o
r
rp
cu
ring.
o
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t.
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6 - Secondary Air Injection
Co
op py
Sensor 1 - G609- t. C rig
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❑ Installed from MY 2009. cop Vo
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7 - Bolt
AG.
❑ 2 Nm
❑ Installed from MY 2009.
8 - Bracket
9 - Gasket
❑ Allocation. Refer to the Parts Catalog.
10 - Bolt
❑ 10 Nm
11 - Connecting Pipe
❑ For the AIR pump.
12 - Secondary Air Injection Pump Motor - V101-
❑ Removing and installing. Refer to ⇒ “4.1 Secondary Air Injection Pump Motor V101 ”, page 187 .
13 - Rubber Bushing
14 - Bolt
❑ 25 Nm
15 - Nut
❑ 10 Nm
❑ With the mounts for the AIR pump motor.
178 Rep. Gr.26 - Exhaust System, Emission Controls

Golf 2004 ➤ , Golf 2009 ➤
17 - Cylinder Head
18 - Connecting Pipe
AG. Volkswagen AG d
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AIR Pipe Bolt Tightening Sequence ise
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– Replace all AIR pipe gaskets -A-. s aut ra
c
s
– Install all bolts only hand tight.
ce
e
nl
pt
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an
itte
– Tighten the bolts -1- first, then the bolt -2- and then the bolt
y li
erm
ab
-3- to 10 Nm.
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
1.2 Exhaust Manifold Overview
l purpos
1 - Gasket
nf
ercia
o
❑ Always replace.
rm
m
atio
m
2 - Nut
o
n in
or c
❑ 25 Nm
thi
te
sd
a
❑ Always replace.
iv
o
r
rp
cu
o
m
f
3 - Exhaust Manifold
en
ng
t.
yi Co
op
❑ Coat the stud bolts on C py
t. rig
the cylinder head with gh ht
yri by
hot bolt paste. cop Vo
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❑ Remove upward.
Prote AG.
4 - Clip
5 - Heat Shield
6 - Bolt
❑ 10 Nm
7 - Heated Oxygen Sensor -
G39-
❑ 55 Nm
❑ Use the Ring Spanner
7-Piece Set - 3337- for
removal and installa‐
tion.
❑ When reusing an old
oxygen sensor again,
only use hot bolt paste
to grease the threads.
Do not let the paste get
onto the slits of the oxy‐
gen sensor body.
❑ Connector color: Black.

Golf 2004 ➤ , Golf 2009 ➤
1.3 Exhaust Pipe with Catalytic Converter Overview
❑ Coat the stud bolts with
hot bolt paste.
2 - Gasket
❑ Always replace.
AG. Volkswagen AG d
❑ Note the installation po‐ lksw
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Gasket recess -arrow A- ut
ho eo
ra
must be located at the ex‐ ss a c
haust manifold recess
ce
le
un
pt
-arrow B-.
an
d
itte
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3 - Nut
ility
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❑ 25 Nm
wit
is n
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❑ Always replace.
ole,
spec
4 - Exhaust Pipe with Catalytic
t to the co
Converter
❑ Protect from shocks and
impact stress.
rrectne
❑ With the coupling ele‐
ment.
ss
❑ Do not bend the cou‐
o
cial p
f i
pling element more than
nform
10° - otherwise it may
mer
get damaged.
atio
om
n
c
i
or
ling. Refer to n thi

te
sd
a
⇒ “4.3 Exhaust Pipe with

iv
o
pr
Catalytic Converter”,
um
r
fo
en
ng
page 189 . yi
t.
Co
op
❑ Align the exhaust sys‐
C py
ht. rig
tem free of tension. Re‐ rig ht
py by
Vo
fer to
co lksw
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cted agen
⇒ “4.5 Exhaust System, Prote AG.
Aligning”, page 191 .
5 - Clamp
❑ Before tightening, ensure the exhaust system is free of tension. Refer to
⇒ “4.5 Exhaust System, Aligning”, page 191 .
❑ Installed position. Refer to ⇒ Fig. ““Installed Position of the Clamp”“ , page 181 .
6 - Nut
❑ 25 Nm
❑ Tighten the nuts evenly.
7 - Nut
❑ 23 Nm
8 - Front Cross Member
9 - Oxygen Sensor after Three Way Catalytic Converter - G130-
❑ 55 Nm
❑ When reusing an old oxygen sensor again, only use hot bolt paste to grease the threads. Do not let the
paste get onto the slits of the oxygen sensor body.
10 - Connector
❑ Brown, 4 pin
❑ Installed position. Refer to ⇒ Fig. ““Oxygen Sensor Connector Installed Position”“ , page 181 .

Golf 2004 ➤ , Golf 2009 ➤
11 - Bolt
❑ 25 Nm
12 - Suspended Mount
Installed Position of the Clamp

– Align the clamp -1- to the mark on the pipe -2-.
-a - = 5 mm
The bolts must not project beyond the lower edge of the clamp.
Oxygen Sensor Connector Installed Position

The connector is located to the right, on the vehicle floor under
the cover.
1- Bracket
2- Oxygen sensor after three way catalytic converter connec‐
tor, brown
AG. Volkswagen AG d
agen oes
olksw not
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nl
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itte
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ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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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.

Golf 2004 ➤ , Golf 2009 ➤
1.4 Exhaust Pipe with Catalytic Converter Overview
❑ Coat the stud bolts with
hot bolt paste. en AG. V
olkswagen AG
ag does
ol ksw not
2 - Gasket yV gu
edb ara
❑ Alwayshoreplace.
ris nte
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❑ Note ss the installed posi‐
a c
tion:
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le
un
pt
an
d
Gasket recess -arrow A-

itte
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must be located at ex‐
erm
ab
ility
haust manifold recess
ot p
wit
-arrow B-.
is n
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ole,
3 - Connector
spec
❑ Black, 4 pin
t to the co
4 - Oxygen Sensor in Bank 1
Center Three Way Catalytic
rrectne
Converter - G465-
❑ 55 Nm
ss
❑ When reusing an old
o
cial p
oxygen sensor again, f inform

only use hot bolt paste
mer
to grease the threads.

atio
m
Do not let the paste get

o
n
c
i
or
onto the slits of the oxy‐

thi
e
gen sensor body.

t
sd
iva
o
pr
cum
5 - Spring Nut
r
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ng
t.
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❑ Insert from the front.
Co
Cop py
t. rig
6 - Clamp
gh ht
pyri by
Vo
o
by c
❑ Before tightening, en‐
lksw
cted agen
Prote
sure the exhaust system
AG.
is free of tension. Refer

to
⇒ “4.5 Exhaust System,
❑ Installed position. Refer to ⇒ Fig. ““Installed Position of the Clamp”“ , page 183 .
7 - Nut
❑ 25 Nm
8 - Nut
❑ 23 Nm
9 - Oxygen Sensor after Three Way Catalytic Converter - G130-
❑ 55 Nm
❑ When reusing an old oxygen sensor again, only use hot bolt paste to grease the threads. Do not let the
paste get onto the slits of the oxygen sensor body.
10 - Connector
❑ Brown, 4 pin
❑ Installed position. Refer to ⇒ Fig. ““Oxygen Sensor Connector Installed Position”“ , page 183 .
11 - Front Cross Member
12 - Bolt
❑ 5 Nm

Golf 2004 ➤ , Golf 2009 ➤
13 - Heat Shield
❑ For the catalytic converter.
14 - Bolt n AG. Volkswagen AG do
lkswage es n
❑ 25 Nm byV
o ot g
ua
d ran
ir se
15 - Suspended Mount utho tee
or
a ac
❑ Replace if damaged. ss
ce
le
un
pt
16 - Bolt
an
d
itte
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❑ 10 Nm rm
ab
pe
ility
17 - Exhaust Pipe with Catalytic Converter
ot
wit
, is n
❑ Protect from shocks and impact stress.
h re
hole
spec
❑ With the coupling element.
es, in part or in w
❑ Do not bend the coupling element more than 10° - otherwise it may get damaged.
t to the co
❑ Removing and installing. Refer to ⇒ “4.3 Exhaust Pipe with Catalytic Converter”, page 189 .
❑ Align the exhaust system free of tension. Refer to ⇒ “4.5 Exhaust System, Aligning”, page 191 .
rrectness of i
18 - Nut
l purpos
❑ 25 Nm
❑ Always replace.
nform
mercia
a
com
tion in
Installed Position of the Clamp
r
te o
thi
s
iva
do
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rp
cum
fo
– Align the clamp -1- to the mark on the pipe -2-.
en
ng
t.
yi Co
op
-a - = 5 mm C py
t. rig
gh ht
yri
The bolts must not project beyond the lower edge of the clamp.
p by
co Vo
by lksw
cted agen
Prote AG.
Oxygen Sensor Connector Installed Position

The connector is located to the right, on the vehicle floor under
the cover.
1- Oxygen sensor after three way catalytic converter connec‐
tor, brown
2- Bracket
3- Oxygen sensor in bank 1 center three way catalytic con‐
verter connector, black

Golf 2004 ➤ , Golf 2009 ➤
1.5 Muffler Overview
Note
♦ After exhaust system repairs, make sure the exhaust system

is not under stress and that it has sufficient clearance from the
body. If necessary, loosen the clamp(s) and align the exhaust
pipe so that sufficient clearance is maintained to the body and
the retaining rings carry uniform loads.
♦ Gaskets and self-locking nuts must be replaced.
1 - Front Muffler
2 - Suspended Mount
3 - Retaining Ring
4 - Nut
❑ 25 Nm
5 - Rear Muffler
❑ Factory installed with
the front muffler as one
unit. If repairs are nec‐
essary, replace sepa‐
rately.
❑ Align the exhaust sys‐
tem free of tension. Re‐
fer to
⇒ “4.5 Exhaust System,
❑ Separating the exhaust
system. Refer to
⇒ “4.4 Muffler”,
page 190 . lkswage es n
o ot g
byV ua
6 - Suspended Mount ir se
d ran
tee
o
auth or
ac
ss
7 - Bolt
ce
e
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an
❑ 25 Nm
itte
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erm
ab
8 - Repair Clamp
ility
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❑ For individual replace‐

wit
, is n
h re
ment of the front and

hole
rear mufflers.
spec
es, in part or in w
❑ Installed position. Refer

t to the co
to
⇒ “4.4 Muffler”,
page 190 .
rrectness of i

l purpos
9 - Center Muffler
❑ Factory installed with the rear muffler as one unit. If repair is necessary, replace separately.
nform
ercia
❑ Align the exhaust system free of tension. Refer to ⇒ “4.5 Exhaust System, Aligning”, page 191 .
m
at
om
❑ Separating the exhaust system. Refer to ⇒ “4.4 Muffler”, page 190 .

ion
c
in t
or
10 - Bolt
his
ate
do
riv
❑ 25 Nm
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
184
co Vo
by lksw
Rep. Gr.26 - Exhaust System, Emission Controls cted agen
Prote AG.
Golf 2004 ➤ , Golf 2009 ➤
2 Specifications

Secondary Air Injection (AIR) Pipe Bolt Tightening Sequence and
Specification
– Tighten the bolts -1- first, then the bolt -2- and then the bolt
-3- to 10 Nm.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Golf 2004 ➤ , Golf 2009 ➤

⇒ “3.1 Secondary Air Injection Solenoid Valve, Checking”,
page 186
3.1 Secondary Air Injection Solenoid Valve,

Checking
♦ Assisting Hose, for example, a Coolant Hose
Test Sequence
Note
Do not use compressed air during following check!

– Disconnect connecting pipe -2- from theswSecondary
agen
AG. VolkAir Injec‐ does
swagen AG
tion Solenoid Valve - N112- -3-. Tobydo
Volso,
k compress the not
gu
securing ring. ris
ed ara
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tho or
– Disconnect the connector -4-.
sa
u ac
s
ce
le
– Slide the assisting hose -1-, for example, a coolant hose, onto
un
the Secondary Air Injection (AIR) solenoid valve. pt

an
d
itte
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rm
– Blow forcefully into the assisting hose -arrow-. ab

pe
ility
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wit
The valve must be closed.
, is n
h re
hole
If air can be blown through the valve with the assisting hose prop‐
spec
erly sealed:
es, in part or in w
t to the co
– Replace the AIR solenoid valve.

If the valve is closed:
rrectness of i
– Connect the terminals on the valve connection -5- with adapter

l purpos
cables from the Connector Test Set - VAG1594C- to battery

positive (+) and negative (-).
nform
ercia
– Blow forcefully into the assisting hose -arrow-.

m
The valve must be opened.

com
tion in
r
If no air can be blown through valve with assisting hose properly

te o
thi
sealed:
s
iva
do
r
rp
cum
– Replace the AIR solenoid valve. Refer to

fo
en
ng
⇒ “4.2 Secondary Air Injection Solenoid Valve N112 ”,

t.
yi Co
op
page 188 . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤ , Golf 2009 ➤

⇒ “4.1 Secondary Air Injection Pump Motor V101 ”, page 187
⇒ “4.2 Secondary Air Injection Solenoid Valve N112 ”,
page 188
⇒ “4.3 Exhaust Pipe with Catalytic Converter”, page 189
⇒ “4.4 Muffler”, page 190
Volkswa
⇒ “4.5 Exhaust System,sAligning”,
wage
n AG. page g191
en AG
does
olk not
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4.1 Secondary Air Injection Pump Motor
ris
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tho eo
ss
V101-
au ra
c
ce
le
Removing
un
pt
an
d
itte
y li
– Remove the throttle valve control module. Refer to
rm
ab
⇒ “5.2 Throttle Valve Control Module J338 ”, page 159 .
pe
ility
ot
wit
– Disconnect the connecting pipes -1 and 2-. To do so, com‐
, is n
h re
press the securing rings.
hole
spec
es, in part or in w
t to the co
Gr. 50 ; Description and operation .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
– Disconnect the connectors -1 and 2-.

thi
s
iva
do
– Press out the clip -3- for the wire guide.

r
rp
cum
fo
en
g
– Press out the wire clip at the top front bolt.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Remove the intake manifold support bolts -1- from the intake
manifold.

Golf 2004 ➤ , Golf 2009 ➤
– Remove the lower bolt -arrow- from the intake manifold sup‐
port.
– Move the intake manifold support slightly to the side. Remove
the nuts and the AIR pump motor.
Installing
olkswagen AG
en AG. V
♦ Make sure that connecting pipes lock securelyoto kswthe AIR
ag does
not
V l
pump motor. ed
by gu
ara
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Tightening Specifications aut
ho eo
ra
ss c
Component Nm
ce
le
un
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an
d
AIR pump motor to intake manifold support 10

itte
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erm
ab
Intake manifold support to intake manifold Refer to
ility
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⇒ “1.1 Secon‐
wit
is n
dary Air Injec‐
h re
ole,
tion System
spec
Overview”,
page 177
t to the co
4.2 Secondary Air Injection Solenoid Valve
rrectne
- N112-
ss
Removing
o
cial p
f inform
– Disconnect the connector -1- and remove the connecting pipe
mer
-2-.
atio
om
n
– Remove the bolts -arrows- from the Secondary Air Injection
c
i
or
n
(AIR) pipe.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove the bolts from the AIR solenoid valve and remove the
valve.
Installing
– Replace the gaskets.
– Only tighten the bolts by hand.
– Tighten the AIR pipe bolts -arrows- to the AIR solenoid valve.

Golf 2004 ➤ , Golf 2009 ➤
– Connect the connector -1- and connecting pipe -2-. Make sureAG. Volkswagen AG d
the connecting pipe is seated securely. lksw
agen oes
n o ot g
yV ua
Tightening Specifications ris
edb ran
tee
tho or
Component au Nm ac
ss
ce
e
AIR solenoid valve 10
nl
pt
du
an
itte
AIR pipe 10
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
4.3 Exhaust Pipe with Catalytic Converter
rrectness of i
l purpos
♦ Hot Bolt Paste. Refer to the Parts Catalog
nform
ercia
Removing
m
at
om
– Remove the right underbody trim retainers -arrows- and trim.
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.
Engine Codes BGP and CBTA

– Unclip the wire -arrow-, pull off the bracket -1- and disconnect
the connector for oxygen sensor after three way catalytic con‐
verter - G130- -2-.
Engine Codes BGQ and CBUA

– Unclip the wires -arrows-, pull off the bracket -2- and discon‐
nect the connectors for the oxygen sensor after three way
catalytic converter -1- and for the oxygen sensor in bank 1
center three way catalytic converter - G465- -3-.

Golf 2004 ➤ , Golf 2009 ➤
Continuation for All wage

es n
lks ot g
Vo
– Loosen the clamp -1- nuts. The front cross member d must not
by ua
ran
be removed. ir se tee
tho
u or
a ac
ss
ce
le
Note
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Remove the exhaust pipe with catalytic converter to exhaust
rrectne
exhaust manifold, slide toward the front at the sides and guide
ss
it under the front cross member.
o
cial p
f in
Installing
form
mer
atio
om
n
c
i
♦ Replace gaskets and self-locking nuts.
or
n thi
te
sd
va
♦ Install the exhaust system free of stress. Refer to

i
o
pr
cum
⇒ “4.5 Exhaust System, Aligning”, page 191 .
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri
Component Nm
p by
co Vo
by lksw
cted agen
Exhaust pipe with catalytic converter to exhaust 25 1
Prote AG.
manifold
♦ Replace nuts
Suspended mount to subframe 25

Clamp 25
♦ 1Coat the stud bolts on the exhaust manifold with hot bolt
paste
4.4 Muffler
Note
♦ A separating point has been provided in the connecting pipe

for individual replacement of the front or rear muffler.
♦ The separating point is marked by depressions around the
circumference of the exhaust pipe.

♦ Body Repair Saw - VAG1523A- or
♦ Chain Pipe Cutter - VAS6254-

Golf 2004 ➤ , Golf 2009 ➤
Separating
WARNING
To prevent injuries from metal shavings, wear protective gog‐

gles and protective clothing.
G. Volkswagen
– Cut the exhaust pipelksat
wathe separation point
gen A AG do
-arrow
es n 2- using
for example, thed bBody
y Vo
Repair Saw - VAG1523A- oat t gua right an‐
ara
gle. or
ise nte
th eo
Joining au ra
c
ss
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
A second technician is needed to install the repair clamp.
wit
, is n
h re
hole
spec
– Secure the front muffler in the retainers. The front clamp re‐
es, in part or in w
mains loosely connected to the pipes.
t to the co
– Align the rear muffler horizontally and hold it in this position.
– Position the repair clamp at the side marks -arrows 1 and 3-.
rrectness of i
l purpos
– Position the repair clamp -A- as shown and tighten it to 25 Nm.

– Then, align the exhaust system free of tension. Refer to
nf
ercia
⇒ “4.5 Exhaust System, Aligning”, page 191 . orm

m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
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4.5 Exhaust System, Aligning

• Align the exhaust system when cold.
– Loosen the front double clamp bolts.
– Push the exhaust system far enough forward so that the pre‐
tension at the retaining rings at the rear muffler = 15 to 17 mm
-a-.

Golf 2004 ➤ , Golf 2009 ➤
– Install the clamping sleeve so that the end of the bolt does not
extend beyond the lower edge of the clamping sleeve.
• Threaded connection points toward the right.
– Tighten the clamping sleeve bolts uniformly to 25 Nm.
Aligning the Tailpipe
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Golf 2004 ➤ , Golf 2009 ➤
5 Special Tools
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Golf 2004 ➤ , Golf 2009 ➤
28 – Ignition/Glow Plug System

⇒ “1.1 Ignition System Component Overview”, page 194
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♦ It is possible that the control module will recognize a malfunc‐
spec
tion and store a Diagnostic Trouble Code (DTC) during some
tests. After completing all checks and repairs, check the DTC
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memory and erase the memory, if necessary.
♦ If the engine only starts briefly and then shuts off again after
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troubleshooting, repairs or checking of the components, it may
be that the immobilizer is blocking the Engine Control Module
(ECM). The ECM may have to be adapted. Refer to the vehicle
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194 Rep. Gr.28 - Ignition/Glow Plug System

Golf 2004 ➤ , Golf 2009 ➤
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⇒ “1.2 Knock Sensor
5 - Bolt
❑ 20 Nm
❑ Tightening specification affects the function of the knock sensor.
6 - Ignition Coil with Power Output Stage - N70, N127, N291, N292, N323-
❑ Removing and installing. Refer to ⇒ “3.1 Ignition Coil with Power Output Stage”, page 199 .
7 - Spark Plug
❑ 25 Nm
❑ Type and electrode gap. Refer to ⇒ “2.1 Test Data and Spark Plugs”, page 198 .
❑ Remove and install using the Spark Plug Removal Tool - 3122B- .
8 - Bolt
❑ 10 Nm
9 - Camshaft Position Sensor - G40-
10 - O-ring

Golf 2004 ➤ , Golf 2009 ➤
Installation Position of the Knock Sensor Connectors

1- Green for the knock sensor 1
2- Gray for the knock sensor 2
1.2 Knock Sensor Overview
Note
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7 - Plug
8 - Wire Clip
❑ Clamped on cover plate
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the right on the outside.
10 - Wire Bracket
❑ Bolted to Secondary Air
Injection (AIR) valve.
11 - Connector
❑ Green for the knock sensor 1.

Golf 2004 ➤ , Golf 2009 ➤
❑ Installed position. Refer to ⇒ Fig. ““Installed Position of the Knock Sensor Connectors”“ , page 197 .
12 - Connector n AG. Volkswagen AG do
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Golf 2004 ➤ , Golf 2009 ➤
2 Specifications
⇒ “2.1 Test Data and Spark Plugs”, page 198
2.1 Test Data and Spark Plugs

Engine Codes BGP, BGQ, CBTA and CBUA
Ignition sequence 1-2-4-5-3
Spark plugs
VW/Audi Refer to the Parts Catalog
Electrode gap 1.0 to 1.1 mm
Tightening specification gen AG
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Golf 2004 ➤ , Golf 2009 ➤

⇒ “3.1 Ignition Coil with Power Output Stage”, page 199
3.1 Ignition Coil with Power Output Stage

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♦ To remove from the spark plugs, place the Ignition Coil Puller
spec
- T40039- on the top most thick rib -arrow- of the ignition coil
with power output stage.
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♦ The lower ribs may be damaged if they are used.
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– Disconnect the connector -arrow- from the Secondary Air In‐
atio
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jection Solenoid Valve - N112- , if applicable.

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In order to prevent damage to the wire guide, remove the ignition
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coil with power output stage as follows:

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– Pull all the ignition coils approximately 10 mm out of the spark

plug shaft using the Ignition Coil Puller - T40039- . Start with
ignition coil -1-.
– Then, pull out all ignition coils a further 10 mm in the same
sequence.
– Disengage all connectors and pull them out only slightly.

Golf 2004 ➤ , Golf 2009 ➤
– Disconnect all the connectors -A- starting at ignition coil -1-

and remove the ignition coils from the spark plug shaft.
Installing
– Insert all ignition coils loosely into the spark plug shaft.
– Align the ignition coils to the recesses in the cylinder head
cover. Connect all the connectors to the ignition coils in the AG. Volkswagen AG d
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Golf 2004 ➤ , Golf 2009 ➤
4 Special Tools
Edition 01/08/2015 - USA51206521 - FU - ESP
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Golf 2004 ➤ , Golf 2009 ➤
5 Revision History AG. Volkswagen AG d

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Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
. Volkswagen AG
does
a suitable workshop for gen AG
•= If you lack the skills, tools and equipment,olkor swa any
not procedure described in this manual, we
y V gu
suggest you leave such repairs to anedauthorized Volkswagen retailer or other
b ara qualified shop. We especially urge
ris nte
you to consult an authorized Volkswagen
tho retailer before beginning repairs on any
e o vehicle that may still be covered
u ra
wholly or in part by any of thessextensive
a warranties issued by Volkswagen. c
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un
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•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
an
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system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
erm
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ility
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•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
is n
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are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
ole,
spec
check with your authorized Volkswagen retailer parts department for the latest information.
t to the co
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
rrectne
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
s
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
s o
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
cial p
f inform
mer
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
atio
m
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
o
n
c
i
or
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become inoperable, even if the correct code is used in a later attempt.
thi
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•=
p
If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
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keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
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ng
t.
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starting the vehicle while you are under it. . Cop py
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•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself andco Vo
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others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
Prote AG.
being fully alert.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing
gen AG
. Volkswagasbestos
en AG
does
fibers and asbestos dust.
Breathing asbestos can cause serious diseases such ol swaasbestosis or cancer,
kas andnot may result in death.
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ed ran
oris tee
•= Finger rings should be removed so that they th cannot cause electrical shorts, get caught in running
or machinery, or be
au ac
crushed by heavy parts. ss
ce
le
un
pt
an
d
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
itte
y li
erm
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
ab
ility
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replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
wit
is n
repairs.
h re
ole,
spec
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
t to the co
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
rrectne
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
s
listed.
s o
cial p
f inform
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
mer
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
atio
om
n
c
i
or
n
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
thi
te
sd
a
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
iv
o
pr
c
govern the disposal of wastes.
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•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be C py
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serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment, rig ht
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trained in related safety precautions, and familiar with regulations governing the discharging and disposal of by c lksw
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automotive chemical refrigerants.
AG.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service techniciansenusing
AG. Vothe
lkswVAG
agen A1551
G do Scan Tool (ST) or an approved equivalent. The airbag unit
ag es n in the vehicle.
must never be electrically olksw
tested while it is not installed ot
V y gu
db ara
rise nte
•= Some aerosol tire uthoinflators are highly flammable. Be extremely cautious
eo
ra
when repairing a tire that may have been
s a aerosol tire inflator. Keep sparks, open flame or other
inflated using san c sources of ignition away from the tire repair
ce
le
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
un
pt
an
d
tire from the rim before attempting any repair.

itte
y li
erm
ab
ility
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
ot p
wit
is n
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
h re
ole,
spec
t to the co
I have read and I understand these Cautions and Warnings.
rrectness o
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f inform
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om
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Page 3 of 3
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00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 New Connecting Rod, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.1 Ribbed Belt Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.2 Ribbed Belt Drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.3 Engine Overview, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.4 Engine Overview, Front/Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.6 Flywheel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.8 Crankshaft, Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.1 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.1 Crankshaft Axial Clearance, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.2 Crankshaft Radial Clearance, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.3 Pistons and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.2 Oil Filter Adapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

3.1 Oil Pressure and Oil Pressure Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4.1 Lower Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4.2 Upper Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

4.3 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

1.1 Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

2.1 Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

2.2 Coolant Pump and Thermostat Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

2.3 Radiator and Fan Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

4.2 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

5.4 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

5.5 Engine Control Module, without Anti-Theft Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

5.6 Engine Control Module. with Anti-Theft Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

5.7 Engine Control Module, without Anti-Theft Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

5.8 Engine Control Module, with Anti-Theft Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t to the co

26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1.1 Secondary Air Injection System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1.3 Exhaust Pipe with Catalytic Converter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

1.4 Exhaust Pipe with Catalytic Converter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

1.5 Muffler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

2.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

⇒ “1.3 Engine Contaminants”, page 4

⇒ “1.1.1 Fuel Supply System”, page 1

⇒ “1.1.2 Road Test with Testing Equipment”, page 2

Fuel lines are under pressure.

Always observe the following when removing and installing the

Note the following whenever working inside the engine com‐

1.1.2 Road Test with Testing Equipment

The coolant system is under pressure when the engine is

Risk of scalding due to hot steam and hot coolant.

Reduce pressure by covering the coolant expansion tank cap

with a cloth and opening carefully.

Note the following whenever working inside the engine com‐