4-Cylinder Diesel Engine (1.9 L Engine)

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Workshop Manual
Golf 2004
Golf Plus 2005
4-cylinder diesel engine (1.9 l engine)
Engine ID
BJB
BKC BRU
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Edition 01.2009
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Service Department. Technical Information
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Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
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21 - Turbocharging/supercharging
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28 - Glow plug system
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26 - Exhaust system
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23 - Mixture preparation - injection
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List of Workshop Manual Repair GroupsList of Workshop Manual

Repair GroupsList of Workshop Manual Repair Groups
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright 2010 Volkswagen AG, Wolfsburg
K0059000420
Golf 2004 , Golf Plus 2005

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
1.2
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
1.2
1.3
1.4
Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
7
7
10
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - sealingn flanges
and
..............................
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Renewing crankshaft
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Removing and iinstalling
sealing flange - pulley end . a.ra.nt. . . . . . . . . . . . . . . . . . . . . . . . . . .
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Renewing crankshaft
sealing flange - flywheel end . . . . .e o. r .a . . . . . . . . . . . . . . . . . . . . . . .
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Removingssand installing engine speed sender G28 . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
2.4
2.5
3
3.1
3.2
4
4.1
4.2
4.3
4.4
4.5
12
12
13
15
19
20
20
21
23
25
31
33
33
38
39
39
40
41
42
42
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
1.5
2
2.1
2.2
2.3
2.4
2.5
44
45
48
50
67
71
74
74
76
78
80
84
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1
1.1
1.2
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
86
86
86

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
98
99
101
102
105
106
108
110
112
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1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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

Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel tank, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
2
3
3.1
3.2
3.3
3.4
3.5
3.6
4
4.1
4.2
4.3
4.4
4.5
4.6
5
5.1
5.2
5.3
5.4
5.5
114
115
116
116
117
121
123
124
125
127
127
128
132
135
137
138
140
140
141
142
143
147
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
ii
Contents
Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
151
151
151
152
156
158
161
162
164
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Parts of lubrication system . . . . . . . . . . . .

Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil filter bracket, oil pressure, engine oil cooler and oil supply line . . . . . . . . . . . . . . . . . .
Assembly overview - oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . .
Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2
2.1
2.2
3
3.1
3.2
3.3
3.4
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Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting non-contact gap of unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the intake manifold flap support, Engine code BLS and BXJ . . . . . . . . . . . . . . . .
Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine control unit, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing anti-theft engine control unit, Golf . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine control unit, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing anti-theft engine control unit, Golf Plus . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

166
166
167
167
169
171
172
174
176
177
178
178
179
180
180
183
183
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

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Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . . .
Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - silencer with mountings (vehicles with front wheel drive) . . . . . . . . . .
Assembly overview - silencer with mountings (vehicles with four-wheel drive) . . . . . . . . . .
Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - parts of exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
1.5
2
2.1
186
186
187
189
191
192
193
193
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

1
1.1
1.2
1.3
Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing, installing and checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Characteristics of ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing, installing and checking ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
198
198
199
200
iii

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Contents
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Technical data
Technical data
Engine number page 1

Engine data page 1
1.1
Engine number
The engine number (code letters and serial number) can be

found at the joint between engine and gearbox.
Additionally there is a sticker on the toothed belt guard with en
gine code and serial number.
The engine code is also included on the vehicle data sticker.
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79.5
95.5
2
19.0
DIN EN
590
1-3-4-2
yes
yes
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yes
yes
yes
yes
no
yes
no
yes
no
yes
AG.
Bore
mm
Stroke
mm
Valves per cylinder
Compression ratio
Fuel
accord
ing to
Firing order
Catalytic converter
Exhaust gas recircu
lation
Turbocharging/super
charging
Charge air cooler
Particulate filter
10.03
04.04
02.06
EU4
EU4
EU4
standard standard standard
1.9
1.9
1.9
77/
66/
77/
4000
4000
4000
250/
210/
250/
1900
1800...250
1900
0
79.5
79.5
79.5
95.5
95.5
95.5
2
2
2
19.0
19.0
18.5
DIN EN
DIN EN
DIN EN
590
590
590
1-3-4-2
1-3-4-2
1-3-4-2
yes
yes
yes
yes
yes
yes
yes
yes
03.06
EU4
standard
1.9
77/
4000
250/
1900
BXF
BXJ
03.06
11.07
EU4
EU4
standard standard
1.9
1.9
66/
66/
4000
4000
210/
210/
1800
1800...250
0
79.5
79.5
95.5
95.5
2
2
19.0
19.0
DIN EN
DIN EN
590
590
1-3-4-2
1-3-4-2
yes
yes
yes
yes
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Torque
l
kW at
rpm
Nm at
rpm
10.03
EU3
standard
1.9
77/
4000
250/
1900
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Manufactured
Emissions fulfil
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Engine code
Capacity
Output
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BJB
BKC
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Engine data
79.5
95.5
2
18.5
DIN EN
590
1-3-4-2
yes
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yes
yes
yes
yes
no
yes
no
yes
no
1. Technical data

10
Removing and installing engine
Removing engine page 2

Securing engine to assembly stand page 7
Notes on installing page 7 .
Assembly mountings page 10 .
1.1
Removing engine
Special tools and workshop

equipment required
Lifting tackle -2024 A Engine bracket -T10012 Engine and gearbox sup
port -VW 540un
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Rep. Gr.10 - Removing and installing engine
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Drip tray -V.A.G 1306-
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Workshop crane -V.A.G

1202 A-
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Support clamp -VW 313-

Torque wrench -V.A.G
1331 Torque wrench -V.A.G
1332 Engine and gearbox jack V.A.G 1383 A Spring-type clip pliers -VAS
5024 Stepladder -VAS 5085 Guide rods -T10093 Cable ties
Note
Before carrying out further work, disconnect battery earth
strap. First check whether a coded radio is fitted. Obtain antitheft coding first if necessary.
The engine is removed downwards together with the gearbox.
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All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine

is installed.
1. Removing and installing engine
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WARNING
When doing any repair work, especially in the engine compart

ment, pay attention to the following due to the cramped condi
tions:
Route all the various lines (e.g. for fuel, hydraulics, acti
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po
sitions.
Ensure that there is sufficient clearance to all moving or
hot components.
Procedure
With ignition switched off, disconnect earth strap from battery.
One-piece engine cover
For one-piece engine cover, pull engine cover abruptly upwards
at front and right -arrows A-, then pull forwards out of rear fas
tening -arrow B-.
Two-piece engine cover

For two-piece engine cover, first pull outer engine cover
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upwards at -arrows-, then pull inner engine cover
abruptly
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Remove air filter housing with air mass meter and connecting
pipe.
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Remove plenum chamber bulkhead.
au General body repairs,
ss plenum chamber bulk
exterior; Rep. Gr. 50 ; Body - front,
head .

Remove bolt -arrow A- and pull air filter housing upwards out
of mounting.
Remove battery and battery tray.
Disconnect fuel supply and return lines as well as coolant line
on cylinder head.
WARNING
The fuel and the fuel lines in the fuel system can become
very hot (danger ofAscalding)!
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The fuel ysystem
is also under pressure!
Before
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place
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connections.
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carefully
loosen connection to release the pressure!
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s Wear eye and hand protection when performing any type

of repair work on the fuel system!
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Remove insulation tray General body repairs, exterior; Rep.

Gr. 50 ; Body - front; Assembly overview
Bring lock carrier into service position General body repairs,

exterior; Rep. Gr. 50 ; Body - front; Lock carrier - service po
sition .
Drain coolant page 102 .
Vehicles with air conditioner
Note
To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or bent.
Remove poly V-belt page 13 .
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To facilitate removing and installing engine without opening re

frigerant circuit:
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Remove air conditioner compressor Heating, air condition

ing; Rep. Gr. 87 ; Removing and installing compressor brack
et .
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Prote
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Secure air conditioner compressor to lock carrier so that re

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

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Remove wiring harness from cable guide on longitudinal mem
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ber and lay to side on engine.
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Open all cable guide fasteners -arrows-.
Separate all connecting, coolant, vacuum and intake hoses

from engine.
Vehicles with manual gearbox
Remove slave cylinder for hydraulic clutch. 6-speed manual

gearbox 02S; Rep. Gr. 30 ; Repairing clutch mechanism; As
sembly overview - hydraulics .
Unbolt gear selector mechanism from gearbox. 6-speed
manual gearbox 02S; Rep. Gr. 34 ; Repairing selector mech
anism .
Vehicles with four-wheel drive:
Remove selector mechanism from gearbox 6-speed man

ual gearbox 02Q, four-wheel drive; Rep. Gr. 34 ; Repairing
selector mechanism .
Separate pressure line for hydraulic clutch control.
r
fo
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Remove subframe Running gear, axles, steering; Rep. Gr.

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

shown.
Fit engine bracket -T10012- to cylinder block with M10 x 25/
8.8 bolt and tighten to approx. 40 Nm.
Raise engine and gearbox slightly using engine and gearbox
jack -V.A.G 1383 A- .
AG.
Vehicles with particulate filter
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Unbolt pendulum support -arrows-.
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Remove front propshaft Final drive 02D, 0AV; Rep. Gr. 39 ;

Assembly overview - repairing propshaft .
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Pull off or disconnect all other electrical connections from en

gine and gearbox as necessary and lay to side.

Unbolt assembly mounting on engine side from engine bracket
-arrows-.
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Carefully lower engine with gearbox.

Note
Engine with gearbox must be guided carefully when lowered to

prevent damage to bodywork.
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1.2
Securing engine to assembly stand
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Disconnect gearbox.
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Procedure
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When working on the engine, secure it to support clamp -VW 313of the assembly stand using engine and gearbox support -VW
540- .
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Unbolt assembly mounting on gearbox side from gearbox

bracket -arrows-.
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To remove securingVbolts,
5085.
not
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Prote
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Attach lifting tackle -2024 A- as shown and raise engine out of

engine and gearbox jack -V.A.G 1383 A- using workshop hoist
-V.A.G 1202 A- .
Pulley end: 2nd hole in hook rail at position 1
Flywheel end: 4th hole in hook at position 8
WARNING
The hooks and locating pins must be secured with locking pins.
Note
The positions marked 1...4 on the bar must be towards the
pulley end.
The holes in the hook rails are counted up from the hook.
Secure engine on support clamp -VW 313- using engine and
gearbox jack -VW 540- .
1.3
Notes on installing
Installation is carried out in the reverse order. When installing,

note the following:

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

suitable size, or similar.

Ensure that the edges of the support arm on the gearbox as
sembly mounting -2- and gearbox support -1- are parallel.
Dimension -x- must be identical at top and bottom.
Note
Torque specifications for assembly mounting page 10 .
Electrical connections and routing. Electrical system; Rep.
Gr. 97
Install pendulum support.
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Install drive shafts Running gear, axles, esteering;
Rep. Gr.
d
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40 ; Removing and installing drive shafts
.
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Install front exhaust pipe page 186 .
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Install slave cylinder for hydraulic clutch 6-speed manual

gearbox 02S; Rep. Gr. 30 ; Repairing clutch mechanism; As
sembly overview - hydraulics .
Remove selector mechanism from gearbox 6-speed man
ual gearbox 02S; Rep. Gr. 34 ; Repairing selector mecha
nism .
Vehicles with four-wheel drive:
Install selector mechanism on gearbox 6-speed manual

gearbox 02Q, four-wheel drive; Rep. Gr. 34 ; Repairing se
lector mechanism .
Install pressure line for hydraulic clutch control.
AG.
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by
Install air conditioner compressor Heating, air conditioning;

Rep. Gr. 87 ; Removing and installing compressor bracket.
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Install alternator Electrical system; Rep. Gr. 27 ; Removing

and installing alternator and poly V- belt .
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On vehicles with particulate filter install subframe Running

gear, axles, steering; Rep. Gr. 40
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Install front propshaft Final drive 02D, 0AV; Rep. Gr. 39 ;

Assembly overview - repairing propshaft .
Install poly V-belt page 13 .

Install insulation tray General body repairs, exterior; Rep.
Gr. 50 ; Body - front; Assembly overview.
Install engine control unit page 178 .
Install plenum chamber bulkhead General body repairs,
exterior; Rep. Gr. 50 ; Body - front; Plenum chamber bulk
head .
Fill cooling system with coolant page 102 .
Carry out road test and then read fault memory page 178 .

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

A = 20 Nm + 90 (1/4 turn) further 1)
B = 40 Nm + 90 (1/4 turn) further 1)
C = 60 Nm + 90 (1/4 turn) further 1)
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1)

Pendulum support
Always note the size and strength class of bolt. Different specified
torques are valid.
Caution
From model year 08, in manual gearboxes 02Q Heli Coil in

serts are installed in the threaded connections to pendulum
support. Difference Rep. Gr. 34
For these and all other gearboxes bolts with strength class 10.9
must be used.
If Heli Coil inserts are not fitted in manual gearboxes 02Q, use
bolts with strength class 8.8 and the specified torques.
Bolt -AM10 x 35 strength class 8.8: turn 40 Nm + 90 further
M10 x 35 strength class 10.9: turn 50 Nm + 90 further
Always renew after removing
Bolt -B-
olkswagen AG
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ise 10.9: turn 50 Nm + 90 further
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M14 x 1.5 x 70
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100 Nm + turn 90 further

Tighten only if pendulum support is bolted to gearbox
Always renew after removing
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13
Crankshaft group
Dismantling and assembling engine
Assembly overview - poly V-belt drive page 12

Removing and installing poly V-belt page 13
Assembly overview - toothed belt drive page 15
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Assembly overview - crankcase page 19
Assembly overview - poly V-belt drive
5 - Poly V-belt tensioning ele

ment
Swing with ring spanner
to slacken poly V-belt.
6 - 25 Nm
7 - Air conditioner compressor
8 - 25 Nm
9 - Dowel sleeves
10 - Poly V-belt
Mark direction of rota
tion before removing.
Check for wear.
Do not kink.
Removing and installing
page 13 .
12
Rep. Gr.13 - Crankshaft group
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4 - Bracket
For alternator and air
conditioner compressor.
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3 - Alternator
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2 - 25 Nm
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1 - Belt pulley and vibration

damper
Can only be installed in
one position, holes are
offset.
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If large quantities of metal particles or other deposits (caused, for

example, by partial seizure of the crankshaft or conrod bearings)
are found in the engine oil when making repairs, clean the oil
passages thoroughly and renew the engine oil cooler in order to
prevent further damage from occurring later.

1.2
Removing and installing poly V-belt
Special tools and workshop equipment required

Locking pin -T10060 A-
16 mm open-end spanner -T 10241-
1.2.1
Removing poly V-belt
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Remove insulation tray. General body repairs, exterior;

Rep. Gr. 50 ; Body - front; Assembly overview .
Pull fuel filter out of bracket and lay it with hoses to side.
rrectness of i
t to the co
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spec
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Mark direction of rotation of poly V-belt.
Swing tensioning element in direction of arrow to remove ten

sion from poly V-belt.
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The open-end spanner 16 mm -T 10241- is particularly well suited

to relieve tension.
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1. Dismantling and assembling engine
13
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Lock tensioning element in position with locking pin -T10060
A- .
Remove poly V-belt.
1.2.2
Installing poly V-belt
Installation is carried out in the reverse sequence of removal.

Note
Before installing poly V-belt, ensure that all ancillaries (alter
nator, air conditioner compressor) are secured tightly.
When fitting poly V-belt, check direction of belt rotation and
ensure proper seating of belt in pulleys.
Lastly, place poly V-belt over alternator.

After completing repairs always:
Start engine and check belt running.
rrectness of i
t to the co
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spec
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Belt drive without air conditioner compressor
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14

1.3
Assembly overview - toothed belt drive
1 - Toothed belt guard upper

part
2 - 100 Nm
3 - 25 Nm
4 - Camshaft pulley
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5 - Hub
With sender wheel
Use counterhold tool T10051- to loosen and
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and installing
a
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and installing camshaft.
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6 - 10 Nm
Renew
7 - Stud
15 Nm
8 - Rear toothed belt guard
9 - 25 Nm
10 - Sealing grommet
Renew if damaged.
11 - 20 Nm + 1/8 turn (45) fur

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14 - Idler roller
15 - Coolant pump
Removing and installing page 106 .
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13 - 20 Nm
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12 - Tensioning roller
Remove engine support
in order to remove and
install page 16 .
AG.
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16 - Crankshaft toothed belt pulley

17 - 120 Nm + 1/4 turn (90) further
Renew
Use counterhold tool -3099- to loosen and tighten.
Do not additionally oil or grease thread and shoulder.
Turning further can be done in several stages.
18 - 15 Nm
19 - Toothed belt guard lower part
20 - Belt pulley and vibration damper
Can only be installed in one position, holes are offset.
21 - 10 Nm + 1/4 turn (90) further
Renew
15

22 - Cover
23 - Toothed belt
Mark direction of rotation before removing.
Check for wear.
Do not kink.
Removing, installing and tensioning page 50 .
24 - 40 Nm + 1/2 turn (180) further
Renew
25 - Toothed belt guard centre part
26 - Engine bracket
1.3.1
olkswagen AG
support
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or
Support bracket -10 - 222 A- auth

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Torque wrench -V.A.G 1331 Remove engine cover.
rrectness of i
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To do this, pull engine cover upwards abruptly at front and right

-arrows A- and then pull forwards out of rear fastening
-arrow B-.
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16
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For two-piece engine cover, first pull outer engine cover abruptly
upwards at -arrows-, then pull inner engine cover abruptly up
wards at -arrows-.

Separate push-on connectors of fuel lines -arrows-.
Note
Do this by pressing in catch of push-on connectors.
Ensure that no fuel escapes (use a cloth).
Lay fuel filter with hoses to side.
Disconnect coolant hose from top of expansion tank.
Remove expansion tank and lay it to side.
Remove charge air pipe between charge air cooler and turbo
charger.
Carefully cover or seal open ends.
Golf, Golf Plus and Touran:
Fit engine support bracket -10-222A- with adapters -10-222A/
13- and take up weight of engine in installation position.
Remove securing bolts from assembly mounting/engine sup

port -arrows- and remove complete assembly mounting.
Note
The assembly mounting may only be removed if the engine is

The engine support must only be loosened when the assembly
mounting has been removed.
When raising and lowering engine using support bracket

-10-222A- , ensure that no components or hoses are damaged
or torn off.
Remove noise insulation tray General body repairs, exteri
or; Rep. Gr. 50 ; Body - front; Assembly overview - noise
insulation .
Remove front right wheel housing liner.
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
WARNING
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supported with support bracket 10-222A!
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AG. Volkswagen A
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Raise engine with support bracket -10-222Aed until both upper
ris removed.
bolts of engine support can be loosenedhand
o
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Lower engine with support bracket -10-222Auntil lower bolt
Remove engine support upwards.
rrectness of i
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spec
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Installing
Position engine support from above on cylinder block.

Insert new bolts and tighten hand-tight.
Caution
The tightening sequence and specified torques for the engine

support securing bolts must always be followed. Otherwise the
engine support can be stressed and it can break.
I : Engine support with less clearance to engine

Prote
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Install assembly mounting between engine and body, renew

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

bringing contact surfaces together using support bracket
-10-222A- . Specified torque: 60 Nm + 90 (1/4 turn) further.
Further assembly is basically the reverse of the dismantling se
quence. In the process, note the following:
Ensure that fuel hose connections are tight.
Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
When installing charge air pipes, ensure that locking lugs en
gage correctly.
Install wheel housing liner.
Install noise insulation tray General body repairs, exterior;
Rep. Gr. 50 ; Body - front; Assembly overview - noise insula
tion
18
AG.
Before installing assembly mounting, tighten all engine support

bolts to prescribed torque.
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II: Engine support with greater clearance to engine
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Tighten bolts for engine support in the sequence shown

-13- to 40 Nm + 1/2 turn (180 ) further. To do this, raise or
lower engine using support bracket -10 - 222 A- .

1.4
Assembly overview - crankcase
1 - Cylinder block
sealing flange and fly
wheel page 20 .
crankshaft page 33
Dismantling and assem
bling pistons and con
rods page 33
2 - Gasket
Renew
3 - Oil filter bracket
bling page 92 .
4 - 15 Nm + 1/4 turn (90) fur
ther
Renew
First fit upper left and
lower right bolts and
then tighten all four bolts
diagonally.
5 - Bracket
6 - 20 Nm
7 - Connection
For thermostat.
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9 - O-ring
Renew
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8 - 15 Nm
ole,
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10 - Thermostat
page 108 .
Observe installation position page 108 , removing and installing thermostat.
Check: Heat thermostat in water
Opening begins at approx. 85 C
Ends at approx. 105 C
Opening lift at least 7 mm.
11 - Hexagon bolt
Tightening sequence and torque specifications Heating, air conditioning; Rep. Gr. 87 ; Removing and
installing compressor bracket .
12 - Bracket
For alternator, if air conditioner compressor is fitted
13 - Poly V-belt tensioning element
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16 - 15 Nm
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15 - Sump
Clean sealing surface before fitting.
Install with silicone sealant -D 176 404 A2- .
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14 - 25 Nm
19

Removing and installing sealing

flange and flywheel
Assembly overview - sealing flange and flywheel page 20

Removing and installing engine speed sender page 31
Renewing crankshaft oil seal - pulley end page 21 .
Removing and installing sealing flange - pulley end
page 21 .
Renewing crankshaft sealing flange - flywheel end page 25 .
Assembly overview - sealing flanges and flywheel

Note
20
AG.
6 - Intermediate plate
Must be positioned on dowel sleeves.
Do not damage or bend when assembling.
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5 - Flywheel
To remove and install
flywheel, counterhold
with 3067.
Prote
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4 - 60 Nm + 1/4 turn (90) fur

ther
Renew
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at
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3 - Cylinder block
crankshaft page 33
bling pistons and con
rods page 33
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2 - Sealing flange
Must be positioned on
dowel sleeves.
page 23 .
Install with silicone seal
ant -D 176 404 A2 page 23 .
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1 - Seal
Do not additionally oil or
grease the oil seal seal
ing lip.
Before installing, re
move oil residue from
crankshaft journal using
a clean cloth.
Renewing crankshaft oil
seal - pulley end
page 21 .
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Repairing clutch 6-speed manual gearbox
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02S; Rep. Gr.
;
Repairing
clutch.
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2.1

7 - 15 Nm
Renew
8 - Sealing flange with oil seal
Renew complete with oil seal and sender wheel only.
9 - Removing and installing engine speed sender -G28- page 31 .,
Loosen and tighten using commercially available ball-ended hexagon key socket
Specified torque: 5 Nm.
2.2
Renewing crankshaft oil seal - pulley end

equipment required
Counterhold tool -3099 Oil seal extractor -3203 Assembly tool -T10053 Torque wrench V.A.G 1331-
AG. Volkswagen AG d
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a
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Removing
Remove toothed belt. page 50
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Torque wrench V.A.G 1332-
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2. Removing and installing sealing flange and flywheel
21
AG.
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Remove crankshaft toothed belt pulley. To do this, lock tooth
ed belt pulley using counterhold tool -3099- .
Note
When bolting on counterhold tool, place two washers between

toothed belt pulley and counterhold tool.
To guide oil seal extractor -3203- , screw central bolt by hand
into crankshaft to stop.
AG. Volkswagen
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Unscrew inner part oflkoil
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swaseal extractor two turns
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Oil threaded
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Using great pressure, screw oil seal extractor as far as possi

ble into seal.
2.2.2
Installing
The oil seal sealing lip must not be additionally oiled or greased.
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Remove oil residue from crankshaft journal using clean cloth.

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Place guide sleeve -T10053/1- onto crankshaft journal.

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Prote
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Slide oil seal over guide sleeve onto crankshaft journal.
AG.
22
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Note
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m
spec
atio
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wit
Loosen knurled screw and turn inner part against crankshaft

until oil seal is pulled out.

Press oil seal in to stop using assembly tool -T10053- and
centre bolt.
Install and tighten toothed belt page 50 .
2.3
Removing and installing sealing flange - pulley end

equipment required
Counterhold tool -3099 Assembly tool -T10053 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Hand drill with plastic brush
attachment
Silicone sealant -D 176 404
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Flat scraper
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Removing
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2.3.1
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23
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Remove crankshaft toothed belt pulley. To do this, lock tooth
ed belt pulley using counterhold tool -3099- .
Note
When bolting on counterhold tool, place two washers between

toothed belt pulley and counterhold tool.
Drain engine oil.
Remove sump page 88 .
Pull off front sealing flange.
Remove sealing flange; if necessary, loosen by applying light
blows with a rubber-headed hammer.
Remove sealant residue from cylinder block with a flat scraper.
Remove residual sealant from sealing flange using a plastic
rotary brush (wear eye protection).
Clean sealing surfaces. They must be free of oil and grease.
Note
Observe expiry date of sealing compound.

Install sealing flange within 5 minutes of applying the silicone
sealant.
Cut off tube nozzle at forward marking (approx. 3 mm nozzle

).
Note
Sealant bead must not be wider than 2...3 mm, because oth
Prote
cted
by
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.
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Before applying sealant bead, cover sealing surface of oil seal
AG.
24
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with a clean cloth.
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erwise excess sealant can enter sump and clog strainer in oil
pump suction pipe as well as drip onto crankshaft oil seal.
thi
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hole
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a
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Installing
rrectness of i
t to the co
nf
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m
spec
atio
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wit
2.3.2
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Apply silicone sealant bead as shown to the clean sealing sur
face of sealing flange.
Install sealing flange immediately and tighten all bolts lightly.
Note
When fitting sealing flange with oil seal installed use guide sleeve
-T10053/1- .
Tighten securing bolts for sealing flange to 15 Nm using alter
nate and diagonal sequence.
Install sump page 88 .
Note
After fitting, allow sealant to dry for approx. 30 minutes. Only then
fill with engine oil.
Installing toothed belt and adjusting valve timing. page 50
2.4
Renewing crankshaft sealing flange flywheel end

AG. Volkswagen AG d
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Assembly tool -T10134-
Vernier gauge
rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
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or
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f
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Socket -V.A.G 1332/11-
ss
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Torque wrench -V.A.G 1331-
Three hexagon bolts M6 x 35 mm

Two hexagon bolts M7 x 35 mm
2.4.1
Pressing out sealing flange with sender

wheel
Note
For the sake of clarity, the work is performed with the engine
removed.
The procedure is identical whether the engine is installed or
Set engine to TDC No. 1 cylinder page 50 , Removing and

installing toothed belt.
AG.
Remove sump page 88 .
agen
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Remove intermediate plate.
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Co
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Remove flywheel.
thi
sd
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cu
m
en
removed.
25

Remove engine speed sender -G28- -arrow- using a commer
cially available ball-ended hex key socket page 31 .
Unscrew sealing flange securing bolts.
Note
Sealing flange and sender wheel are pressed off the crankshaft
together using three M6 x 35 mm bolts.
2.4.2
Pressing in sealing flange with sender

wheel
Note
The sealing flange with a PTFE seal is equipped with a sealing
lip support ring. This support ring serves as a fitting sleeve and
must not be removed prior to installation.
Prote
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by
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.
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turned after removal from packaging.
ht
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Sealing flange and sender wheel must not be separated or
The sender wheel is held in its installation position on the as
sembly device -T10134- by a locating pin.
Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
The assembly device -T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the

crankshaft.
Assembly tool -T10134A - Clamping surface

B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
G - Guide pin for petrol engines (red knob)
26
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Screw bolts alternately (max. 1/2 turn 180 for each bolt) into
sealing flange and press sealing flange together with sender
wheel off crankshaft.
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
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erm
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Screw three M6 x 35 mm bolts into threaded holes -arrows- of

sealing flange.
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2.4.3
. Volkswagen AG
gen AG
d
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A - Assembling seal
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b
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on assembly tool
ise -T10134r
o
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h
ut
rrectness of i
t to the co
nform
spec
a
t
i
h re
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wit
thi
s
un
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es, in part or in w
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a
Screw in hexagon nut -Bss to just before clamping surface -Aof threaded spindle.
Clamp assembly device -T10134- in a vice on clamping sur

face -A- of threaded spindle.
ht
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Co
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Inner part of assembly tool and assembly housing must be at

same height.
do
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Note
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Press assembly housing -C- downwards so that it lies on hex

agon nut -B- -arrow-.
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Prote
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by
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rig
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.
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Remove securing clip -arrow- from new sealing flange.

Note
The sender wheel must not be taken out of the sealing flange or
twisted.
Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
Place sealing flange with front side downwards on a clean flat
surface.
27

Push sealing lip support ring -A- downwards in direction of ar
row until it lies on flat surface.
Upper edge of sender wheel and front edge of sealing flange

must align -arrows-.
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hole
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Place sealing flange with front side on assemblyistool
ed -T10134tee
r
o
so that locating pin -A- can be inserted in sender
wheel hole
h
t
or
u
ac
a
-A-.
ss
Note
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Ensure sealing flange lies flat on assembly device.
Push sealing flange and support ring for sealing lip -B- against
surface of assembly device -T10134- whilst tightening the
three knurled screws -A- so that locating pin cannot slide out
of sender wheel hole.
Note
Engine positioned at TDC No. 1 cylinder
28
Prote
cted
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Crankshaft flange must be free of oil and grease.
AG.
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B - Attaching assembling tool -T10134with sealing flange on crankshaft flange
ht
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Co
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2.4.4
do
c
um
en
When installing sealing flange, ensure that sender wheel remains

fixed in assembly device.

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

hexagon socket head bolts -A-.
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap
prox. 5 full turns).
s no
t gu
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Vol
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ss
rrectness of i
t to the co
nform
spec
a
t
i
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wit
thi
s
2.4.5
es, in part or in w
l purpos
hole
ercia
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To guide sealing flange, screw two M7 35 mm bolts -A- into

cylinder block.
e
wage
C - Bolting assembly tool -T10134- onto

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

sealing lip support ring -B- contacts crankshaft flange -A-.
AG.
Prote
cted
by
Screw hexagon nut -E- onto threaded spindle by hand until it

lies on assembly housing -C-.
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.
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Hand-tighten both hexagon socket head bolts of assembly

tool.
ht
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py
Co
t.
The guide pin for petrol engines (red knob) -F- must not be inser
ted in threaded hole of crankshaft.
do
c
um
en
Note
r
te o
iva
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rp
fo
g
n
Push guide pin for diesel engines (black knob) -D- into hole in
crankshaft. This ensures that the sender wheel reaches its fi
nal installation position.
29
Golf 2004
4-cylinder
D - Pressing sender wheel onto crank

shaft flange using assembly tool T10134-
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
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2.4.6
AG. Volkswagen AG d
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, Golf Plus 2005
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diesel engine (1.9 l engine)uth- Edition 01.2009
ra
a
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s
Tighten hexagon nut of assembly tool -T10134- to 35 Nm us

ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G
1332/11- .
Note
After hexagon nut is tightened to 35 Nm, a small air gap must be

present between cylinder block and sealing flange.
Prote
cted
by
c
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rig
ht
.
C
op
yi
Screw hexagon nut -E- to end of threaded spindle.
Remove assembly tool -T10134- .

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

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

Measure distance -a- between crankshaft flange and sender
wheel.
If measurement -a- is too small:
Press sender wheel further. page 31
If dimension -a- is attained:
Tighten new securing bolts for sealing flange to 15 Nm using
alternate and diagonal sequence.
30
AG.
Screw the three knurled screws -B- out of sealing flange.
agen
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by
Remove the two bolts -A- from cylinder block.
ht
rig
py
Co
t.
E - Checking sender wheel installation

position on crankshaft
thi
sd
o
cu
m
en
2.4.7

Install engine speed sender -G28- -arrow- and tighten secur
ing bolt to 5 Nm.
Install sump page 88 .
Install intermediate plate.
Install flywheel using new bolts. Tighten securing bolts to 60
Nm +1/4 turn (90).
2.4.8
F - Re-pressing sender wheel
Secure assembly tool -T10134- to crankshaft flange using

hexagon socket head bolts -A-.
Hand tighten both hexagon socket head bolts.
Push assembly tool -T10134- by hand to sealing flange.
AG. Volkswagen AG d
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rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
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f
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ility
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ce
Screw hexagon nut -E- onto threaded spindle by hand until it

lies on assembly housing -C-.
Tighten hexagon nut of assembly tool -T10134- to 40 Nm us

ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G
1332/11- .
If dimension -a- is too small again:
AG.
2.5
agen
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Prote
cted
by c
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C
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Check installation position of sender wheel on crankshaft

again. page 30
ht
rig
py
Co
t.
Tighten hexagon nut for assembly tool -T10134- to 45 Nm.
thi
sd
o
cu
m
en
Check installation position of sender wheel on crankshaft

again. page 30
Removing and installing engine speed

sender -G28-
31

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

. Volkswagen AG
mm
gen AG
does
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Note
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insulation .
Clamp off coolant hoses at engine oil cooler using hose clip
and pull off hoses.
Remove oil filter bracket.
Remove securing bolt -arrow- and pull out engine speed send
er -G28- .
AG.
agen
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by
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.
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32
ht
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Co
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r
fo
ng
Installation is performed in the reverse order, observing the fol

lowing: specified torque for engine speed sender -G28- securing
bolt: 5 Nm.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Two different bolts are installed, check which tool is to be used.

Crankshaft
Assembly overview - crankshaft page 33

Crankshaft dimensions page 38 .
3.1
Assembly overview - crankshaft
es n
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ir se
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o
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or
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a
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es, in part or in w
l purpos
hole
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1 - Bearing shells 1, 2, 4 and 5

For bearing cap without
oil groove.
For cylinder block with
oil groove.
Do not interchange
used bearing shells
(mark).
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
2 - 65 Nm + 1/4 turn (90) fur

ther
Renew
To measure radial clear
ance, tighten to 65 Nm
but not further.
ht
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Prote
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.
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4 - Bearing shell 3
For bearing cap without
oil groove.
For cylinder block with
oil groove.
thi
sd
o
cu
m
en
3 - Bearing cap
Bearing cap 1: pulley
end.
Bearing cap 3 with re
cesses for thrust wash
ers.
Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
5 - Thrust washer
For bearing cap 3.
Note fixing arrange
ment.
6 - Crankshaft
Axial clearance new: 0.070.17 mm, wear limit: 0.37 mm
Check radial clearance with Plastigage new: 0.03...0.08 mm, wear limit: 0.17 mm
Do not rotate crankshaft when checking radial clearance.
Crankshaft dimensions page 38 .
7 - Thrust washer
For cylinder block, bearing 3
3. Crankshaft
33

3.1.1
Renewing needle bearing in crankshaft

- vehicles with dual clutch gearbox
6-speed dual clutch gearbox: If the engine or gearbox has to be

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

removing engine or gearbox.
ility
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AG. Volkswagen AG d
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s
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
e
ng
6-speed dual clutch gearbox
This gearbox can be identified by the gearbox oil cooler

Special tools, testers, measuring instruments and auxiliary items
required
ht
rig
py
Co
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AG.
Prote
cted
by
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thi
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34

1 - -1- Kukko 21/2
2 - Centring mandrel -3176-
AG. Volkswagen AG d
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Puller -T10055- with adapter -T10055/3Gearbox is unscrewed from engine.

AG.
Prote
cted
by
Pulling needle bearing out:
agen
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C
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ht
rig
py
Co
t.
Procedure
do
c
um
en
r
te o
iva
r
rp
fo
g
n
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
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3 - Drift -VW 207 C-
3. Crankshaft
35

Pull out needle roller bearing using Kukko 21/2, adapter T10055/3- and puller -T10055- .
7-speed dual clutch gearbox

No gearbox oil cooler is installed.
AG. Volkswagen AG d
oes
not
gu
ara
auxiliary items
nte
eo
ra
c
gen or gearbox.
Always renew needle bearing when removingolkengine
swa
un
le
r
fo
ng
AG.
agen
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Prote
cted
by
c
o
py
rig
ht
.
C
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36
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
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p
ility
ab
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an
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a
ss
ht
rig
py
Co
t.
V
by
ed
Special tools, testers, measuring instruments
and
ris
ho
required
t
u

1 - -1- Kukko 21/2 and -4- Kuk
ko 22/1
2 - Centring mandrel -3176-
ht
rig
py
Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
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d
p
ility
ab
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an
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un
le
3 - Drift -VW 207 C-
AG. Volkswagen AG d
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AG.
Prote
cted
by c
o
p
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gh
t.
C
op
yi
Procedure
Gearbox is unscrewed from engine.
Pulling needle bearing out:

Pull out using commercially available puller -A-, e.g. Kukko
21/2 and Kukko 22/1.
Installing
3. Crankshaft
37

Drive needle bearing in with drift -VW 207 C- or with centring
mandrel -3176- .
Carefully drive needle bearing in.
Always measure the driving depth when driving in.
Crankshaft bearing
journal
Basic dimension 54.00
38
-0.022
-0.042
47.80
Conrod
journal
-0.022
-0.042
AG.
Honing dimen
sion
agen
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(Dimensions in mm)
r
fo
ng
Crankshaft dimensions
Prote
cted
by c
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p
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t.
C
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yi
3.2
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
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d
p
Driving depth: Dimension -a- = 1.5 to 1.8 mm.
ht
rig
py
Co
t.
AG. Volkswagen AG d
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un
le
Renew bearing, if driving depth is too deep.

Pistons and conrods
Assembly overview - pistons and conrods page 39 .

Separating new conrod page 40 .
Checking piston projection at TDC page 41
Piston and cylinder dimensions page 42 .
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Piston rings, cylinder bore and piston installation position

page 42
Assembly overview - pistons and conrods

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2 - Piston
With combustion cham
ber.
Mark installation posi
tion and cylinder num
ber.
Installation position and
allocation of piston to
cylinder page 43 .
Arrow on piston crown
points to belt pulley end.
Install using piston ring
clamp.
Cracks on piston skirt,
renew piston.
Checking piston projec
tion at TDC
page 41
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1 - Piston rings
Offset gaps by 120.
Use piston ring pliers to
remove and install.
TOP faces towards
piston crown.
Checking piston ring
gap page 42 .
Checking ring-to-groove
clearance page 42 .
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4.1
3 - Piston pin
If difficult to remove,
heat piston to 60 C.
Remove and install us
ing drift -VW 222- .
4 - Circlip
5 - Conrod
Mark cylinder allocation -A- with coloured pen.
Installation position: Marking -B- faces towards pulley end.
With industrially cracked conrod cap.
6 - Bearing shell
Note installation position.
Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi
cation: Black line on bearing surface in area of joint.
4. Pistons and conrods
39

Do not interchange used bearing shells.

Insert bearing shells centrally.
Check for secure seating.
Axial clearance, wear limit: 0.37 mm.
Check radial clearance with Plastigage: Wear limit: 0.08 mm, do not rotate crankshaft when checking
radial clearance.
7 - Cylinder block
Checking cylinder bore page 43 .
Piston and cylinder dimensions page 42 .
8 - Conrod bearing cap
The cap only fits in one position and only on the appropriate conrod due to the breaking procedure
(cracking), separating the cap from conrod.
9 - Oil spray jet
For piston cooling
Note
10 - 25 Nm
Insert without sealant.
11 - Conrod bolt, 30 Nm + 1/4 turn (90) further
Renew
Oil threads and contact surface.
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Use old bolt for measuring radial clearance.
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Mark cylinder allocation of conrod Item 5 (page 39)

Lightly clamp the conrod in a vice using aluminium vice
clamps, as shown in the illustration.
Note
To prevent damage to the conrod, only clamp conrod in lightly.

Clamp conrod in below the marked line.
Unscrew the two bolts -arrows- approx. 5 turns.
AG.
Prote
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40
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Using a plastic hammer, carefully knock against conrod bear

ing cap -arrow- until it is loose.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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wit
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Separating new conrod
or
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4.2
by
ed
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ss

4.3
Checking piston projection at TDC

Measuring bridge -VW 382/7-
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Dial gauge
Test procedure
Note
If different values are determined during the projection measure

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

pistons or a short engine. Install the appropriate cylinder head
gasket depending upon piston projection, according to following
table:
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Turn engine clockwise to measure piston projection at TDC.

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Piston projection
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0.91 mm ... 1.00 mm

1.01 mm ... 1.10 mm
1.11 mm ... 1.20 mm
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End dimension plate -VW 385/17-
Identification
Holes/notches
1
2
3
41

olkswagen AG
en AG. V01.2009
does
-agEdition
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Cylinder head gasket identification horis
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Part number = arrow 1
ss
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Production control code = arrow 2 (can be disregarded)
Piston and cylinder dimensions

mm
79.47
79.51
mm
mm
79.72
79.97
79.76
80.01
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Cylinder bore
Piston rings, cylinder bore and piston in

stallation position
AG.

Feeler gauges
Push piston ring squarely from above down to approx. 15 mm
from bottom end of cylinder.
Piston ring
dimensions in mm
1. compression ring
2. compression ring
Oil scraper ring
New
Wear limit
0.20...0.40
0.20...0.40
0.25...0.50
1.0
1.0
1.0
Checking ring-to-groove clearance

Feeler gauges
42
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Checking piston ring gap
do
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Basic dimen
sion
Stage I
Stage II
Piston
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Honing dimension
4.5
rrectness of i
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spec
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4.4
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Holes = arrow 3

Clean ring groove before checking.
Piston ring
dimensions in mm
1. compression ring
2. compression ring
Oil scraper ring
New
Wear limit
0.06...0.09
0.05...0.08
0.03...0.06
0.25
0.25
0.15
Checking cylinder bores

Cylinder gauge 50...100 mm
Take measurements at 3 positions in both transverse -A- and
longitudinal -B- directions, as illustrated. Difference between
actual and nominal diameter max. 0.10 mm.
Note
lkswagen AG
n AG. Vo
Cylinder bores must not be measured
cylinder
block
gewhen
doesis
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k
not ,
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mounted on a repair stand with
engine
support
bracket
-VW
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as measurements may then
incorrect.
nt
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and allocation of piston to cylinder
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Piston in cylinders 1 and 2:

Piston in cylinders 3 and 4:
rrectness of i
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nform
spec
a
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Larger inlet valve chamber towards flywheel -arrows-.
ee
or
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Piston installation
tho
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s
position
Larger inlet valve chamber towards belt pulley side -arrows-.

Note
New piston allocation to cylinders is shown by a coloured
marking on piston crown.
Piston for cylinders 1 and 2: marked 1/2
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Piston for cylinders 3 and 4: marked 3/4
43
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15
Cylinder head, valve gear
Cylinder head
Note
When installing an exchange cylinder head with fitted cam
shaft, the contact surfaces between the bucket tappets and

the cam must be oiled before installing the cylinder head cov
er.
The plastic protectors fitted to protect the open valves must be
removed only immediately before the cylinder head is fitted.
If the cylinder head is replaced, all the coolant in the system
AG. Volkswagen AG d
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Rep. Gr.15 - Cylinder head, valve gear
ht
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44
do
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rrectness of i
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spec
a
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must also be renewed.

Removing and installing cylinder head cover page 48 .
Removing, installing and tensioning toothed belt page 50
Removing and installing cylinder head page 67
Checking compression page 71 .
1.1
Assembly overview - cylinder head
1 - Toothed belt guard upper

part
2 - Toothed belt
Mark direction of rota
tion before removing.
Check for wear.
Do not kink.
Removing, installing
and tensioning
page 50 .
3 - 10 Nm
Renew
4 - 25 Nm
5 - 100 Nm
6 - Camshaft pulley
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- Hub
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With sender wheel
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Use counterhold
tool pe
rm
itte
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hole
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, is n
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rrectness of i
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nform
spec
a
t
i
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wit
thi
s
T10051- to loosen and

tighten.
To remove, use puller T10052 Removing and installing
8 - Rear toothed belt guard

9 - Sealing grommet
Renew if damaged.
10 - Hall sender -G40 For camshaft position
To remove, unbutton
sealing grommet
Item 9 (page 45) from rear toothed belt guard.
do
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11 - Stud
15 Nm
12 - Cylinder head bolt

Observe sequence when loosening and tightening page 67 .
Before installing, place washers in cylinder head Item 4 (page 74) .
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14 - Fuel supply line
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13 - Fuel return line

15 - Coolant line
16 - Cylinder head cover

Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth.
1. Cylinder head
45

17 - Pressure regulating valve
For crankcase ventilation.
18 - To turbocharger.
19 - Sealing cap
Renew seal if damaged
20 - Seal
Renew if damaged.
21 - 10 Nm
Observe tightening sequence page 48 .
22 - Gasket for cylinder head cover
Renew together with cylinder head cover only.
Before fitting, seal transitions with AMV 174
004 01 page 48
Volkswa
23 - 20 Nm
24 - Lifting eye
26 - 10 Nm
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25 - Unit injector
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27 - Central connector
For unit injector
28 - From brake servo
29 - Tandem pump
For fuel and vacuum supply
Checking page 147 .
Must not be dismantled.
Prote
cted
by
34 - 20 Nm
35 - Cylinder head
After renewing, renew entire coolant
36 - Cylinder head gasket
Renew
Note marking page 47
After renewing, renew entire coolant
46
AG.
33 - Bracket
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32 - Gasket
Renew
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31 - Return hose
To fuel filter
Blue or with blue marking.
Secure with spring-type clips.
thi
sd
o
cu
m
en
30 - Supply hose
From fuel filter.
White or with white marking.
Secure with spring-type clips.

37 - Glow plug
15 Nm
Checking page 198 .
38 - Tensioning roller
Remove engine support in order to remove and install page 16 .
39 - 20 Nm + 1/8 turn (45) further
Checking cylinder head for distortion
Feeler gauges
Max. permissible distortion: 0.1 mm.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Note
ility
ab
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ce
Straight edge
es, in part or in w
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hole
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Reworking diesel cylinder heads is not permissible.

Cylinder head gasket identification
Part number = arrow 1
Production control code = arrow 2 (can be disregarded)

Holes = arrow 3
Note
Prote
cted
by
c
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py
rig
ht
.
C
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Piston projection at TDC must be determined when installing
agen
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AG.
new pistons or a short engine. page 41
ht
rig
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Co
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pending on the piston projection. When renewing gasket,

install new gasket with same identification.
1. Cylinder head
thi
sd
o
cu
m
en
Different thicknesses of cylinder head gasket are fitted de
47

1.2
Removing and installing cylinder head

cover

Torque wrench -V.A.G 1331 Sealant -AMV 174 004 01 page 4 Removing
Remove engine cover. To do this, pull engine cover upwards
abruptly at front -arrows A- and then pull forwards out of rear
fastening -arrow B-.
AG. Volkswagen AG d
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For two-piece engine cover, first pull outer engine cover abruptlyy Volksw
b
upwards at -arrows-, then pull inner engine cover abruptly up
ed
ris
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wards at -arrows-.
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Remove upper toothed belt guard.
not
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Disconnect crankcase breather hose at union of rear of charge

air pipe.
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48
rrectness of i
t to the co
nform
spec
at
i
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wit
in t
his
Unbolt bracket from exhaust gas recirculation valve.
ht
rig
py
Co
t.

Engine codes BLS, BXJ: to remove cylinder head cover, addi
tionally remove:
-1- upper toothed belt guard
-2- intake hose
-3- intake manifold flap Renew seal.
-4- bolt, 8 Nm
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gen AG
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Remove cylinder
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e
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Cylinder head cover, engine codes: BLS, BXJ

Installing for all engine codes
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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thi
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Cylinder head cover, engine codes: BJB, BKC, BRU, BXE, BXF
Note
ht
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Co
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fo
ng
Installation is carried out in the reverse sequence of removal. In

the process, note the following:
c
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Renew cylinder head cover gasket and seal for bolts if dam
agen
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Prote
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by
aged.
Renew seal for intake manifold flap. Engine codes BLS, BXJ
AG.
Place a drop of sealant -AMV 174 004 01- ( approx. 5 mm)

-arrows- on edges of both sealing surfaces of bearing cap and
cylinder head at front of engine.
1. Cylinder head
49

Cylinder head cover, engine codes: BJB, BKC, BRU, BXE, BXF
Screw on cylinder head cover hand-tight in the sequence -1 to
13.-
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Tighten bolts to 10 Nm in the sequence -1...13-.
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hole
ercia
, is n
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Cylinder head cover, engine codes: BLS, BXJ
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Screw on cylinder head cover hand-tight in the sequence -1 ...

13-.
Tighten bolts to 10 Nm in the sequence -1...13-.
To change the tensioning roller, for both versions the engine
support must be removed.
Determine which type of engine support is installed in the ve

hicle.
-1-: Engine support bolted close to engine (removal necessary)
page 51 .
50
AG.
is no longer necessary to remove the engine support and sup

porting the engine for the procedure removing, installing and
tensioning toothed belt.
agen
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by
Prote
cted
by c
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C
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From 05.05 a modified engine support has been introduced, it
do
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Note
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Removing, installing and tensioning

toothed belts
ht
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1.3

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1.3.1
rrectness of i
t to the co
nform
spec
a
t
i
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wit
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hole
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-2-: Engine support bolted further away from engine (removal

not necessary) page 60 .
Removing and installing toothed belt (vehicles with engine support bolted
close to engine)

equipment required
Pin wrench -T10020- or
hexagon wrench
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Crankshaft stop -T10050AG.
Prote
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by
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Locking pin -T10115-
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Locking pin -3359-
1. Cylinder head
51

Support bracket -10-222Awith adapters -10-222A/1 Counterhold tool -T10172with pins -T10172/4 Crankshaft stop -T10100(on vehicles with oval
crankshaft belt pulley)
es, in part or in w
l purpos
hole
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Note
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Removing
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Adjustment work on toothed belts must be performed only on cold

engines, as the indicator position on the tensioning element varies
depending on the engine temperature.
Prote
cted
by
Remove lower and centre parts of toothed belt guard.
52
AG.
Remove belt pulley with vibration damper.
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ht
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Remove tensioning element for poly V-belt.
do
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Remove engine cover. page 4

Set up support bracket -10-222A- with adapters -10-222A/22and support engine in installation position.
Note
If toothed belt is to be removed in order to remove cylinder head,

set up support bracket -10-222A- with higher adapters -10-222A/
13- . This will provide the space necessary for removing the cyl
inder head.
Pull fuel filter out of bracket.
Unscrew filler neck for window wash system.
Unbolt fuel filter bracket from engine mounting -arrows-.
Unbolt coolant expansion tank and lay to side (hoses remain
AG. Volkswagen AG d
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connected).
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rrectness of i
t to the co
nform
spec
at
i
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es, in part or in w
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hole
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Remove securing bolts between assembly mounting and en

gine bracket and between assembly mounting and body
-arrows- and remove complete assembly mountings.
Note
The assembly mounting may only be removed if the engine is
supported with support bracket -10-222A- !
The engine bracket must be loosened only when the assembly
mounting has been removed.
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AG.
Remove refrigerant line securing clamp from longitudinal

member.
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Lower engine with support bracket -10-222A- until both lower

bolts of engine bracket can be loosened.
do
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en
Raise engine with support bracket -10-222A- until both upper

bolts of engine bracket can be loosened.
Remove engine bracket rearwards.

Turn crankshaft to TDC No. 1 cylinder.
Note
Gradual introduction of oval crankshaft toothed belt pulleys.

When installing this toothed belt pulley, the crankshaft stop T10100- must be installed to determine the TDC position instead
of crankshaft stop -T10050- . Observe identification characteris
tics -arrows-.
1. Cylinder head
53

Characteristics of crankshaft toothed belt pulley
A = Round belt pulley, lock using crankshaft stop -T10050- , TDC
marking at 12 o'clock
B = Oval belt pulley, lock using crankshaft stop -T10100- . TDC
marking at 1 o'clock
Vehicles with round crankshaft belt pulley
Note
Turn crankshaft until marking on crankshaft pulley and tooth seg

wagen AG
Volkstoothed
AG.rear
ment of camshaft pulley is on top. The markingaon
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belt guard must line up with the markingy Von
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wheel -arrow-.
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Note
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spec
at
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in t
his
Lock crankshaft toothed belt pulley with crankshaft stop T10050- . To do this, push crankshaft stop into teeth of belt
pulley from face side.
The marks on the crankshaft toothed belt pulley and the crank
shaft stop must align. When doing this, the pin of the crankshaft
stop must insert in the drilling of the sealing flange.
Vehicles with oval crankshaft belt pulley
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54
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Lock hub using locking

. To do this, slide locking
pin through the free elongated hole on left into hole in cylinder
head.
tee
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pinss-3359-

Note

ment of camshaft pulley is on top. The marking on the rear toothed
belt guard must align with the marking on the camshaft sender
wheel -arrow-.
Lock hub using locking pin -3359- . To do this, slide locking
head.
Lock crankshaft toothed belt pulley with crankshaft stop T10100- . To do this, push crankshaft stop into teeth
of toothed
. Volkswagen AG
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belt pulley from its face side.
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Mark direction of rotation of toothed belt.
Loosen securing bolts -1- of camshaft toothed belt pulley until
camshaft pulley can be moved within the elongated holes.
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Turn pin wrench -T10020- anti-clockwise until toothed belt

tensioning roller can be locked with locking pin -T10115- .
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Loosen tensioning roller securing nut.
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shaft stop must align. At the same time, the crankshaft stop pin
must engage in the drilling in the sealing flange.
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A hexagon key can be used to tension or relieve tension on the

tensioner.
1. Cylinder head
55

Now turn pin wrench -T10020- clockwise to stop and tighten
securing nut -1- hand tight.
Remove toothed belt first from coolant pump and then from
remaining pulleys.
Installing
Camshaft locked with locking pin -3359- .
ks
The crankshaft is locked with crankshaft stop
Vol -T10050- or
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crankshaft stop -T10100- .
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Tensioning roller locked with locking
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-T10115- and se

Turn camshaft pulley in its elongated holes to centre position
-arrows-.
Fit toothed belt onto crankshaft toothed belt pulley, tensioning
roller, camshaft toothed belt pulley and idler roller.
Prote
cted
by
Now carefully turn tensioning roller clockwise using pin wrench

-T10020- until indicator is in middle of gap in the base plate
-arrow-.
Ensure that securing nut does not turn as well.
Hold tensioning roller in this position and tighten tensioning
roller securing nut as follows: 20 Nm and 45 (1/8 turn) further.
56
AG.
Loosen tensioning roller securing nut and pull out locking pin
-T10115- .
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Ensure that tensioning roller seats correctly in rear toothed belt

guard -arrow-.
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Then fit toothed belt on coolant pump toothed belt pulley.

Fit counterhold tool -T10172- with pins -T10172/4- as shown.
Press counterhold tool -T10172- in direction of arrow, keeping
camshaft toothed belt pulley under tension.
In this position, tighten camshaft toothed belt pulley securing
bolts -1- to 25 Nm.
Remove locking pin -3359- and crankshaft stop -T10050- .
lkswagen AG
Vorotation
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Turn crankshaft two rotations in engine direction
does
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until crankshaft is just before TDC No.
1
cylinder.
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Vehicles with round crankshaft belt
ho pulley
rrectness of i
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spec
at
i
h re
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in t
his
Check whether crankshaft can be locked with crankshaft stop

-T10050- .
If crankshaft cannot be locked
ht
rig
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Loosen securing bolts -1- for camshaft toothed belt pulley.
do
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Lock hub with locking pin -3359- whilst turning engine in di

rection of rotation.
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Prote
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Turn crankshaft slightly against engine direction of rotation

until the pin of the crankshaft stop is positioned just before the
hole in the sealing flange -arrow-.
Now turn crankshaft in engine direction of rotation until crank
shaft stop pin engages in sealing flange whilst turning.
Vehicles with oval crankshaft belt pulley
1. Cylinder head
57

Lock hub with locking pin -3359- whilst turning engine in di
rection of rotation.
Check whether the crankshaft can be locked with crankshaft
stop -T10100- .
If crankshaft cannot be locked:
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Loosen securing bolts -1- for camshaft
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toothed belt
is pulley.
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Turn crankshaft against engine direction of rotation slightly

until pin of crankshaft stop is located just before hole in sealing
flange -arrow-.
Turn crankshaft two rotations in engine direction of rotation

until crankshaft is just before TDC No. 1 cylinder.
Repeat check.
58
AG.
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bolts -1- to 25 Nm.
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Now turn crankshaft in engine direction of rotation until crank

shaft stop pin engages in sealing flange from rotational move
ment.

Set engine bracket against cylinder block and tighten securing
bolts -arrows- to 40 Nm + 1/2 turn (180 ) further.
Note
Before installing assembly mounting, tighten all engine bracket

bolts to prescribed torque.
Install assembly mounting between engine and body (renew
securing bolts).
Specified torque, M8 bolts: 20 Nm + 90 (1/4 turn)
Specified torque, M10 bolts: 40 Nm + 90 (1/4 turn)
olkswagen AG
en AG. V
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Bolt engine assembly mounting to engine bracket by bringingolkswag

V
by.
contact surfaces together using support bracket -10-222Aed
Specified torque: 60 Nm + 90 (1/4 turn)
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Install centre and lower parts of toothed belt guard.
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Install belt pulley vibration damper (renew securing bolts).

Install toothed belt guard upper part.
rrectness of i
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spec
at
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h re
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his
Install front right wheel housing liner.

Install coolant expansion tank.
Bolt fuel filter bracket to engine mounting to 8 Nm torque

-arrows-.
Engage fuel filter in bracket.
Bolt on filler neck for window wash system.
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1. Cylinder head
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Fit engine cover.
59

1.3.2
Removing and installing toothed belt (vehicles with engine support bolted
further away from engine)
Note
A revised engine support has been introduced gradually and it is no longer necessary to remove the engine
support and to support the engine for the procedure removing, installing and tensioning toothed belt.
To change the tensioning roller, for both versions the engine support must be removed.
equipment required
Diesel injection pump lock
ing pin -3359 Locking pin -T10060 A Crankshaft stop -T10100 Counterhold tool -T10172 Special wrench, long reach
-T10264-
ole,
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60
ht
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Remove engine cover. page 4 To do this, pull engine cover

upwards abruptly at front -arrows A- and then pull forwards out
of rear fastening -arrow B-.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
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wit
i
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thi
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Removing
AG. Volkswagen AG d
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Locking tool -T10265-

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

connecting pipe, to do this, lightly lift retaining clips -arrows-.
1. Cylinder head
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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Remove bolt -1-.
61
AG.
Prote
cted
by

Pull fuel filter out of bracket -arrow-.
Unscrew bolt at filler neck -2- for windscreen washer system
reservoir.
Unscrew bracket -3- for fuel filter.
Disconnect electrical connector on coolant expansion tank

-1-.
Remove coolant expansion tank, coolant hoses remain con
nected. Place it on engine.
Remove tensioning element for poly V-belt.
Remove upper toothed belt guard, to do this, loosen retaining

clips -arrows-.
Remove belt pulley with vibration damper.
Remove lower and centre parts of toothed belt guard.
AG. Volkswagen AG d
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62
rrectne
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spec
atio
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Note

ment of camshaft pulley is on top. The marking on the rear toothed
belt guard must line up with the marking on the camshaft sender
wheel -arrow-.
Lock hub using locking pin -3359- . To do this, slide locking
head.
Lock crankshaft toothed belt pulley with crankshaft stop T10100- . To do this, push crankshaft stop into teeth of belt
pulley from face side.
Note
shaft stop must align. When doing this, the pin of the crankshaft
stop must insert in the drilling of the sealing flange.
Mark direction of rotation of toothed belt.
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Loosen tensioning roller securing nut -1-.
ht
rig
py
Co
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fo
ng
Turn eccentric of tensioning roller anti-clockwise -arrow- using

socket -T10264- , until the tensioning roller can be locked with
locking tool -T10265- .
rrectne
s
s
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f
i
t to the co
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form
spec
atio
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Loosen securing bolts -1- of camshaft toothed belt pulley
y Vuntil
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camshaft pulley can be moved within the elongatedisholes.
ed
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1. Cylinder head
63
AG.
Prote
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Now turn tensioning roller eccentric clockwise -arrow- onto
stop and tighten securing nut -1- hand-tight.
Remove toothed belt first from coolant pump and then from
remaining toothed belt pulleys.
Installing
Camshaft locked with locking pin -3359- .
Crankshaft locked with crankshaft stop -T10100- .
Tensioning roller locked with locking pin -T10265- and se wagen AG. Volkswagen AG does
not
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cured to right stop with securing nut.
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Note
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spec
atio
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wit

Turn camshaft pulley in its elongated holes to centre position
-arrows-.
Guide toothed belt through gap between engine support and
engine.
Fit toothed belt onto crankshaft toothed belt pulley, tensioning
roller, camshaft toothed belt pulley and idler roller.
Then fit toothed belt on coolant pump toothed belt pulley.
Prote
cted
by
Turn eccentric of tensioning roller clockwise -arrow- using

special wrench, long reach -T10264- until indicator -2- is in
middle of gap in base plate.
Note
Ensure that securing nut does not turn as well.

Hold tensioning roller in this position and tighten tensioning
roller nut to 20 Nm + 45 (1/8 turn).
64
AG.
Loosen tensioning roller securing nut -1-.
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Remove locking pin -T10265- from tensioning roller.
ht
rig
py
Co
t.
Ensure that tensioning roller seats correctly in rear toothed belt

guard -arrow-.
thi
sd
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cu
m
en
Note

Fit counterhold tool -T10172- with pin -T10172/4- as shown in
illustration, and keep the toothed belt under tension on pulling
side, by pressing in -direction of arrow-.
Tighten bolts -1- of camshaft toothed belt pulley to 25 Nm.
until the crankshaft is just before TDC again.
Lock hub of camshaft with locking pin -3359- whilst turning

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

-T10100- .
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ht
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Co
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Loosen securing bolts -1- for camshaft toothed belt pulley.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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thi
sd
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If crankshaft cannot be locked
1. Cylinder head
65
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AG. Volkswagen AG d
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Turn crankshaft slightly against engine direction
rotation
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until the pin of the crankshaft stop is positioned
e
ris
hole in the sealing flange -arrow-.
tho
au
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
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ss of rotation until crank

Now turn crankshaft in engine direction
shaft stop pin engages in sealing flange whilst turning.
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bolts -1- to 25 Nm.
Repeat check and adjustment if necessary.
Install toothed belt guard upper part.

Install connecting pipe between charge air cooler and intake
connecting pipe.
Install front right wheel housing liner.
Install coolant expansion tank.
Bolt fuel filter bracket to engine mounting to 8 Nm torque
-arrows-.
Engage fuel filter in bracket.
Bolt on filler neck for window wash system.
Fit engine cover.
66
AG.
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Prote
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rig
ht
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Install belt pulley vibration damper (renew securing bolts).
ht
rig
py
Co
t.
Install centre and lower parts of toothed belt guard.
do
c
um
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until crankshaft is just before TDC No. 1 cylinder.

G. Volkswagen AG d
gen Aengine
4-cylinderkdiesel
(1.9 l engine)
a
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Removing and installing cylinder head
Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Hand vacuum pump with
accessories -V.A.G 1390-
rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
Drip tray -V.A.G 1306- or

drip tray -VAS 6208-
es, in part or in w
l purpos
hole
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equipment required
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Water drainage container V.A.G 1390/1-
Retainer -T10014- (only ve

hicles 05.05)
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Support bracket -10-222A- with adapters -10-222A/13- (only
vehicles 05.05)
1. Cylinder head
67

Note
All cable ties which are opened or cut through when cylinder head
is removed must be replaced in the same position when cylinder
head is installed.
olkswagen AG
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hot components.
1.4.1
Removing
Note
Before removing cylinder head, extract fuel using hand-operated

vacuum pump with accessories -V.A.G 1390- and water drainage
container -V.A.G 1390/1- page 147 .
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Remove two-piece engine cover page 4

Prote
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by
Remove plenum chamber bulkhead. General body repairs,

exterior; Rep. Gr. 50 ; Body - front, plenum chamber bulk
head .
pipe.
68
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Remove engine cover panel page 4 . To do this, pull engine

cover upwards abruptly at front -arrows A- and then pull for
wards out of rear fastening -arrow B-.
do
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tions:

of mounting.
Drain coolant. page 102
Disconnect fuel supply and return lines as well as coolant line
on cylinder head.
Before removing cylinder head, extract fuel from tandem pump
using hand-operated vacuum pump with accessories -V.A.G
1390- and water drainage container -V.A.G 1390/1 page 147 .
Pull fuel filter module upwards out of bracket and lay it with
hoses to side.
Remove front exhaust pipe page 186 .
Remove turbocharger support and oil return from turbocharg
er.
Remove oil supply line and lay it to side page 95 .
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From 05.05 a modified
engine
support
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no longer necessary
to
remove
the
engine
support
and
supporting
ss
Note
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the engine for the procedure removing, installing and tensioning

toothed belt page 50
Remove toothed belt tensioning roller.

Install hub for camshaft pulley page 80 , Removing and
installing camshaft.
Remove rear toothed belt guard securing bolts -2- and -4-.
Unscrew Hall sender -G40- -3-.
Remove exhaust gas recirculation connecting pipe.
Pull off or disconnect all other electrical connections as nec
essary from cylinder head and lay to one side.
Only vehicles 05.05)

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Note
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Separate all connection, coolant, vacuum and intake hoses

from cylinder head.
rrectness of i
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spec
a
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Both lifting eyes for the support are located on the cylinder head,
so an additional bracket for supporting the engine must be se
cured on the cylinder block.
1. Cylinder head
69
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Prote
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by

Screw retainer -T10014- into threaded hole above coolant
pump and tighten to 20 Nm.
Lift engine slightly using spindle -A- until spindle -B- is relieved.
Unhook spindle -B- and push it to side.
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Remove cylinder head cover. page 48
Lift cylinder head slightly and remove from engine laterally

past toothed belt guard.
Note
The cylinder head must be guided carefully to prevent damage.
1.4.2
Installing
Note
In cases of repair carefully remove gasket remains from cyl

Prote
cted
by
Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
Turn crankshaft to TDC marking before fitting cylinder head.

Turn crankshaft opposite engine direction of rotation until all
pistons are approximately equally placed below TDC.
Fit cylinder head gasket.
Note
Note identification on cylinder head gasket page 47 .
70
AG.
Carefully remove remains of emery and abrasives.
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inder head and cylinder block. Ensure that no long scores or

scratches are created. When using abrasive paper do not use
a grade less than 100.
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Always renew cylinder head bolts.
rrectne
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Maintain sequence when loosening cylinder head bolts.

Fit cylinder head and tighten all cylinder head bolts hand-tight.
Tighten cylinder head in four stages in sequence as shown as
follows:
1-
Tighten initially with torque wrench:
2-
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Stage II = 60 Nm
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Stage I = 35 Nm
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Turn further with rigid spanner:
Stage III = 1/4 turn (90)
Note
rrectness of i
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nform
spec
at
i
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wit
in t
his
Stage IV = 1/4 turn (90)
After repair work it is not necessary to retighten the cylinder head

bolts.
Further installation is carried out in the reverse order. In the proc
ess, note the following:
AG.
Install oil supply line page 95 .
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Install toothed belt page 50 .
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Install hub for camshaft toothed belt pulley page 147 , Re

moving and installing camshaft.
do
c
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en
After tightening cylinder head, turn camshaft so that cams for

No. 1 cylinder equally point upwards. Before fitting toothed
belt, turn crankshaft in engine direction of rotation
page 50 , removing, installing and tightening toothed belt.
Install insulation tray General body repairs, exterior; Rep.

Gr. 50 ; Body - front; Assembly overview.
Install plenum chamber bulkhead General body repairs,
exterior; Rep. Gr. 50 ; Body - front; Plenum chamber bulk
head .
Carry out road test and then read fault memory page 178 .
1.5
Checking compression
Note
If ceramic glow plugs are fitted, before removing check idling

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

equipment required
V.A.G 1331-
es, in part or in w
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hole
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Adapter -V.A.G 1381/12-
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Compression tester V.A.G 1763-
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Engine oil temperature min. 30 C.
Test procedure
Pull off central connector for unit injectors.
Note
If ceramic glow plugs are fitted, always observe notes on remov

ing and installing ceramic glow plugs page 198 .
Remove all glow plugs or ceramic glow plugs using jointed
extension and socket -3220- .
72
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Test prerequisite
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Jointed spanner -3220- oris
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Torque wrench s
Golf
2004 , Golf Plus 2005
AG. Volkswagen
does 01.2009
agen(1.9 l engine) -AG
4-cylinder diesel oengine
Edition
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Screw in adapter -V.A.G 1381/12- in place of

ceramic glow plugs.
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glowthplugs
or
or
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ss
Check compression using compression tester -V.A.G 1763- .
rrectness of i
t to the co
nform
spec
at
i
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in t
his
Note
Using compression tester Operating instructions.

Operate starter until tester shows no further pressure in
crease.
Compression pressures:
New: 25...31 bar, wear limit: 19 bar
Maximum permissible difference between all cylinders: 5 bar

Note
AG.
Prote
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Read fault memory of engine control unit. page 178
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Remove glow plugs or ceramic glow plugs using jointed ex

tension and socket -3220- .
do
c
um
en
If ceramic glow plugs are fitted, always observe notes on remov

ing and installing ceramic glow plugs page 198 .
Note
Disconnecting the central connector for unit injectors causes

faults to be stored. Therefore, read fault memory and clear if nec
essary.
1. Cylinder head
73

AG. Volkswagen AG d
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Valve gear
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
Assembly overview - valve gear page 74 .
Checking valve guides page 76 .
Renewing valve stem seals page 78 .
Removing and installing camshaft page 80

Removing and installing camshaft seal page 84
3 - Cylinder head bolt

Renew
Note sequence when
loosening and tighten
ing page 67 , Remov
ing and installing cylin
der head.
Before installing, insert
washers
Item 4 (page 74) in
cylinder head.
4 - Washer
For cylinder head bolts.
Insert in cylinder head
before installing bearing
caps
5 - Bucket tappet
Do not interchange.
With hydraulic valve
clearance compensa
tion.
Store with cam contact
surface downwards
Before installing, check camshaft axial clearance page 76 .
Oil contact surfaces.
Before removing, remove camshaft bearing caps
74
AG.
2 - Rocker arm shaft

Do not interchange.
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1 - 20 Nm + 1/4 turn (90) fur

ther
Renew
Note sequence when
loosening and tighten
ing page 80 , Re
moving and installing
camshaft.
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Assembly overview - valve gear
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2.1
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spec
atio
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6 - Valve cotter
7 - Valve spring plate
8 - Outer valve spring
Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder
head installed page 78 , Renewing valve stem seals.
9 - Inner valve spring
Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder
head installed page 78 , Renewing valve stem seals. Volkswa
10 - Valve stem seal
Renewing page 78
13 - Cylinder head
See note page 74 .
14 - Seal
Do not additionally oil or grease the oil seal sealing lip.
Before installing, remove residual oil from camshaft journal using a clean cloth.
To install, tape over groove in taper of camshaft (e.g. using Sellotape).
15 - Valves
Valve dimensions page 76
16 - Bearing shell
Do not interchange used bearing shells (mark).
Ensure that retaining lugs are correctly seated in bearing caps and cylinder head
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17 - Camshaft
Checking axial clearance page 76 .
Check radial clearance with Plastigage, wear limit: 0.11 mm.
Runout: max. 0.01 mm.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
12 - Unit injector
do
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hole
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11 - Valve guide
Checking page 76 .
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18 - Bearing cap
Installation sequence page 80 , removing and installing camshaft
To install, seal parting surfaces of bearing caps 1 and 5 with sealant -AMV 174 004 01- page 76
19 - 8 Nm + 1/4 turn (90) further
Renew
2. Valve gear
75

Checking camshaft axial clearance

Universal dial gauge bracket -VW 387 Dial gauge
Check with bucket tappets
bearing caps fitted.
Seal parting surfaces of bearing caps 1 and 5 with sealant -AMV

174 004 01-
Note
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Apply sealant -AMV 174 004 01- thinly and evenly on the sur
faces -1-.
Be careful that no sealant gets into grooves -arrows-.
Valve dimensions
Note
Valves must not be reworked. Only grinding-in is permissible.
31.45
6.956
89.95
45
Checking valve guides
76
AG.
35.95
6.980
89.95
45
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2.2
mm
mm
mm
Exhaust valve
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Inlet valve
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Dimension
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Wear limit: max. 0.15 mm
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Dial gauge
Test procedure
Insert new valve into guide. The end of the valve stem must
be flush with the guide. Due to slight differences in stem di
ameters, use only an inlet valve in inlet guide and an exhaust
valve in exhaust guide.
Determine rock. Wear limit: max. 1.3 mm
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Cylinder head must be renewed if the rock is greater than the

wear limit.
rrectne
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spec
atio
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Universal dial gauge bracket -VW 387-
2. Valve gear
77
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Renewing valve stem seals

equipment required
Assembly tool -2036un
le
Valve lever -VW 541/1A-
r
fo
ng
Thrust piece -VW 541/5-
(With cylinder head installed)

Remove camshaft. page 80
Remove bucket tappets and place them with the contact sur
face downwards. When doing this, ensure that tappets are not
interchanged.
Set piston of respective cylinder to top dead centre (TDC).
78
AG.
Removing
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2.3.1
rrectne
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form
spec
atio
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i
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Fitting tool -3129-
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Puller -3047 A-
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2.3

Insert valve assembly device -2036- and adjust mounting to
height of studs.
Remove valve springs using valve lever -VW 541/1A- and
press tool -VW 541/5- .
Note
The valves are supported by the piston crown.
Pull off valve stem seals using puller -3047 A- .
es, in part or in w
l purpos
hole
ercia
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m
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Installing
rrectness of i
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spec
atio
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wit
2.3.2
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Place the plastic sleeve -A- supplied on the respective valve

stem. This will prevent the new valve stem seal -B- being
damaged.
Insert new valve stem seal in fitting tool -3129- .
Lubricate sealing lip of valve stem seal and carefully push on
valve guide.
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2. Valve gear
79
AG.
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AG. Volkswagen AG d
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w01.2009
4-cylinder diesel engine (1.9 l engine) - Edition
s
k
no
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Removing and installing camshaft
ility
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equipment required
es, in part or in w
l purpos
hole
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2.4
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Puller -T10052-
rrectness of i
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m
spec
atio
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n in
wit
Counterhold tool -T10051-
Torque wrench (550 Nm)

-V.A.G 1331 Torque wrench (40200
Nm) -V.A.G 1332-
Sealant -AMV 174 004 01-
Prote
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Pull camshaft toothed belt pulley off hub.
80
AG.
Remove securing bolts for camshaft toothed belt pulley -1-.
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2.4.1

Loosen hub securing bolt -1-.
To do this, use counterhold tool -T10051- .
. Volkswage
Loosen hub securing boltwaabout
gen AG2 turns. n AG doe
Apply tension to hub by evenly tightening puller until hub sep

arates from taper of camshaft.
Note
When doing this, hold puller with 30 mm spanner.

Remove hub from taper of camshaft.
Remove cylinder head cover.
Mark rocker arm shafts using a permanent felt tip marker to
prevent interchanging. This will prevent having to perform ba
sic settings of unit injectors -arrows-.
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AG.
Note
ht
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Remove rocker arm shafts.
rrectness of i
t to the co
nform
spec
at
i
h re
o
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wit
in t
his
Apply puller -T10052- and screw securing bolts -1- into hub.
do
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es, in part or in w
l purpos
hole
ercia
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First loosen both outer and then inner securing bolts respectively.
Remove tandem pump page 147 .
First remove bearing caps 5, 1 and 3. Then loosen bearing
caps 2 and 4 alternately and diagonally.
Remove camshaft.
2. Valve gear
81

2.4.2
Installing
Note
When camshaft is installed, No. 1 cylinder cams must point
upwards.
pe
rm
itte
d
Before installing bearing caps, ensure that cylinder head bolt
washers are inserted in the cylinder head.

es, in part or in w
l purpos
hole
ercia
, is n
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com
rrectness of i
t to the co
nform
spec
a
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i
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Oil bearing shell running surfaces.
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When installing the camshaft,uthensure proper seating of retain
or
ac
a
ing lugs in bearing caps and
ss cylinder head.
Install bearing caps 2 and 4 using new bolts.

Tighten bearing caps 2 and 4 diagonally and alternately to
8 Nm + 1/4 turn (90).
Install bearing caps 5, 1 and 3 using new bolts.
Note
Seal parting surfaces of bearing caps 1 and 5 with sealant -
AMV 174 004 01- page 76 .
head, because otherwise leaks can develop at tandem pump.
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Install camshaft oil seal. page 84
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Install rocker arm shafts and tighten securing bolts, first the
inner -2- and then the outer -1-, evenly and diagonally to 20 Nm
+ 1/4 turn (90).
Tighten hub securing bolt -1- to 100 Nm.

To do this, use counterhold tool -T10051- .
82
AG.
Fit hub onto camshaft.
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Tighten bearing caps 5, 1 and 3 likewise to 8 Nm +1/4 turn

(90).
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Bearing cap 5 must align flush with outer edge of cylinder

Push camshaft toothed belt pulley onto hub.
Note
The toothed segment -arrow- of the camshaft toothed belt pulley

must be on top.
Align camshaft toothed belt pulley at centre of elongated
holes.
Hand tighten securing bolts -1- to camshaft toothed belt pulley
so that there is no play.
Lock hub using locking pin -3359.
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Screw new adjustment
screws
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fit lock nut. ss au
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Vol belt page 50 .
Install and tighten toothed
by
Turn crankshaft in direction of engine rotation until roller of

rocker arm is located at tip of drive cam. Roller side
-arrow A- is positioned at highest point and dial gauge
-arrow B- is positioned at lowest point.
Remove dial gauge.
Now turn the adjuster screw into rocker arm until significant
resistance can be felt (unit injector is at limit stop).
Turn adjustment screw 180 back off stop.

Hold adjuster screw in this position and tighten lock nut to 30
Nm.
Install tandem pump page 147 .
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Install cylinder head cover.
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Fit the dial gauge onto the adjustment screw of the unit injector
as shown.
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When new tappets have been installed the engine must not be
started for about 30 minutes, hydraulic compensation elements
must settle (otherwise valves will strike pistons).
2. Valve gear
83
AG.

2.5
Removing and installing camshaft oil seal

equipment required
Fitting sleeves -10-203 Oil seal extractor -3240 Torque wrench -V.A.G
1331 Torque wrench -V.A.G
1332 Bolt M121.5 65
Removing

Remove camshaft toothed belt pulley and hub page 80 ,
Removing and installing camshaft.
Unscrew inner part of oil seal extractor -3240- two turns (ap
prox. 3 mm) out of outer part and lock with knurled screw.
Lubricate threaded head of oil seal extractor -3240- , place it
in position and exerting firm pressure, screw it as far as pos
sible into oil seal.
Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
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Note
Installing
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d
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4-cylinder
diesel
engine
(1.9
l
engine)
- Edition
01.2009
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The oil seal sealing lip must not be additionally oiled or greased.
Remove oil residue from camshaft journal using a clean cloth.
Tape over groove in taper of camshaft (e.g. with Sellotape).
Fit oil seal carefully on camshaft.
Press in oil seal with press piece of fitting tool -10-203- and
bolt M12 5x65 onto stop.
Install and tighten toothed belt page 50 .
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2. Valve gear
85
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Engine oil
Note
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Lubrication
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17
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The oil level must not be above the max. mark - danger of damage
to catalytic converter! Markings.
Engine oil specification Maintenance ; Booklet 38
With oil filter change: 3.8 l

Without oil filter change: 3.3 l
Engine codes BLS and BXJ
With oil filter change: 4.3 l
Without oil filter change: 3.8 l
1.2
Checking engine oil level
1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched field: Can be topped up with engine
oil.
c - Area from min. mark up to hatched field: Must be topped up,
max. 0.5 l of engine oil!
86
Rep. Gr.17 - Lubrication
AG.
Engine codes BJB, BKC, BRU, BXE and BXF
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Checking engine oil level page 86
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Oil capacities page 86

- Edition 01.2009
Parts of lubrication system
Finding metal shavings or a large quantity of small metal par

ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
Thoroughly clean oil channels.
Renew oil cooler.
Renew oil filter element

Assembly overview - oil pump, sump page 87
Removing and installing sump page 88
r
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AG.
2 - Sealing flange
With seal.
Must be positioned on
dowel sleeves.
page 23 .
Install with silicone seal
ant -D 176 404 A2 page 23 .
Do not additionally oil or
grease the oil seal seal
ing lip.
Before installing, re
move oil residue from
crankshaft journal using
a clean cloth.
Renewing crankshaft oil
seal - pulley end
page 21 .
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1 - 15 Nm
Assembly overview - oil pump, sump

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Caution
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AG. Volkswagen AG d
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oeengine
(1.9 l engine)
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3 - Chain tensioner with ten

sioning rail, 15 Nm
When installing, preten
sion spring and fit
4 - Dipstick
The oil level must not be
above the max. mark!
Markings page 86
5 - Dipstick guide
6 - Guide tube
7 - Dowel sleeves
8 - O-ring
Renew
2. Parts of lubrication system
87

9 - 15 Nm
10 - Suction line
Clean strainer if soiled
11 - Baffle plate
12 - 15 Nm
13 - 15 Nm
14 - Sump
Clean sealing surface before fitting.
Install with silicone sealant -D176404A2 Removing and installing page 88 .
. Volkswagen AG
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15 - Oil drain plug, 30 Nm
wage
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16 - 10 Nmauth
18 - Seal
Renew
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17 - Oil level and oil temperature sender -G266 Black connector, 3-pin.
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19 - Oil pump
With 12 bar pressure relief valve
Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
Renew if running surfaces and gears are scored
20 - Chain sprocket for oil pump
21 - Bracket
For oil level/temperature sender wiring harness.
22 - 20 Nm + 1/4 turn (90) further
Renew
23 - Chain
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2.2
AG.
Note
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25 - Oil spray jet

For piston cooling
Removing and installing sump
88
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24 - 25 Nm
Insert without sealant.

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Hexagon key extension, 5 mm -3249-
Hand drill with plastic brush attachment

Silicone sealant -D176404A2-
Flat scraper
Removing

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Drain engine oil.
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2.2.1
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Eye protection
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Hand drill with plastic brush attachment
Observe environmental regulations for disposal.

Pull 3-pin connector off oil level and oil temperature sender G266- .
Remove sump.
Loosen sump with light blows of a rubber headed hammer if
necessary.
Remove sealant residue from cylinder block with a flat scraper.
89

Remove sealant residue on sump using a rotating brush, e.g.
an electric drill with a plastic brush attachment (wear safety
goggles).
Clean sealing surfaces. They must be free of oil and grease.
2.2.2
Installing
Note
Observe expiry date of sealing compound.
The oil sump must be installed within 5 minutes of applying
silicone sealing compound.
Cut off tube nozzle at forward marking (approx. 3 mm nozzle

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

compound will enter the oil sump
and may block the oil suction
es n
wage
line strainer.
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90
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Install sump immediately and tighten all sump bolts lightly.

Ensure that sump is flush against intermediate plate and gear
box flange.
Note
When installing sump with engine out of vehicle, ensure that sump
is flush with cylinder block at flywheel end.
Tighten sump bolts diagonally to 15 Nm.
Tighten bolts securing sump to gearbox to 45 Nm.
Let sealing compound dry for approx. 30 minutes after installing

sump. Only then fill with engine oil.
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Note
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Apply silicone sealing compound bead as shown to the clean

sealing surface of the sump. (The figure shows the position of
the sealant bead on the cylinder block.)
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Further assembly is basically the reverse of the dismantling se

quence.
91
AG.

Oil filter bracket, oil pressure, engine

oil cooler and oil supply line
Assembly overview - oil filter bracket and oil cooler page 92

Checking oil pressure and oil pressure switch page 93
Assembly overview - oil supply line to turbocharger page 94
Removing and installing oil supply line to turbocharger
page 95
3.1
Assembly overview - oil filter bracket and engine oil cooler
1 - Oil filter bracket
es, in part or in w
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hole
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4 - Seal
Renew
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3 - Gasket
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2 - 15 Nm + 1/4 turn (90) fur

ther
Renew
First fit upper left and
lower right bolts and
then tighten all four bolts
diagonally.
5 - Connection, 35 Nm
6 - Oil supply line, 22 Nm

To turbocharger.
page 95 .
7 - Sealing cap, 25 Nm
Prote
cted
by
12 - Plug, 25 Nm
13 - Seal
Renew.
14 - Engine oil cooler
Ensure clearance to adjacent components.
See note page 87 .
92
AG.
11 - Oil pressure switch -F1 0.7 bar switch: brown.

Tighten to 20 Nm.
If seal is leaking, nip open and renew.
Checking page 93 .
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10 - Plug, 10 Nm
If seal is leaking, nip
open and renew.
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9 - Oil filter element

Ensure "Top" is upper
most when fitting
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8 - Seal
Renew

Checking engine oil cooler for leaks page 112
15 - Gasket
Renew.
17 - 10 Nm
Voltage tester V.A.G 1527 B-
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3.2.1
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Auxiliary measuring set V.A.G 1594 A-
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hole
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com
Oil pressure tester V.A.G 1342-
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a
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equipment required
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Checking oil pressure and oil pressure switch
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3.2
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16 - Bracket
Test procedure
Note
Functional check and repair of optical and acoustic oil pressure

warning: Current flow diagrams, Electrical fault finding and Fit
ting locations Guided fault finding with VAS 5051.
3. Oil filter bracket, oil pressure, engine oil cooler and oil supply line
93

Remove oil pressure switch -F1- and screw into tester.
Screw tester into oil filter bracket
in place of oil pressure
AG. Volkswagen AG d
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switch.
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Connect brown
ris
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Connects avoltage
tester -V.A.G 1527 B- to
s
and oil pressure
switch using cables from auxiliary measuring
set -V.A.G 1594 A- . LED must not light up.
Start engine and increase speed slowly.
rrectne
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spec
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At 0.550.85 bar the LED must light up; otherwise renew oil
pressure switch.
Increase engine speed further. At 2000 rpm and an oil tem
perature of 80 C the oil pressure should be at least 2.0 bar.
At higher engine speed, oil pressure must not exceed 7.0 bar. If
necessary renew oil filter bracket.
3.3
Assembly overview - oil supply line to turbocharger
1 - Retaining clamp
2 - 25 Nm
Prote
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4 - 10 Nm
5 - Bracket
8 - Union nut, 22 Nm
94
AG.
7 - 10 Nm
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3 - Oil supply line

To turbocharger.

3.4
Removing and installing oil supply line

to turbocharger

3.4.1
Removing
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Remove engine cover. page 4 To do this, pull
V engine cover
gu
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e
upwards abruptly at front -arrows A- and then
pull
forwards
out
nte
is
r
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h
of rear fastening -arrow B-.
ut
ra
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c
s
s
of mounting.
Loosen securing bolts for retaining clips.
Loosen oil supply line union nuts on oil filter bracket and tur
bocharger.
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Installing
Prote
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3.4.2
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Remove oil supply line.
rrectne
s
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form
spec
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pipe.
Note
The procedure must be followed to ensure that oil supply line is

installed tension-free.
3. Oil filter bracket, oil pressure, engine oil cooler and oil supply line
95

rrectness of i
t to the co
nf
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m
spec
atio
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wit
es, in part or in w
l purpos
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Tighten union nut -8- on oil filter bracket hand tight.

Tighten union nut -6- on turbocharger hand-tight.
First tighten union nut -8- on oil filter bracket and then union
nut -6- on turbocharger to 22 Nm.
Attach retaining clips -1- to brackets and tighten securing bolts
to 10 Nm.
Tighten securing nut -2- to 25 Nm.
Further installation is basically the reverse of the removal proce
dure.
96
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Start union nuts for oil supply line on connections.
thi
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Loosen securing nut -2- from retainer -5-.

19
Cooling
Parts of cooling system

WARNING

tions:
sitions.
hot components.
Note
When the engine is warm, the cooling system is under pres
AG. Volkswagen AG d
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Hoses are secured with spring-type clips.
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Spring-type clip pliers -VAS 5024- or hose clip pliers -
or
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When installing coolant hoses, route stress-free so that they
do
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do not come into contact with other components (observe

markings on coolant connection and hose).
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only use spring-type clips.
1. Parts of cooling system
97
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Prote
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Perform leakage test of cooling system using cooling system test
er -V.A.G 1274- and adapters adapter -V.A.G 1274/8- and adapt
er -V.A.G 1274/9- .
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Parts of cooling system - body side pageby98
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Parts of cooling system - engine sideth
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Coolant hose schematic diagram
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Draining and filling with coolant page 102

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Removing and installing radiator page 105 .
rrectness of i
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a
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Removing and installing coolant pump page 106 .

Removing and installing thermostat page 108
Checking cooling system for leaks page 110
Checking engine oil cooler for leaks page 112
1.1
Parts of cooling system, body side
1 - Upper coolant hose

Coolant hose schematic
diagram page 101
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Prote
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6 - 5 Nm
7 - Expansion tank
Check using cooling
system tester V.A.G 1274- and adapt
er -V.A.G 1274/8- .
8 - 5 Nm
9 - 10 Nm
10 - Fan support
11 - Additional fan
Vehicles with optional
equipment only.
12 - Radiator fan
13 - Connector
14 - Lower coolant hose
Coolant hose schematic diagram page 101
98
Rep. Gr.19 - Cooling
AG.
5 - Connector
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4 - Sealing cap
Check using cooling
system tester V.A.G 1274- and adapt
er -V.A.G 1274/9- .
Test pressure: 1.4...1.6
bar.
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3 - Cooler
page 105 .
After renewing, renew
entire coolant
do
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2 - O-ring
Renew if damaged.

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

diagram page 101
11 - 40 Nm
12 - T-piece
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10 - To heat exchanger
diagram page 101
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9 - 10 Nm
Prote
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8 - Connection
AG.
7 - To exhaust gas recircula

tion cooler
diagram page 101
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er -G62 With coolant tempera
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5 - Retaining clip
Check for secure seat
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4 - O-ring
Renew.
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3 - To bypass flap
diagram page 101
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2 - Upper coolant pipe

Bolted to cylinder head
cover
13 - To bypass flap
14 - T-piece
15 - To top of radiator
16 - 15 Nm
17 - To bottom of expansion tank
18 - Coolant pipe
19 - To bottom of radiator
99
22 - To heat exchanger
Coolant hose schematic diagram page 101 .
24 - 10 Nm
25 - To auxiliary heater

29 - Coolant pump
Check for ease of movement.
100
AG.
27 - To exhaust gas recirculation cooler

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26 - Coolant pipe
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23 - Rear coolant pipe
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21 - Thermostat
Observe installation position page 108 , removing and installing thermostat.
Check: Heat thermostat in water
Opening begins at approx. 85 C
Ends at approx. 105 C
Opening lift at least 7 mm.
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20 - Connection
For thermostat.
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1.3
Coolant hose schematic diagram
1 - Expansion tank
2 - Bypass flap
3 - Exhaust gas recirculation
cooler
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4 - Heat exchanger for heater

unit
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5 - Cylinder head/cylinder
block
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at
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6 - Gearbox oil cooler

For gear oil
Only on vehicles with
automatic gearbox
7 - Upper coolant hose
8 - Cooler
9 - Lower coolant hose

11 - Coolant pump and ther

mostat
do
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12 - Auxiliary heater
Vehicles with optional
equipment only.
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Note
Coolant hose schematic diagram for vehicles with optional equip

ment Heating, ventilation, air conditioning system; Rep. Gr.
82 ; Connection diagram for coolant hoses in vehicles with auxil
iary heater
101

1.4
Draining and filling with coolant

equipment required
Refractometer -T10007-wagen AG. Volkswagen AG doe
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Drip tray -V.A.G e1306db
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s
VAS 5024s A-
Cooling system charge unit

-VAS 6096-
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Draining
Open cap on coolant expansion tank.

WARNING
Steam may be released when cap is removed from expansion

tank. Cover cap with a cloth and open carefully.
102
thi
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1.4.1
rrectness of i
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spec
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Adapter -V.A.G 1274/8-

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

engine oil cooler -arrow-.
Note
Observe environmental regulations for disposal.
rrectness of i
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spec
at
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1.4.2
Filling
Note
In vehicles as of model year 2008, only G 12 plus-plus ac
cording to TL VW 774 G may be used as coolant additive.
For vehicles up to and including model year 2007 coolant ad
ditive G 12 plus according to TL VW 774 F and G 12 plus-plus

according to TL VW 774 G can be used.
The coolant additive G 12 plus-plus can be mixed with the
previous coolant additive G 12 plus. Identification: Both are

coloured purple.
Coolant additives marked according to TL VW 774 G or ac
cording to TL VW 774 F prevent frost and corrosion damage,

scaling and also raise boiling point of coolant. Therefore, the
cooling system must be filled all year round with coolant ad
ditive and corrosion protection additive.
Because of its higher boiling point, the coolant improves en
gine reliability under heavy loads, particularly in countries with

tropical climates.
Frost protection is required down to about -25 C (in countries
with arctic climates: down to about -35 C).
The coolant concentration must not be reduced by adding wa
ter even in warmer seasons and in warmer countries. The

coolant additive concentration must be at least 40 %.
If for climatic reasons greater frost protection is required, the
amount of coolant additive can be increased, but only up to 60

% (frost protection to about -40 C). Otherwise frost protection
and cooling effectiveness are reduced again.
The refractometer -T10007- is recommended for determining

the current anti-freeze concentration.
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If radiator, heat exchanger,
ed cylinder head or cylinder head
ris reuse old coolant.

gasket is renewed, dothonot
Frost
protection to
1)
G 12 plus1)
G 12 plusplus1)
Water 1)
3.2 l
4.0 l
4.8 l
4.0 l
40 %
50 %
rrectness of i
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nform
spec
at
i
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his
-25 C
-35 C
Anti-freeze
proportion
The quantity of coolant can vary depending upon the vehicle

equipment.
Close radiator drain plug.
Connect coolant hoses to oil cooler.
Install noise insulation tray. General body repairs, exterior;
Screw adapter -V.A.G 1274/8- onto expansion tank.
Fill coolant circuit using cooling system charge unit VAS 6096- Operating instructions for cooling system charge
unit VAS 6096
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104
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Recommended mixture ratios:
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1.5
Removing and installing radiator

equipment required
Refractometer -T10007 Drip tray -V.A.G 1306 Torque wrench V.A.G 1331 Spring-type clip pliers VAS 5024 An AG. Volkswagen AG do
Adapter -V.A.G 1274/8e
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1.5.1
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Bring lock carrier into service position. General body re

pairs, exterior; Rep. Gr. 50 ; Body - front; Lock carrier service
position .
Pull coolant hoses off radiator.
Separate connector for radiator fan.
Remove radiator securing bolts.
Remove radiator downwards.
1.5.2
Installing

note the following:
Fill with coolant. page 102
105

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Removing and installing coolant pump
Adapter -V.A.G 1274/8 Cooling system charge unit

-VAS 6096-
es, in part or in w
l purpos
hole
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Spring-type clip pliers VAS 5024 A-
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Removing
Note
Always renew seals and gaskets.

Drain coolant page 102 .
Remove toothed belt page 50 .
106
do
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1.6.1
rrectness of i
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spec
at
i
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AG.
Drip tray -V.A.G 1306-
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Refractometer -T10007-
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equipment required
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1.6

Remove securing bolts -1- for coolant pump -2- and carefully
remove coolant pump.
1.6.2
Installing

note the following:
Moisten new O-ring -3- with coolant.
Insert coolant pump -2- in cylinder block and tighten securing
bolts -1- to 15 Nm.
Note
The coolant pump plug faces downwards.

Install toothed belt page 50 .
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107
Prote
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1.7
Removing and installing thermostat

equipment required
Refractometer -T10007 Drip tray -V.A.G 1306 Torque wrench V.A.G 1331 Spring-type clip pliers VAS 5024 A Adapter -V.A.G 1274/8 Cooling system charge unit
-VAS 6096-
Note
es, in part or in w
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hole
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Removing
rrectness of i
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spec
at
i
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1.7.1
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Always renew seals and gaskets.

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

moving and installing alternator with poly V-belt .
Pull coolant hose off connection.
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do
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108

Remove securing bolts -1- of connection -2- and remove con
nection -2- with thermostat -4-.
Turn thermostat -4- 1/4 turn (90) to left and remove it from
connection -2-.
1.7.2
Installing

note the following:
Moisten new O-ring -3- with coolant.
Insert thermostat -4- into connection -2- and turn 1/4 turn (90
) to right.
Note
The brace on the thermostat must

be almost vertical.
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Replenish coolant. page 102
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Insert connection
-2- with thermostat -4- in cylinder
ara block.
db
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Tightenut securing bolts -1- to 15 Nm.
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109
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1.8
Checking cooling system for leaks

equipment required
Cooling system tester V.A.G 1274-
r
fo
ng
Prote
cted
by
Engine at operating temperature.
Test sequence:
WARNING
Hot steam may escape when expansion tank is opened. Place

rag over cap and open with caution.
Open cap on coolant expansion tank.
110
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Test prerequisite
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s
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form
spec
atio
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un
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Adapter for cooling system

tester -V.A.G 1274/9-
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Adapter for cooling system

tester -V.A.G 1274/8-

Attach cooling system tester -V.A.G 1274- with cooling system
tester adapter -V.A.G 1274/8- to expansion tank.
Use hand pump on tester to create a pressure of about 1.0 bar.
If pressure drops:
Find leaks and rectify.
Checking pressure relief valve in filler cap
The pressure relief valve must not open.

If the pressure relief valve opens prematurely:
ility
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of max. 1.6 bar.
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Attach cooling system
tester -V.A.G 1274- withscooling
V
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tester adapter
1274/9to
cap.
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Use hand
on
cooling
system
tester
to
create
a
pressure
c
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s
rrectness of i
t to the co
nform
spec
at
i
h re
o
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in t
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Renew sealing cap.

Increase pressure to over 1.6 bar.
The pressure relief valve must open.
If the pressure relief valve does not open:
Renew sealing cap.
do
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111
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4-cylinder diesel engine (1.9
Edition 01.2009
olkswagen- A
AG.l Vengine)
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Checking engine oil cooler for leaks

ss
es, in part or in w
l purpos
hole
ercia
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e
t
a
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equipment required
Refractometer -T10007-
rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
Hose clamps up to
25 mm -3094 Cooling system tester V.A.G 1274 Adapter for cooling system
tester -V.A.G 1274/8 Spring-type clip pliers -VAS
5024A Drip tray -VAS 6208-
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Not illustrated:
Expansion tank -1K0 121 407 A- or -6Q0 121 407 A- or -1J0
121 407 B Plug -191 211 343-
112
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Cap -1J0 121 324 Coolant hose -251 265 056 Screw clamp
Test prerequisite:
Engine cold
Test procedure
insulation .
Clamp supply line and return line off engine oil cooler using
hose clips to 25 mm -3094- .
Loosen spring type clips -arrows- using spring type clip pliers
-VAS 5024A- .
Note
Collect escaping coolant with drip tray -VAS 6208- .

Pull coolant hoses off oil cooler.
Push sealing cap -5- to rear connection of oil cooler -4-.
Secure sealing plug -2- to breather connection of expansion
tank -1-.
Secure coolant hose -3- to oil cooler and
expansion tank.
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Attach cooling system
tester
-V.A.G
1274with
cooling
system
o
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u 1274/8- to expansion tank.
ac
tester adapter -V.A.G
a
ss
Use hand pump on tester to create a pressure of about 1.6 bar.
Watch pressure drop on pressure gauge. A pressure drop within

10 minutes is not permitted.
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If pressure drops:
Renew oil cooler.
Assembly is carried out in the reverse order, note the following:

Check coolant level, if necessary replenish coolant.
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Fill expansion tank up to Max
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113
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20
Fuel supply system
Safety precautions when working on

fuel supply system
es, in part or in w
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WARNING
AG. Volkswagen AG d
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tions:
sitions.
hot components.
very hot (danger of scalding)!
Prevent skin contact with fuel! Wear fuel-resistant gloves!
114
Rep. Gr.20 - Fuel supply system
AG.
Before beginning work, place an extraction hose close to

sender opening in fuel tank to extract escaping fuel fumes and
switch on exhaust extraction system. If no exhaust gas ex
traction system is available, a radial fan with a displacement
greater than 15 m3/h can be used providing that motor is not
in air flow.
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When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
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Wear eye and hand protection when performing any type

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The fuel system is also under pressure! Before opening

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

Rules for cleanliness
When working on the fuel supply and injection systems, pay care
ful attention to the following 6 rules for cleanliness:
Thoroughly clean all unions and adjacent areas before dis
connecting.
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Place removed parts eon
d b a clean surface and cover. Do not use
nte
s
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fluffy cloths!
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When system is open: do not work with compressed air if this

can be avoided. Do not move vehicle unless absolutely nec
essary.
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Also ensure that no diesel fuel runs on to the coolant hoses.

Should this occur, the hoses must be cleaned immediately.
Damaged hoses must be renewed.
rrectness of i
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spec
a
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wit
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Install clean components only. Do not remove replacement

parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
or
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Carefully coverss opened components or seal if repairs cannot

be carried out immediately.
2. Rules for cleanliness
115
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Fuel tank, vehicles with front-wheel

drive
Observe safety precautions page 114 .

Observe rules for cleanliness page 115 .
Assembly overview - fuel tank page 116 .
Emptying fuel tank page 117 .
Removing and installing fuel tank page 121 .
Removing and installing fuel delivery unit page 123 .
Removing and installing fuel gauge sender page 124 .
Checking fuel pump page 125 .
3.1
Assembly overview - fuel tank
1 - Sealing cap
2 - 1.5 Nm
3 - Earth connection
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5 - Wiring duct
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8 - Clamping washer
Prote
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11 - Seal
Renew if damaged.
Moisten with fuel when installing
116
AG.
10 - Heat shield
For fuel tank.
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9 - Securing strap
Note installation posi
tion.
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7 - 25 Nm
To secure the securing
straps for the fuel tank,
only bolts with loose
washers must be used.
If other bolts are used,
the securing straps
could be twisted whilst
tightening. Bolts ET
KA (electronic parts
catalogue) .
Renew.
rrectne
s
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6 - Fuel tank
When removing, sup
port using engine and
gearbox jack -V.A.G
1383/A- .
page 121 .
AG. Volkswagen
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4-cylinder ddiesel
engine (1.9 l engine) - Edition
by
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12 - Fuel delivery unit

With fuel gauge sender (G).
Note installation position of flange on fuel tank page 117 .
Removing and installing fuel gauge sender page 124 .
Clean strainer if soiled
13 - Locking ring
Remove and install using fuel tank sender unit tool -T10202- .
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15 - Return line
From fuel cooler
Blue or with blue marking.
Clipped onto fuel tank
To pull off flange, press release button on connecting piece.
do
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14 - Supply line
To fuel filter
Clipped onto fuel tank
Black
To pull off flange, press release button on connecting piece.
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16 - Tank flap unit

Removing and installing General body repairs, exterior; Rep. Gr. 55 ; Tank flap unit .
Installation position of fuel delivery unit
Marking -3- on the flange must align with marking on the fuel tank.
Return line blue or with blue marking -1-.
Supply line (black) -2-.
Note
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
3.2
Emptying fuel tank
3. Fuel tank, vehicles with front-wheel drive
117
olkswagen AG
en AG. V
does
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- Edition 01.2009
se
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spec
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Fuel extractor -VAS 5190-
ri
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ss
Fuel tank sender unit tool -T10202-
Emptying fuel tank if less than 3/4 full page 120
3.2.1
Emptying fuel tank, bleeding fuel system

when fuel pump is intact

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

tective clothing to avoid possible injury and skin contact. Before
loosening hose connections, wrap a cloth around the connec
tion. Then release pressure by carefully pulling hose off con
nection.
Note
Press in securing ring to release fuel lines.
118
AG.
Emptying fuel tank if more than 3/4 full page 120
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Emptying fuel tank, bleeding fuel system when fuel pump is intact
page 118 .
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Note safety precautions before beginning work page 114 .
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Torque wrench (40200 Nm) -V.A.G 1332-

Pull off supply line -arrow- and catch escaping fuel with a cloth.
rrectness of i
t to the co
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o
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m
spec
atio
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n in
wit
es, in part or in w
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hole
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Connect fuel extractor -VAS 5190- with adapter for fuel ex

tractor -VAS 5190 /3 - to fuel supply line.
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The fuel pump is being activated when engine is not running.
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Connect a diagnostic tester.
AG.
Prote
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Switch on ignition.
Remove filler cap from fuel tank filler neck.
Perform the function Emptying fuel system in guided func
tions.
If the fuel tank is emptied, stop the function to prevent the fuel
pump from running dry.
Operate shut-off tap on fuel extractor -VAS 5190- , until the
fuel tank is emptied.
Bleeding fuel system
1) Low-pressure section
Fuel tank filled.

Perform the function Bleeding fuel system in guided func
tions.
119

3.2.2
Emptying fuel tank if it is more than 3/4

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

part of the body.
Remove cotter -2- from shaft -1- of fuel extractor -VAS 5190- .
At distance -a- = 1180 mm from end, mark extraction hose with
insulating tape -arrow-.

Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel
filler neck.
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Push extraction hose into fuel tank until marking eon
d b hose
s
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-arrow- coincides with shaft end.
tho
Note
rrectness of i
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nform
spec
at
i
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A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; it must not be damaged by the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
Empty fuel tank as far as possible.
Carefully pull out extraction hose.
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enough for the sender flange to be opened without danger.
3.2.3
Emptying fuel tank if it is less than 3/4 full
Remove bench seat General body repairs, interior; Rep.

Gr. 72 ; Rear seats; Removing and installing bench seat .
120
AG.
page 120
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If the fuel tank has to be drained fully, proceed as follows:
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When no more fuel is extracted, the tank is emptied just
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Note

Remove cover from fuel delivery unit.
WARNING

nection.
Pull connector and fuel lines off flange.
Note
Press buttons on hose couplings to do this.

Open locking ring using fuel tank sender wrench -T10202- .
Lift sender flange.
Insert extraction hose of fuel extractor -VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, reinstall sender flange.
3.3
Removing and installing fuel tankgen AG. Volkswagen AG

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Special tools and workshop equipment requiredby Vo

ed
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a
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Engine and gearbox jack -V.A.G 1383/A-
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121
Prote
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Removing
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3.3.1
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4-cylinder diesel engine (1.9 l engine) -
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Edition 01.2009
u
ac
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ss
Note
rrectness of i
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nform
spec
at
i
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in t
his
Before carrying out further work, disconnect battery earth
strap. Check whether a coded radio is fitted. Obtain anti-theft

coding first if necessary.
When lowering fuel tank, guide it carefully to prevent damage.

With the ignition switched off, disconnect battery earth strap.
Fold rear seats forwards.
Remove bolts from filler neck -arrows-.

Disconnect fuel lines at front right of fuel tank.
Note

If vehicle has supplementary heating, separate connector to
metering pump and unclip wire. Supplementary heating;
Rep. Gr. 82 ; Removing and installing metering pump -V54
Support fuel tank using engine and gearbox jack -V.A.G 1383/
A- .
Remove securing bolts -arrows- for the fuel tank.
Slowly lower fuel tank.
Tilt fuel tank to get it past rear axle.
3.3.2
Installing

122
Prote
cted
by
Remove rear right wheel housing liner. General body re

pairs, exterior; Rep. Gr. 66 ; Removing and installing wheel
housing liner .
AG.
Remove fuel flap unit. General body repairs, exterior; Rep.

Gr. 55 ; Fuel flap unit
agen
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Pull connector off flange.
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Detach carpet under seats and fold it back. General body

repairs, interior; Rep. Gr. 70 ; Load and luggage compartment
trim; Removing and installing luggage compartment floor
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Empty fuel tank page 117 .

Install breather and fuel hoses free of kinks.
Clip fuel lines onto fuel tank.
3.4
Removing and installing fuel delivery

unit

es, in part or in w
l purpos
hole
ercia
, is n
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or
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t
a
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Removing
rrectness of i
t to the co
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spec
atio
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wit
3.4.1
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First check whether a coded radio is fitted. If so, obtain antitheft coding.
The fuel tank must not be more than 3/4 full when removing
the suction-jet pump. Drain fuel tank if necessary
page 117 .
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123
AG.
Prote
cted
by

Note

WARNING
very hot (danger of scalding)!
The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
Wear eye and hand protection when performing any type
Remove union nut using fuel tank sender unit tool -T10202- .
Pull fuel delivery unit with seal out of opening in fuel tank.
Note
If delivery unit is to be renewed, drain old delivery unit before dis

posal.
3.4.2
Installing
. Volkswagen AG
n AG
Installing the fuel delivery unit is carried out in reverse korder
wage
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of removal.
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Do not bend fuel gauge sender when installing.

Insert seal for flange or fuel delivery unit dry into opening of
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
fuel tank.
Moisten seal with fuel only when installing flange or fuel de
livery unit.

After installing fuel delivery unit, check that the supply, return
and breather lines are still clipped onto the fuel tank.
Note installation position of fuel delivery unit flange: mark on
flange must align with mark on fuel tank.
Removing and installing fuel gauge

sender
AG.
Prote
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124
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Remove fuel delivery unit. page 123
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Removing
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3.5

Release connector tabs of lines -3- and -4- and pull them off.
Raise retaining tabs -1- and -2- using a screwdriver and pull
fuel sender off downwards -arrow-.
Installing
Insert fuel gauge sender into guides on fuel delivery unit and
press upwards until it engages.
Checking
Checking
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voltage supply of fuel pump
ir se -G6- page 125
tee
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current consumption sof
fuel
pump
-G6
page
126
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3.6.1
Checking fuel pump
es, in part or in w
l purpos
hole
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3.6
Checking function and voltage supply
rrectness of i
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m
spec
atio
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n in
wit
Hand multimeter -V.A.G 1526 B- or multimeter -V.A.G 1715-
Diode test lamp -V.A.G 1527 BFuses must be OK.
The battery voltage must be at least 11.5 V.
All electrical consumers, e.g. lights and rear window heating,

must be switched off.
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Test prerequisites
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Auxiliary measuring set -V.A.G 1594 C-
AG.
Prote
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Switch on ignition. Fuel pump must be heard to run.
Switch off ignition.
If the fuel pump does not start:
Pull 4-pin connector off fuel delivery unit flange.
125

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wage
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olks 1527 B- to outer contacts
Connect diode test lamp -V.A.G
tof
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b
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connector using auxiliary
cables
from
auxiliary
measuring
setaran
e
is
tee
r
-V.A.G 1594 C- . utho
o
sa
un
le
Check actuation of fuel pump relay and wiring for open circuit
or short circuit. Vehicle diagnosis, testing and information
system VAS 5051
If LED lights up (voltage supply OK):
Check that electrical wiring between flange and fuel pump is
connected and has continuity.
If no open circuit can be found:
Renew fuel delivery unit. page 123
3.6.2
Checking current draw of fuel pump

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Prote
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Note
The current pick-up clamp of multimeter -V.A.G 1715- can also

be attached to an auxiliary cable between contacts -1- of con
nector and fuel pump.
Connect contacts -4- of connector and fuel pump using an

auxiliary cable from auxiliary measuring set -V.A.G 1594 C- .
Start engine and run at idling speed.
Measure current draw of fuel pump: Specification: max. 7.5
Amperes.
If the measured value is not within specifications:
126
ht
rig
py
Co
t.
Set multimeter to measuring range 20 A and connect in series

between contacts -1- of connector and fuel pump using auxil
iary cables from auxiliary measuring set -V.A.G 1594 C- .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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If LED does not light up
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s The LED must light up for about 2 seconds.

Switch on ignition.

Fuel tank, vehicles with four-wheel

drive

Assembly overview - fuel tank page 127 .
Emptying fuel tank page 128 .
Removing and installing fuel tank page 132 .
Removing and installing fuel gauge sender 2 -G169 page 135 .
Removing and installing suction jet pump page 137
4.1
1
Assembly overview
- fuel tank
Volkswa
2 - Return line
Blue
ing.
3 - Seal
Renew if damaged.
When installing, fit dry in
fuel tank opening
Moisten with fuel only
when installing flange.
r
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ng
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4 - Fuel delivery unit

page 123 .
Checking fuel pump
page 125 .
tion on fuel tank
page 128 .
With fuel gauge sender
-G Removing and installing
fuel gauge sender
page 124 .
rrectne
s
s
o
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form
spec
atio
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ise
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5 - Locking ring, 110 Nm

ing.
Remove and install us
ing wrench -T10202- .
6 - Tank flap unit
With rubber cup
Removing and installing General body repairs, exterior; Rep. Gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit .
4. Fuel tank, vehicles with four-wheel drive
127

7 - Cap
Renew if damaged.
8 - Securing bolt
Tighten to 1.5 Nm.
9 - Earth connection
10 - 10 Nm
AG. Volkswagen AG d
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12 - Fuel gauge sender 2 -G169-
ility
ab
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11 - Suction-jet pump
Clipped onto fuel gauge sender 2 -G169 Removing and installing page 137 .
13 - Fuel tank
When removing, support using engine and gearbox jack -V.A.G 1383 A- .
14 - Securing strap
15 - 25 Nm
To secure the securing straps for the fuel tank, only bolts with loose washers must be used. If other bolts
are used, the securing straps could be twisted whilst tightening. Bolts ETKA (electronic parts cata
logue) .
Renew.
Prote
cted
by
The marking on the fuel tank is not clearly visible.
4.2
Emptying fuel tank

128
AG.
Note
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The marking on the flange must align with the marking on the fuel
tank -arrow-.
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Installation position of flange for fuel delivery unit and fuel gauge
sender 2 -G169-
thi
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16 - Heat shield
Riveted to exhaust pipe mounting

Torque wrench (40200 Nm) -V.A.G 1332 Note safety precautions before beginning work page 114 .
Emptying fuel tank when fuel pump is intact page 129 .
Emptying fuel tank if it is more than 3/4 full page 130 .
Emptying fuel tank if it is less than 3/4 full page 131 .
4.2.1
Emptying fuel tank, bleeding fuel system

when fuel pump is intact

Diagnostic tester

nection.
Note
Press in securing ring to release fuel lines.
ht
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Pull off supply line -arrow- and catch escaping fuel with a cloth.
rrectne
s
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i
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form
spec
atio
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WARNING
un
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Adapter for fuel extraction -VAS
AG. Volkswagen AG d
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129
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Connect fuel extractor -VAS 5190- with adapter for fuel ex
AG. Volkswagen AG d
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tractor -VAS 5190 /3 - to fuel supply line.
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Note
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The fuel pump is being activated when engine is not running.

Switch on ignition.
2) Low-pressure section
Fuel tank filled.

Perform the function Bleeding fuel system in guided func
tions.
4.2.2
Emptying fuel tank if it is more than 3/4

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

part of the body.
130
AG.
Bleeding fuel system
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Operate shut-off tap on fuel extractor -VAS 5190- , until the

fuel tank is emptied.
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If the fuel tank is emptied, stop the function to prevent the fuel
pump from running dry.
do
c
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en
Perform the function Emptying fuel system in guided func

tions.

els engine)
wage diesel engine (1.9
4-cylinder
- Edition 01.2009
s
k
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Remove cotter -2- from shaft -1- of fuel
ho extractor -VAS 5190- .
ut
a
ss mark extraction hose with
At distance -a- = 1180 mm from end,
insulating tape -arrow-.
rrectness of i
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m
spec
atio
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n in
wit

Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel
filler neck.
Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
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Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; it must not be damaged by the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
Empty fuel tank as far as possible.
Carefully pull out extraction hose.
Note
When no more fuel is extracted, the tank is emptied just
enough for the sender flange to be opened without danger.
If the fuel tank has to be drained fully, proceed as follows:
page 131
4.2.3
Emptying fuel tank if it is less than 3/4 full

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

nection.
131

Note

Open locking ring using
If fuel tank needed only to be emptied, reinstall sender flange.
4.3
Removing and installing fuel tank
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Engine and gearbox jack -V.A.G 1383 A-
Remove fuel tank page 132 .
4.3.1
Removing fuel tank
132
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Insert extraction hose of fuel extractor -VAS 5190- as deeply

as possible into fuel tank and extract fuel.
ility
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Lift sender flange.
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fuel tank
is sender wrench -T10202- .
r
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Note
rrectness of i
t to the co
nform
spec
a
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Vehicles up to 06/2007 are fitted with a two-part propshaft. For

these vehicles it is sufficient to remove the rear propshaft. Vehi
cles from 06/2007 are fitted with a single part propshaft. For these
vehicles the complete propshaft must be removed.
ility
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AG. Volkswagen AG d
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Engine and gearbox jack -V.A.G 1383 A-
do
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Before disconnecting battery, open fuel tank flap and if necessary
remove wheel lock adapter from luggage compartment.
Electrical system; Rep. Gr. 27 ; Disconnecting and con
necting batteries .
If necessary, drain fuel tank using fuel extractor -VAS 5190- .
page 128
Unbolt rear right wheel.
Remove rear right wheel housing liner. General body re
pairs, exterior; Rep. Gr. 66 ; Removing and installing wheel
housing liner; Rear wheel housing liner .
Unscrew securing bolts and remove tank flap unit. General
body repairs, exterior; Rep. Gr. 55 ; Fuel flap unit
133

Unscrew filler neck from body -arrows- and unclip electrical
wire from filler neck.
Gr. 72 ; Rear seat; Removing and installing seat bench .
Remove covers and separate electrical connectors -arrows-.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
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es, in part or in w
l purpos
hole
ercia
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Remove centre and rear silencers.
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Secure exhaust system to underbody using wire.

Remove rear propshaft Manual gearbox; Rep. Gr. 39 ; Final
drive, differential, differential lock
Vehicles from 06/2007 (single part propshaft):
Remove complete exhaust system page 186 .
134
AG.
Pull off adapter cable on four-wheel drive control unit -J492- .
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nection.
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WARNING
do
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Remove complete propshaft Propshaft and rear final drive;

Rep. Gr. 39 ; Repairing propshaft - Golf .

Support fuel tank using engine and gearbox jack -V.A.G 1383
A- and unscrew tensioning straps and securing bolts.
Slowly lower fuel tank.
Note
Installing fuel tank
Clip in cable for four-wheel drive control unit -J492- on fuel

tank.
With the aid of a 2nd mechanic, guide the filler neck in between
rear axle and body. Then place the fuel tank on the engine and
gearbox jack -V.A.G 1383 A- .
Raise the fuel tank slowly up to the installation position and

secure -arrows-.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
4.3.2
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
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or
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AG. Volkswagen AG d
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V
The filler neck must bebyguided
out between body andnorear
ara
ed tank off engine and gearbox jack -V.A.G
To do this, take therisfuel
nte
o
eo
h
1383 A- with theutassistance of a 2nd mechanic.
ra
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Fit adapter cable on four-wheel drive control unit -J492- .

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

sender 2 -G169-
The fuel tank should be no more than half full
135

Note
Ensure that the fuel gauge sender is not bent.
If necessary, drain fuel tank using fuel extractor -VAS 5190- .
page 128
Note safety precautions before starting work page 114 .

Removing:
With the ignition switched off, disconnect nbattery
swagenstrap.
. Volkearth
AG do
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es n
Electrical system; Rep. Gr. 27 o; lkDisconnecting
and con
swa
ot g
V
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ua
necting batteries .
b
d
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e
ris
un
le
pe
rm
itte
d
Remove left cover (as seen facing direction of normal travel)

from fuel gauge sender 2 -G169- .
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Disconnect electrical connectors.
an
tee
or
ac
ility
ab
y li
an
pt
ce
tho
Remove bench seat General
body repairs, interior; Rep.
au
s
Gr. 72 ; Rear seat; Removing
and installing seat bench .
s
Pull fuel gauge sender 2 -G169- upwards slightly and unclip it

from the suction-jet pump.
agen
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Prote
cted
by
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rig
ht
.
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Caution
When installing do not bend fuel gauge sender 2 -G169- float

arm.
136
AG.
Place fuel gauge sender 2 -G169- in fuel tank.
ht
rig
py
Co
t.
Installing:
do
c
um
en
r
te o
iva
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rp
fo
g
n
Open locking ring using wrench -T10202- .

Fit suction-jet pump on sender on inside of fuel tank. Locating
lugs must engage.
Place a new flange seal dry into opening in fuel tank and mois
ten inside (contact to flange) only with fuel.
Note installation position of fuel gauge sender 2 -G169 page 128
es n
wage
s
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tee
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Check for correct position of seal.
pe
rm
itte
d
Tighten locking ring using wrench -T10202- . Specified torque:

110 Nm.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Install cover.
Install bench seat. General body repairs, interior; Rep. Gr.
72 ; Rear seat; Removing and installing seat bench .
Removing and installing suction-jet

pump
Note
do
c
um
en
r
te o
iva
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rp
fo
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n
4.5
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Fit connectors.
On vehicles with four-wheel drive, fuel has to be pumped from

ht
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the area of fuel gauge sender 2 -G169- to the fuel delivery unit
by means of a suction jet pump due to the shape of the fuel
tank.
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Prote
cted
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Checking is only necessary when the engine stops due to lack

AG.
of fuel, even though the fuel gauge shows that the tank is still
1/4 full.
Procedure
Remove fuel delivery unit page 123 .
Pull return hose of suction-jet pump out of fuel delivery unit
-arrow-.
Separate quick-release coupling of supply line from suctionjet pump on Y-piece of fuel delivery unit.
Remove fuel gauge sender 2 -G169- page 135 .
Now the suction-jet pump can be pulled out from side of fuel
gauge sender 2 -G169- (left side of vehicle).
Check that the fuel lines on suction-jet pump are fitted securely
and are not damaged.
Additionally check suction-jet pump for possible soiling.
137

4.6
Checking fuel pump
Checking voltage supply of fuel pump -G6- page 138

Checking current consumption of fuel pump -G6- page 139
4.6.1
Test prerequisites

Hand multimeter -V.A.G 1526C- or multimeter -V.A.G 1715-
Auxiliary measuring set -V.A.G 1594 C Diode test lamp -V.A.G 1527 B
t
au
All electricalss consumers, e.g. lights and rear

must be switched off.
Checking function and voltage supply

Switch on ignition. Fuel pump must be heard to run.
If the fuel pump does not start:
AG.
Prote
cted
by
agen
lksw
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by
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138
ht
rig
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Co
t.
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fo
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rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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c
um
en
ole,
cial p
is n
mer
m
ot p
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c
erm
or
e
t
a
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v
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4.6.2
not
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window heating, c
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AG. Volkswagen AG d
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Fuses must be OK. y Volksw

b
ed
ris must be at least 11.5 V.
The battery voltage
ho
un
le

Connect diode test lamp -V.A.G 1527 B- to outer contacts of
connector using auxiliary cables from auxiliary measuring set
-V.A.G 1594 C- .
Switch on ignition. The LED must light up for about 2 seconds.
If LED does not light up
Check actuation of fuel pump relay and wiring for open circuit
or short circuit. Vehicle diagnosis, testing and information
system VAS 5051
If LED lights up (voltage supply OK):
Check that electrical wiring between flange and fuel pump is
connected and has continuity.
If no open circuit can be found:
4.6.3
Checking current draw of fuel pump

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

be attached to an auxiliary cable between contacts -1- of con
nector and fuel pump.
AG. Volkswagen AG d
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Vol
by
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Connect contacts -4- of connector
ris and fuel pump using an
tho
auxiliary cable from auxiliary umeasuring
set -V.A.G 1594 Ca
ss
If the measured value is not within specifications:
ht
rig
py
Co
t.
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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thi
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is n
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or
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a
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Measure current draw of fuel pump: Specification: max. 7.5

Amperes.
agen
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139
AG.
Prote
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Repairing fuel supply system
es n
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V
ua
by
d
ran
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fuel
cooler
page
141
s
i
tee
r
o
h
or
ut
ac
a
Assembly overview
accelerator
mechanism
page
142
.
ss
Removing and installing tandem pump page 147
5.1
Assembly overview - fuel filter
1 - Supply line
From fuel tank.
White or with white
marking.
ing.
2 - 8 Nm
r
fo
ng
Prote
cted
by
6 - Supply line
To tandem pump
White or with white
marking.
ing.
7 - Return line
From tandem pump
Blue marking
ing.
8 - Fuel filter upper part
9 - Fuel temperature sender -G8110 - Seal
Renew.
11 - Filter insert
Observe change intervals.
12 - Seal
Renew.
140
AG.
5 - Seal
Renew.
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4 - Plug for water extraction

Unscrew and drain ap
prox. 100 cm3 of liquid
using diesel extractor VAS 5226-
ht
rig
py
Co
t.
3 - Return line
To fuel cooler
ing.
Blue or with blue mark
ing.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
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um
en
ole,
cial p
is n
mer
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or
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Checking tandem pump page 143
ility
ab
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an
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un
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gepage 140 .
wa
Assembly overview - fuel filter
olks

13 - Fuel filter lower part
14 - 8 Nm
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
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17 - Retaining clip
es, in part or in w
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16 - Seal
Renew.
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15 - Bracket
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18 - Return line
With connection for fuel temperature sender -G8119 - From tandem pump
5.2
Removing and installing fuel cooler
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Removing
Note
The fuel cooler is located in the return line to fuel tank. It is located
on the vehicle underbody.
Remove underbody panel.
Separate fuel lines at fuel cooler.
Remove securing nuts -arrows-.
Installing
Tighten fuel cooler securing nuts to 15 Nm.
5. Repairing fuel supply system
141

5.3
Assembly overview - accelerator mechanism
1 - Connector
Black, 6-pin.
2 - Accelerator position sender
-G79 Not adjustable.
The accelerator position
sender passes the posi
tion of the accelerator
on to the engine control
unit.
To remove, release us
ing release tool T10238- or release tool
-T10240- .
-A- openings for release tool T10238- .
3 - 10 Nm
4 - Cap
es, in part or in w
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Removing
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142
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Release tool -T10238-

Before removing accelerator pedal module, remove cover in
footwell by removing plastic nuts -arrows-.
Lever out cap Item 4 (page 142) using a screwdriver.
Remove bolt Item 3 (page 142) .
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Releasing accelerator pedal moduleho
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To remove accelerator pedals module, push release tool pe
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T10238- (for right-hand drive vehicles release tool -T10240- )

into openings provided to stop.
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5.3.2
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Separate electrical connection and pull wire guide off accel

erator pedal module.
Installing

note the following:
Push electrical connector -1- onto accelerator pedal module.
Insert centring pin -6- into hole in floor of vehicle.
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5.4
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Install steering column trim.
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Secure accelerator pedal module with bolt -2-, specified tor

que 10 Nm and fit cap -3-.
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Press accelerator pedal module onto securing pins -5-.
Checking tandem pump
Checking delivery pressure page 143

Checking for internal leaks page 146
5.4.1
Checking delivery pressure

Vehicle diagnosis, testing and information system -VAS 5051-
143

- Edition 01.2009
. Volkswage
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Diagnosis cable, 3 m withd bvoltage
supply -VAS 5051/1- or di
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Tandem pump tester -VAS 5187-
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Test prerequisites
Coolant temperature must be at least 85 C.
Unit injectors OK
Fuel filter and fuel lines must not be blocked.
The non-return valve in the fuel supply hose must be OK.
Intact fuel delivery unit
144
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Banjo bolt -5187/1A-

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

Connect vehicle diagnosis, testing and information system VAS 5051- and select vehicle self-diagnosis operating mode.
Press key 01 - Engine electronics on display.
agen AGblock.
Press diagnosis function 08 - Read
n AG. Volkswvalue
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Enter display group 1 using
ed
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confirm entry with Q key.
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Increase engine speed to 4,000 rpm.

Observe pressure indicated on pressure gauge.
rrectness of i
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spec
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wit
Specification: min. 7.5 bar

If the specification is not attained:
Using a hose clip, clamp off return line between fuel filter and
tandem pump.
Increase engine speed to 4,000 rpm.
Observe pressure indicated on pressure gauge.
Specification: min. 7.5 bar
If specification is now obtained:
Pressure loss at unit injectors.
Renew unit injector O-rings.
If the specification is not attained:
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Renew tandem pump. page 147
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Read engine idlingssspeed in display zone 1.
After removing pressure tester, tighten plug to 25 Nm. Always

renew seal.
145
AG.

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

fuel side and oil side after reinstalling a used tandem pump, for
example after renewing or repairing a cylinder head and/or when
installing a "short" engine. When leaking it is possible for the fuel
to mix with the oil which may cause the engine to fail.
Tester -V.A.G 1687-
Prepare test unit -V.A.G 1687- as follows:

Unscrew pressure regulating valve -2- and close valves -3and -4-.
Connect test connection -5- to fuel supply union of tandem

pump using a commercially available compressed air connec
tion and a section of fuel hose. Use a spring-type clamp to
secure.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
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146
rrectness of i
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Seal fuel return union on tandem pump with a plug. Secure

sealing plug with a spring-type clamp.
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Procedure
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r hose (white marking) and fuel return hose
Pull fuel supply
o
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or
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(blue marking)
off
tandem
pump.
ss

Connect compressed air hose -1- (compressed air source) to
charge air system tester -V.A.G 1687- .
Note
olkswagen AG
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If there is water in the sight
-6-.
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Caution
Open valve -4- and wait until the test circuit is filled. If neces
sary readjust pressure to 1.0 bar.
Close valve -3- to retain pressure and observe the pressure
drop over a period of 1 minute.
If the pressure does not drop the tandem pump can be reused, if
the pressure drops the tandem pump must be renewed.
5.5
Removing and installing tandem pump
DANGER!
The tandem pump may, under no circumstances, be disman

tled as the vacuum part could otherwise malfunction. This
would result in the failure of the brake servo.
rrectness of i
t to the co
nform
spec
at
i
h re
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in t
his
The maximum test pressure is 1.3 bar and this must not be
exceeded.
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Adjust pressure to 1.0 bar with pressure regulating valve -2-.
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valve -3-.
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147
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equipment required
Torque wrench -V.A.G
1331 Hand vacuum pump with
accessories -V.A.G 1390 Water drainage container V.A.G 1390/1 Spring-type clip pliers -VAS
5024 A-
es, in part or in w
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hole
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Removing
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Connect hand vacuum pump with accessories -V.A.G 1390and water drainage container -V.A.G 1390/1- to return hose
-2-.
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Operate hand vacuum pump until no more fuel comes out of

return hose. Be careful that no fuel is sucked into hand vacuum
pump.
pipe.
148
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Pull supply hose (white marking) and return hose (blue mark
ing) off fuel filter.
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5.5.1
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of mounting.
Pull vacuum line from brake servo -1- off tandem pump -4-.
Pull supply hose -2- (white marking) and return hose -3- (blue
marking) off tandem pump -4-.
Remove securing bolts -arrows-.
wagen AG head.
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Remove tandem pump
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Installing

note the following:
Note
Ensure that tandem pump coupling seats properly in cam
shaft.
Always renew tandem pump seals.

Install tandem pump and tighten upper securing bolts to
20 Nm.
thi
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Tighten lower securing bolts to 10 Nm.
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5.5.2
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Attach return hose (blue marking) to return connection -3- of

tandem pump.
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Attach supply hose (white marking) to supply connection -2and vacuum hose from brake servo -1- to tandem pump -4-.
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Connect supply hose (white marking) to fuel filter.
149
AG.

Connect hand vacuum pump with accessories -V.A.G 1390and water drainage container -V.A.G 1390/1- to return hose
-2-.
Operate hand vacuum pump -V.A.G 1390- until fuel comes out
of return hose. Be careful that no fuel is sucked into hand vac
uum pump.
Connect return hose (blue marking) to fuel filter.
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150
rrectness of i
t to the co
nform
spec
at
i
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wit
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es, in part or in w
l purpos
hole
ercia
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21
Turbocharging/supercharging
Charge air system with turbocharger
Safety precautions page 151

Rules for cleanliness page 151 .
Installing hose connections with connector couplings
page 161
Assembly overview - turbocharger page 152
Removing and installing turbocharger page 156
Assembly overview - parts of charge air cooling page 158
Checking charge air system for leaks page 162
1.1
Safety precautions
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WARNING
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When doinguthany repair work, especially in the engine compart
ra
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ment, payss aattention to the following due to the cramped condi
pe
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hot components.
Observe following if test and measuring instruments are required

during a road test:
Test and measuring instruments must be secured to rear seat
and operated by a second person from this location.
1.2
When working on the turbocharger, pay careful attention to the

following rules for cleanliness:
do
c
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If test and measuring instruments are operated from front pas

senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
rrectness of i
t to the co
nform
spec
a
t
i
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thi
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sitions.
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connecting.
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Place removed parts on a clean surface and cover. Do not use

fluffy cloths!
Carefully cover opened components or seal if repairs cannot
tool boxes etc.).
Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
When making repairs, remove oil from connection and hose
ends.
1. Charge air system with turbocharger
151

essary.
1.3
Assembly overview - turbocharger

Note
All hose connections are secured.

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

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Rep. Gr.21 - Turbocharging/supercharging
do
c
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152
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
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AG. Volkswagen AG d
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Engine codes BJB, BKC, BRU, BXE and BXF page 153
Engine codes BLS and BXJ page 155
1.3.1
1 - 10 Nm
3 - Oil supply line
Before installing oil sup
ply line, ensure that it is
not blocked.
Before installing, fill tur
bocharger with engine
oil through oil supply line
connection
page 95 .
5 - Gasket
Renew.
tion.
6 - Washer
15 - Oil return line

To cylinder block.
Tighten union nut to 30 Nm.
16 - 17 Nm
17 - Vacuum hose
To solenoid valve block
r
fo
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ole,
cial p
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13 - Seal
Renew.
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12 - Gasket
Renew.
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11 - Connecting piece
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10 - Connecting pipe
Air filter/turbocharger
rrectne
s
s
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t to the co
n
form
spec
atio
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i
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thi
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9 - 40 Nm
First hand tighten all
bolts
AG. Volkswagen AG d
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8 - Support
Between turbocharger
and cylinder block.
un
le
7 - 25 Nm
Renew.
18 - Turbocharger
Can only be renewed with exhaust manifold.
To remove turbocharger, remove right drive shaft Running gear, axles, steering; Rep. Gr. 40 ; Re
moving and installing drive shafts .
AG.
153

19 - 20 Nm
First hand tighten all bolts
20 - 20 Nm
Renew.
21 - Heat shield
22 - Gasket
Renew.
23 - Clamp, 7 Nm
24 - Front exhaust pipe
rrectness of i
t to the co
nform
spec
at
i
h re
o
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in t
his
es, in part or in w
l purpos
hole
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To bypass flap
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25 - Bracket
AG. Volkswagen AG d
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For oil supply line Item 3 (page 153) .
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Before installing, secure oil supply line. rise
nte
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26 - 22 Nm
c
s
s
Renew.
Renew.
Coat threads and bolt head seating surface with G 052 112 A3.
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154
2 - Bracket
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
1 - 10 Nm
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
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t
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riv
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1.3.2
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Golf 2004
u
ac , Golf Plus 2005
a
ss
3 - Heat shield
4 - Oil supply hose

To oil supply line con
nection on turbocharger
Before installing oil sup
ply line, ensure that it is
not blocked.
Before installing, fill tur
bocharger via oil supply
hose with engine oil
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6 - Vacuum hose
do
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5 - Turbocharger
Can only be renewed
with exhaust manifold.
page 156 .
7 - Gasket
Renew.
tion.
8 - To particulate filter
9 - Clamp, 7 Nm
For turbocharger/partic
ulate filter
10 - Exhaust manifold
Can only be renewed to
gether with turbocharg
er
11 - 25 Nm
Renew.
12 - 25 Nm
13 - Gasket
Renew
For exhaust gas recirculation.
Assembly overview - parts of exhaust gas recirculation page 196
15 - 25 Nm
Renew
16 - 15 Nm
17 - O-ring
Renew
18 - Banjo bolt, 60 Nm
Renew
19 - Support
For turbocharger
155

With oil return line
20 - Exhaust gas temperature sender bank 1 -G235- , 45 Nm
Lubricate thread of sender using high-temperature paste -G 052 112 A3 Use tool set -T10395- to remove and install.
21 - Heat shield
22 - Connection
For intake hose for air filter/turbocharger
Assembly overview - air filter page 177 .
23 - 9 Nm
pe
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d
1.4
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24 - 10 Nm
es n
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Removing and installing turbocharger
rrectness of i
t to the co
nform
spec
a
t
i
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156
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Tool set -T10395-
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Lambda probe open ring spanner set -3337-

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

destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To prevent this from causing further damage,
AG. Volkswagen AG d
perform the followingwrepairs:
agen
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Check airedfilter
ara hoses
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for soiling.
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or
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If foreign objects are found in the charge air system, the charg
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
Removing
or; Rep. Gr. 50 ; Body - front; Noise insulation .
Remove subframe and the right drive shaft Running gear,
axles, steering; Rep. Gr. 40 .
Pull electrical connector off exhaust gas pressure sensor 1 G450- Item 2 (page 188) in engine compartment and un
screw securing bolts.
Separate electrical connectors to particulate filter.
ht
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Remove particulate filter.
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Check
complete charged air routing and charge air cooler
ss
for foreign objects.
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Disconnect fasteners -arrows- of coolant pipes for auxiliary

heater, if part of original equipment.
157
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un
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Remove turbocharger support and oil return line.

Remove connecting pipe to exhaust gas recirculation cooler.
Separate charge pressure line from turbocharger.
Pull vacuum hose off turbocharger.
Separate oil supply line from turbocharger.
Unscrew securing bolts for exhaust manifold.
Tilt the engine forwards in lower mounting and remove turbo

charger with exhaust manifold downwards.
Installing
Charge air system must be free of leaks.

When making repairs, remove oil from connection and hose
ends.
All hose connections of charge air system are secured by
spring-type clips or by connector couplings.
Checking charge air system for leaks page 162
158
Prote
cted
by
Note
AG.
Assembly overview - parts of charge air

cooling
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Torque setting of pendulum support page 10 .
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Installation is carried out in the reverse sequence of removal.
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Unbolt pendulum support -arrows-.
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4-cylinder diesel engine (1.9 l engine) -
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Edition 01.2009

Engine codes BJB, BKC, BRU, BXE and BXF page 159
page 161
1.5.1
1 - 8 Nm
Fitting location
page 160
2 - Bracket
tion.
3 - Charge air cooler
4 - Connecting hose
5 - 8 Nm
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Connecting pipe ho
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To intake connecting
pipe.
6 - To turbocharger.
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7-
9 - Vacuum reservoir
10 - 15 Nm
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11 - 8 Nm
12 - O-ring
Renew if damaged.
13 - Charge air pressure send
er -G31- with intake air tem
perature sender -G4214 - 3 Nm
do
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159
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1.5.2
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Golf 2004
4-cylinder
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, Golf
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diesel
engine (1.9 l engine) - Edition 01.2009
s
rrectness of i
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spec
at
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in t
his
1 - 8 Nm
Fitting location page 160

2 - Bracket
tion.
3 - Charge air cooler
To remove, bring lock
carrier into service posi
tion General body re
pairs, exterior; Rep. Gr.
50 ; Body - front; Lock
carrier - service position
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6 - Charge air pressure sender

-G31- with intake air tempera
ture sender -G427 - O-ring
Renew if damaged.
8 - Bracket
9 - 5 Nm
10 - Connecting hose
11 - Charge air pipe
To intake manifold flap
motor -V157 Assembly overview - in
take manifold page 174
13 - 8 Nm
To turbocharger.
Securing bolts for charge air cooler
To loosen or tighten securing bolts -arrow-, bumper cover must
be removed.
160
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5 - 3 Nm
do
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4 - Sealing strip
Pushed onto top and
bottom of charge air
cooler

1.6
Hose connections

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

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

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

engaged by pulling hose.
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spec
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Bring securing clip to locking position -2- and then push charge
air hose again.
161
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1.6.2
Hose connections with spring band ring
Note
There is a danger of a hose detaching whilst driving after re

moving and reinstalling charge pressure lines with spring-type
clamps. For this reason, spring band rings are used which can be
opened if a defect item requires the charge pressure line has to
be disconnected. In cases of repair, destroy the spring band ring
using a suitable tool and renew it with a replacement part from
ETKA (electronic parts catalogue) .
un
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Checking charge air system for leaks
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1.7
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Charge air system tester -V.A.G 1687 Adapter -V.A.G 1687/10 Remove intake hose -1- from air filter.
Insert adapter -V.A.G 1687/10- in intake hose -1- and secure
with clip.
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Turn pressure regulating valve -2- anti-clockwise onto stop.

Close valves -3- and -4-.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
162
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Prepare charge air system tester -V.A.G 1687- as follows:
rrectne
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s
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form
spec
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Connect charge air system tester -V.A.G 1687- to adapter V.A.G 1687/10- as shown.
Connect compressed air hose -1- (compressed air source) to

charge air system tester -V.A.G 1687- .
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Note
If there is water in the sight glass, drain at water drain screw -6-.
Open valve -3-.
Adjust pressure to 0.5 bar with pressure regulating valve -2-.
Caution
The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.
Open valve -4- and wait until the test circuit is filled. If neces
sary readjust pressure to 0.5 bar.
Check the charge air system for leaks by hearing, touching,
with leak detector spray or using ultrasonic tester -V.A.G
1842- .
Note
How to use the ultrasonic tester -V.A.G 1842- operating
instructions
If leaks occur, when doing any repair work observe notes for
charge air system page 158 .
Depressurise test circuit by detaching coupling from adapter -
V.A.G 1687/10- before removing adapter.
163

AG. Volkswagen AG d
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- Edition 01.2009
no
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Vacuum hose schematic diagram

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Vehicles with particulate filter page 164
t gu
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Vehicles without particulate filter page 165
Vehicles with particulate filter
rrectness of i
t to the co
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spec
a
t
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com
1.8.1
1 - Turbocharger
2 - Connecting pipe air filter/

turbocharger
3 - Non-return valve
tion.
4 - To brake servo
Prote
cted
by
10 - Cooler
For exhaust gas recircu
lation.
valve -N1812 - Exhaust gas recirculation
cooler change-over valve N34513 - Non-return valve
tion.
14 - Vacuum unit
Turbocharger
164
AG.
9 - Bypass flap
lation cooler.
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8 - Intake manifold
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6 - Air filter
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5 - Charge pressure control

solenoid valve -N75-

1.8.2
Vehicles without particulate filter
1 - Solenoid valve block

tion.
3 - To brake servo

valve -N1812 - Turbocharger
tion.
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10 - Cooler
lation.
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9 - Bypass flap
lation cooler.
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8 - Vacuum reservoir
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5 - Air filter
AG. Volkswagen AG d
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4 - Connecting pipe air filter/

turbocharger
165

23
Mixture preparation - injection
Diesel direct injection system
The diesel direct injection system control unit is equipped with a

fault memory. Read fault memory before and after making repairs
or adjustments.
Safety precautions page 166
Rules for cleanliness page 167 .
Assembly overview - unit injector page 167
Removing and installing unit injector page 169
Adjusting non-contact gap of unit injectors page 171
Removing and installing O-rings for unit injector page 172
Repairing intake manifold flap page 174
Assembly overview - air filter page 177 .
1.1
Safety precautions
WARNING

tions:
vated charcoal filter system, coolant and refrigerant, brake
sitions.
hot components.
olkswagen AG
en AG. V
un
le
does
not
gu
ara
nte
instruments are required
eo
ra
c
If test and measuring instruments are operated from front pas

senger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive
serious injuries when the airbag is triggered.
To prevent injuries to persons and/or destruction of the injection
and glow plug system, the following must be noted:
The ignition must be switched off before connecting or dis
connecting injection or glow plug system wiring or tester ca
bles.
If the engine is to be turned at starter speed, without starting,
e.g. when checking compressions, disconnect unit injector
connector on cylinder head.
Before disconnecting battery, obtain radio code for radios with
anti-theft coding.
AG.
Prote
cted
by
Rep. Gr.23 - Mixture preparation - injection
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166
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Disconnecting and connecting the battery must only be done

with the ignition switched off, as otherwise the control unit for
diesel direction injection system could become damaged.
rrectne
s
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t to the co
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spec
atio
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Test and measuring instruments must be secured to rear seat

and operated by a second person from this location.
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Observe followingthiforitest and measuring
au
during a road test:
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1.2
AG. Volkswagen
doesPlus 2005
agen Golf 2004 A, GGolf
ksw
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V engine (1.9 l engine) - Edition
4-cylinder diesel
gu01.2009
y
b
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When working on fuel supply and injection system, pay careful

attention to the following rules for cleanliness:
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit

connecting.
Place removed parts on a clean surface and cover. Do not use
fluffy cloths!
Carefully cover opened components or seal if repairs cannot
tool boxes etc.).
essary.
Assembly overview - unit injector
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Always renew seals and O-rings
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1.3
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Also ensure that no diesel fuel runs on to the coolant hoses.

Should this occur, the hoses must be cleaned immediately.
Damaged hoses must be renewed.
1. Diesel direct injection system
167
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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AG. Volkswagen AG d
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Golf 2004 ,oGolf
Plus 2005
ris
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4-cylinder diesel
a
c
s
s
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
1 - 20 Nm + 1/4 turn (90) fur

ther
Renew
2 - Rocker arm shaft
With rocker arms
page 169 .
3 - Lock nut, 30 Nm
4 - Adjuster screw
Renew
5 - Ball stud
Renew
10 - Heat shield seal

Renew
11 - Circlip
12 - Cylinder head
13 - Tensioning block
14 - 12 Nm + 3/4 turn (270)
further
Renew.
168
AG.
9 - O-ring
Renew page 172 .
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8 - O-ring
Renewing page 172
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7 - O-ring
Renewing page 172
do
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6 - Unit injector
page 169 .

1.4
Removing and installing unit injector

equipment required
Universal dial gauge brack
et -VW 387-
es, in part or in w
l purpos
hole
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1.4.1
rrectness of i
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spec
atio
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Puller -T10055-
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Special wrench, long reach

-T10054-
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Special wrench, long reach

-3410-
Removing
Remove toothed belt guard upper part.

Remove cylinder head cover. page 48
Turn crankshaft until the cam pair point evenly upwards for the
unit injector which is to be removed.
Loosen lock nuts of adjustment screws -1- and remove ad
justment screws.
Remove rocker arm securing bolts -2- (from outwards to in
wards) with socket XZN 10 -3410- and remove rocker arm
shaft.
Remove tensioning block securing bolt -3- with special
wrench, long reach -T10054- and remove the block.
Lever connector off unit injector with a screwdriver. To avoid
canting, support opposite side of connector with light finger
pressure.
Observe unit injector cylinder allocation.
169

Insert puller -T10055- in place of the clamping block in the slot
on the side of the unit injector.
swagen A
. Volkgentle
n AGwith
Pull unit injector out of cylinder head
seat
upward
G do
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atio
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wit
1.4.2
ara
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Installing
Note
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New unit injectors are supplied with O-rings and heat shield
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seal.
Heat shield seal and O-rings must be renewed if old unit in

jector is reused. page 172
AG.
Check that the three O-rings and the heat shield seal along
with securing clip are seated correctly before installing unit in
jector.
Note
The seals must not be twisted.

Oil the seals and fit the unit injector into the seat in cylinder
head with great care.
Push the unit injector evenly into the cylinder head onto its limit
stop.
Insert tensioning block in slot on side of unit injector.
Note
If the unit injector is not at right angles to the tensioning block the
securing bolt may loosen and this can damage the unit injector or
the cylinder head.
Therefore align the unit injector as follows.
Screw the new securing bolt into the tensioning block until the
unit injector can still be turned easily.
Now align unit injector at right angles to camshaft bearing seat.
170
ht
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unit injector, the adjustment screw in the rocker arm and also
the unit injector ball stud must be renewed.
thi
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Each time work is performed which requires adjustment of the

Check dimension a from outer edge of cylinder head to roun
ded surface of unit injector with a vernier gauge (measuring
range min. 400 mm).
1
2
3
4
333,0
245,0
153,6 0.8 mm
65,6 0.8 mm
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Dimension a
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Cylinder
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spec
at
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in t
his
If necessary, adjust the unit injector and tighten the securing

bolt as follows:
Tighten securing bolt to 12 Nm and turn 270 (3/4 turn) further
(turning further can be done in several stages).
Fit rocker arm shaft and tighten new securing bolts as follows:
First evenly tighten inner bolts -2- and then outer bolts -1hand-tight. Then using same sequence, tighten to 20 Nm and
90 (1/4 turn) further evenly.
Adjust non-contact gap of unit injectors page 171 .
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Fit dial gauge onto adjustment screw of unit injector as shown.
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Adjusting non-contact gap of unit injec

tors
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1.5
Turn crankshaft in direction of engine rotation until roller of

rocker arm is located at tip of drive cam. Roller side
-arrow A- positioned at highest point, dial gauge -arrow Bpositioned at lowest point.
Remove dial gauge.
Now turn the adjuster screw into rocker arm until significant
resistance can be felt (unit injector is at limit stop).
Turn adjustment screw 180 back off stop.

Hold adjuster screw in this position and tighten lock nut to 30
Nm.
Connect unit injector connector.
Install cylinder head cover page 48 .
171

1.6
Removing and installing O-rings for unit

injector

Assembly sleeves -T10056-
1.6.1
Removing
Lever old O-rings very carefully out of unit injector.

Ensure above all that no burrs are formed on O-ring seat.
Installing
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1.6.2
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Always use the assembly sleeves to fit the O-rings. There is a
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
danger of damaging the O-rings if the sleeves are not used.
Gradual introduction of O-rings without different coloured
markings. Note the correct allocation of O-rings to grooves:

the thickness of the rings reduces towards injector nozzle.
Prevent O-rings from rolling when sliding them on. The O-rings
must not be twisted in their seats in unit injector.
Pull heat shield seal off together with securing clip.

Clean seating surfaces for O-rings on unit injector very care
fully.
Place assembly sleeve -T10056/1- onto stop on unit injector.
Push the upper, thicker O-ring carefully onto assembly sleeve
and into seat on unit injector.
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172
do
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Remove assembly sleeve.

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

Push the lower O-ring carefully onto the assembly sleeve and
into the seat of the unit injector.
Fit new heat shield seal together with securing clip.
rrectness of i
t to the co
nform
spec
at
i
h re
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in t
his
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173
AG.
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Assembly overview - intake manifold
Engine codes BKC, BRU, BXE and
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Engine code BJB page 175
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1.7
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BXF uthpage 174
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Engine codes BKC, BRU, BXE and BXF
1 - Intake manifold
Tighten securing bolts
to 22 Nm.
2 - O-ring
Renew.
8 - 22 Nm
9 - Gasket
Renew.
174
AG.
7 - Connecting pipe
To exhaust gas recircu
lation cooler.
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6 - 10 Nm
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5 - Intake manifold flap motor V157 The intake manifold flap

is closed for approx. 3
seconds when stopping
engine and then opens
again. This reduces the
stop jolt.
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4 - 10 Nm
r
fo
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3 - Intake connecting pipe

With exhaust gas recir
culation valve
rrectne
s
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form
spec
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1.7.2
Engine code BJB
1 - Intake manifold
to 22 Nm.
2 - O-ring
Renew.
3 - Intake connecting pipe
culation valve and in
take manifold flap
4 - 10 Nm
5 - Gasket
Renew.
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6 - Connecting pipe
To exhaust gas recircu
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7 - 10 Nm
8 - Bracket
9 - Vacuum unit
10 - To solenoid valve block
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11 - 22 Nm
175
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1.7.3
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Golf 2004
,
Golf
Plus
2005
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4-cylinder
diesel engine (1.9 l engine) - Edition 01.2009
ut
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rrectness of i
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spec
a
t
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1 - Gasket
Renew.
2 - Intake manifold
to 22 Nm
3 - Seal
Renew
4 - Connection
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AG.

valve -N18- with exhaust gas
recirculation potentiometer G212 Assembly overview - ex
haust gas recirculation
page 196
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7 - 10 Nm
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6 - From charge air cooler
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5 - Intake manifold flap motor V157 The intake manifold flap

is closed for approx. 3
seconds when stopping
engine and then opens
again. This reduces the
stop jolt.
9 - Gasket
Renew
lation cooler.
Assembly overview parts of exhaust gas re
circulation
page 193
11 - 22 Nm
12 - Bracket
13 - 22 Nm
1.8
Cleaning the intake manifold flap sup

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

the combination of unfavourable factors. If these are found, e.g.
when disassembling the exhaust gas recirculation valve -N18- or
the intake manifold flap motor -V157,- , the support will have to
be cleaned.
176

WARNING
Acetone is highly inflammable. Please observe the accidental

regulations and safety notes when handling with highly inflam
mable fluids. Wear eye protection and protective clothing to
avoid possible injury and skin contact.
Remove intake manifold flap connection.
G. Volkswagen
A
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Remove the exhaust gas recirculation
ines n
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V
take manifold flap motor -V157y.
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Allow the acetone to evaporate fully, assemble the cleaned

intake manifold flap support, replace the seals and insert it
back in position.
1.9
Assembly overview - air filter
1 - Intake hose
To turbocharger.
2 - Air mass meter -G703 - O-ring

Renew if damaged.
4 - 8 Nm
AG.
Prote
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by
9 - Air duct
To lock carrier.
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8 - Filter element
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To solenoid valve block
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6 - 8 Nm
r
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ng
5 - Air filter upper part
rrectne
s
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form
spec
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Wipe off intake manifold flap support using a lint-free cloth.
ran
tee
or
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ho
Thoroughly clean intake manifold
flap support, especially
ut
a
around exhaust gas return
ss valve, using commercially available
acetone according to DIN 53247 and cleaning brush.
10 - Air filter lower part

11 - 10 Nm
177

Engine control unit
Reading and clearing engine control unit fault memory

page 178
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engine control unit, Golf page 180 . ris
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anti-theft engine control unit, Golf ss
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Adapting functions and components page 179 .
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page 180 .
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Removing and installing engine control unit, Golf Plus

page 183 .
2.1
rrectness of i
t to the co
nform
spec
at
i
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Removing and installing anti-theft engine control unit Golf Plus

page 183 .
Reading and erasing engine control unit

fault memory
Vehicle diagnostic, testing and information system -VAS 5051-
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178
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Connect vehicle diagnostic, testing and information system VAS 5051- as follows:

Push diagnosis cable connector onto diagnosis connector.
Only when engine does not start:
Switch on ignition.
Select operating mode
Press button on display for Vehicle self-diagnosis.
Select vehicle system
Press button 01 - Engine electronics on display.
The control unit identification and coding are indicated on display.
Select diagnostic function
Press button 02 - Read fault memory on display.
If no fault is stored in engine control unit 0 fault detected is
displayed.
If faults are stored in the engine control unit, these are shown
one below the other on the display.
Press button.
Press button 05 - Clear fault memory on display.
Press function 06-End output.
2.2
Adapting functions and components
ility
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rrectness of i
t to the co
nform
spec
at
i
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hole
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Vehicle diagnostic, testing and information system -VAS 5051gu
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Select guided fault finding in vehicle diagnostic, testing and in

formation system -VAS 5051- .
When all control units have been read:
Press GoTo button.
Select Function/component selection.
Select Function or component.
AG.
Select Functions.
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Select Engine management.
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Select 01-Systems capable of self-diagnosis.
2. Engine control unit
do
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Select Engine code.
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Select Drive train.
179
Golf 2004 , Golf Plus 2005 AG. Volkswagen

AG do
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wage
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olksl engine) - Edition 01.2009
Removing and installing engine control

unit, Golf
Removing
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Before removing engine control unit, read the control unit iden
tification and thus the coding of the current control unit.
page 179
Remove wiper arms, plenum chamber cover and plenum

chamber bulkhead: Electrical system; Rep. Gr. 92 ; Wind
screen wiper system; Removing and installing windscreen
wiper system .
Bend catch open slightly -1-.
Then push engine control unit out of retainer -arrow-.
Now release connector on engine control unit and pull off con
nector.
Installing
Fit connector to engine control unit and lock connector in po

sition.
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by
Press catch -1- against engine control unit.
Install plenum chamber bulkhead, plenum chamber cover and

wiper arms Electrical system; Rep. Gr. 92 ; Windscreen
wiper system; Removing and installing windscreen wiper sys
tem .
2.4
Removing and installing anti-theft en

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

page 183 .
Electric cutter -V.A.G 1561 A Saw set -V.A.G 1561/14-
180
ht
rig
py
Co
t.
Push engine control unit onto bracket.
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
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or
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2.3
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db
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Note
rrectne
s
s
o
f
i
t to the co
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form
spec
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AG. Volkswagen AG d
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Grip pliers
If the engine control unit is to be renewed, connect vehicle
diagnostic, testing and information system -VAS 5051B- and

perform Renewing engine control unit in guided functions.
The shear-head bolt threads are coated with locking com
pound. To simplify removing, the shear-head bolts can be

heated using hot air blower -VAS 1978/14- . When doing this,
ensure that no adjacent cables, connectors or components are
damaged!
Removing
ht
rig
py
Co
t.
r
fo
ng
Remove wiper arms, plenum chamber cover and plenum

chamber bulkhead: Electrical system; Rep. Gr. 92 ; Wind
screen wiper system; Removing and installing windscreen
wiper system .
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Cut into heads of shear-head bolts so that two parallel surfa

ces are created -arrows-.
AG.
Remove bolts with grip pliers .
Insert a screwdriver between protective housing -A- and

bracket -arrow-.
181

. Volkswagen AG
gen AG
does
not
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swa and pull to

Lever up protective housing using screwdriver
k-AVol
y
b
side off bracket -arrow-.
ed
rrectness of i
t to the co
nform
spec
at
i
h re
o
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in t
his
es, in part or in w
l purpos
hole
ercia
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ris
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ss
Bend catch open slightly -1-.
Then push engine control unit out of retainer -arrow-.

Now release connector on engine control unit and pull off con
nector.
Installing
Fit connector to engine control unit and lock connector in po

sition.
Prote
cted
by
Install plenum chamber bulkhead, plenum chamber cover and

wiper arms Electrical system; Rep. Gr. 92 ; Windscreen
wiper system; Removing and installing windscreen wiper sys
tem .
182
AG.
Tighten new shear-head bolts -1- evenly until heads shearhead off.
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Push protective housing onto bracket.
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Press catch -1- against engine control unit.
do
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Push engine control unit onto bracket.

2.5
Removing and installing engine control

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

nostic, testing and information system -VAS 5051B- and perform
Renewing engine control unit in guided functions.
Removing:
Remove plenum chamber bulkhead General body repairs;
Rep. Gr. 50 ; Body - front; Plenum chamber bulkhead .
Loosen securing nuts -arrows-.
AG. Volkswagen AG d
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rrectness of i
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spec
a
t
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hole
ercia
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com
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Release connectors on engine control unit and pull off con

nector.
Push bracket -1- off engine control unit in direction of arrow.

Installing:
Tighten securing nuts -arrows- to 10 Nm.
AG.
2.6
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Install plenum chamber bulkhead General body repairs;

ht
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Co
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Fit connectors and lock in position.
do
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fo
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Push bracket onto engine control unit.
Removing and installing anti-theft en

gine control unit, Golf Plus

Grip pliers
183

Note
If the engine control unit is to be renewed, connect vehicle
diagnostic, testing and information system -VAS 5051B- and

perform Renewing engine control unit in guided functions.
The shear-head bolt threads are coated with locking com
pound. To simplify removing, the shear-head bolts can be

heated using hot air blower -VAS 1978/14- . When doing this,
ensure that no adjacent cables, connectors or components are
damaged!
Removing
Remove plenum chamber bulkhead General body repairs;
Rep. Gr. 50 ; Body - front; Plenum chamber bulkhead
. olkswagen AG
en AG. V
ag
lksw
o
Twist shear-head bolts -arrows- out using grip
y V pliers and re
db
e
move cover from protective housing. ris
ho
ut
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
o
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t
a
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a unit bracket -arrows-.

Then remove securing nuts for control
ss
does
not
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c
Release connectors on engine control unit and pull off con

nector.
184
AG.
Fit connectors to engine control unit and lock in position.
agen
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Push engine control unit onto control unit bracket until it en

gages in catches.
ht
rig
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Co
t.
Installing
do
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en
Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in direction of arrow.
Tighten
es n
wage
s
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4-cylinder
diesel
engine
(1.9 l engine) - Edition 01.2009
yV
u
b
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ed
nte
ris
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th
ra
securingaubolts
-arrows- to 10 Nm.
c
ss
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Tighten new shear-head bolts -arrows- evenly until heads

shear-head off.
Install plenum chamber bulkhead General body repairs;
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
rp
o
nl
f
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ng
ility
ab
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an
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ce
Install cover of protective housing.
185
ht
rig
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Co
t.
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Prote
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26
Exhaust system
Exhaust system
Assembly overview - front exhaust pipe with catalytic converter

page 186 .
Assembly overview - front exhaust pipe with particulate filter
page 187
Assembly overview - silencer with mountings (vehicles with front
wheel drive) page 189 .
Assembly overview - silencer with mountings
(vehicles
fourgen AG
G. Volkswawith
nA
does
wage
wheel drive) page 191 .
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Assembly overview - front exhaust pipe with catalytic converter

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1.1
1 - Front exhaust pipe with cat

alytic converter
2 - 40 Nm
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spec
atio
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wit
3 - Support
4 - Marking
For clamp.
Installation position of
clamp page 187 .
5 - To front silencer
6 - 25 Nm
7 - Mounting
Renew if damaged.
AG.
Prote
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by
Rep. Gr.26 - Exhaust system
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186
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10 - Clip
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9 - Gasket
tion.
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8 - 7 Nm

Installation position of clamp
Position clamp at distance -a- = 5 mm from marking on front ex
haust pipe.
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1.2
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Assembly overview - front exhaust pipe

with particulate filter

Lambda probe open ring spanner set -3337-
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Tool set -T10395-
Note
If the particulate filter or the exhaust gas pressure sensor 1 G450- is changed, the exhaust gas pressure sensor 1 -G450must always be adapted using diagnostic tester : Guided
functions; adapting exhaust pressure sensor 1 -G450- .
1. Exhaust system
187

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Prote
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7 - Exhaust gas temperature

sender bank 2 -G448- , 45 Nm
Lubricate thread of
sender using high-tem
perature paste -G 052
112 A38 - Particulate filter
is removed downwards
with exhaust gas pres
sure sensor 1 -G450 To remove, remove
subframe and steering
Running gear, axles,
steering; Rep. Gr. 40 .
9 - Front exhaust pipe
10 - Marking
For clamp.
Installation position of clamp page 189 .
11 - To front silencer
12 - 25 Nm
13 - Mounting
Renew if damaged.
14 - Temperature sender after particulate filter -G527 45 Nm
Lubricate thread of sender using high-temperature paste -G 052 112 A315 - From turbocharger
16 - Clamp, 7 Nm
17 - Gasket
Renew
188
thi
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6 - Lambda probe -G39- , 50

Nm
Grease only the threads
with high-temperature
paste -G 052 112 A3- ;
high-temperature paste
-G 052 112 A3- must not
get into the slots of
probe body.
To remove use lambda
probe open ring span
ner set -3337-
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4 - 10 Nm
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3 - Bracket
For control lines
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2 - Exhaust gas pressure sen

sor 1 -G450-
or
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1 - 8 Nm
ua
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b
ed
ris
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18 - 40 Nm
19 - Bracket
Bolted to cylinder head
Assembly overview - silencer with mountings (vehicles with front wheel

drive)
1 - 25 Nm
Renew
2 - Retaining ring
Renew if damaged.
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3 - Separating point
Marked by indentation
on exhaust pipe
During production, front
and rear silencers are
installed as a single
component. For repairs,
front and rear silencers
are supplied separately.
The connection is made
with a clamp.
Cutting exhaust pipe
page 190
Installation position of
rear clamp (repair dou
ble clamp)
page 190 .
Evenly tighten threaded
connections of clamp
(repair double clamp).
Specified torques for
clamp (repair double
clamp): M8 = 25 Nm,
M10 = 40 Nm.
Before tightening, align
cold exhaust system
free of tension
page 192
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1.3
ex
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Installation position
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Position
ut double clamp -a- = 5 mm from marking on front
ra
a
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s
haust
s pipe of particulate filter.
Prote
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4 - Rear silencer
5 - Mounting
Renew if damaged.
1. Exhaust system
189

6 - 25 Nm
7 - Tunnel bridge
8 - Front silencer
9 - Mounting
Renew if damaged.
Installation position of rear clamp (repair double clamp)
Install clamp so that ends of bolts do not protrude beyond bot
tom of clamp.
Bolt connection faces to left.
1.3.1
Separating front and rear silencers

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Eye protection
Procedure
WARNING
Wear eye protection.
Cut exhaust pipe at right angles at separating point

-arrow 2-.
AG.
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190
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When installing, position repair double clamp -4- at side mark

ings -arrow 1- and -arrow 3-.
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Pneumatic sabre saw -V.A.G 1523 A-

Install repair double clamp so that end of bolt does not extend
beyond lower edge of clamp.
Bolted connection faces rear.
Align cold exhaust system free of stress page 192 .

Tighten bolts on repair double clamp.
Specified torque, M8: 25 Nm
1.4
Assembly overview - silencer with mountings (vehicles with four-wheel

drive)
1 - From particulate filter

2 - Clamp
Align exhaust system
free of stress before
tightening clamp
page 192 .
Installation position
page 192
Tighten threaded con
nections evenly.
3 - Bracket
For retaining ring
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6 - Rear silencer
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5 - Retaining ring
Renew if damaged.
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7 - Mounting
Renew if damaged.
rrectness of i
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spec
at
i
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do
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4 - 25 Nm
1. Exhaust system
191
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Installation position of clamp
Install clamp so that ends of bolts do not protrude beyond bot
tom of clamp.
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Aligning exhaust system free of stress
Engine must be cold
Procedure
rrectness of i
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nform
spec
at
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Prerequisite
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1.5
Loosen bolted connection of clamp between front exhaust

pipe and silencer.
Position clamp at distance -a- = 5 mm from marking on front
exhaust pipe and lightly tighten front bolted connection.

Once clamp has been tightened, check distance -a- and cor
rect if necessary.
192
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With parts in this position, tighten bolted connections of clamp.
ht
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Align rear silencer horizontally.
do
c
um
en
Push exhaust pipe with silencer forwards into clamp until di

mension -a- 15...17 mm is attained between mounting attach
ment points for body and rear silencer. -Arrow- points in
direction of travel.

Exhaust gas recirculation system
2.1
Assembly overview - parts of exhaust

gas recirculation
Engine codes BKC, BRU, BXE and BXF page 193

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BXJ page
196
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Engine code BJB page 195

Engine codes BLS and
rrectness of i
t to the co
nform
spec
at
i
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his
The exhaust gas recirculation system is activated by the diesel
ility
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Note
Engine codes BKC, BRU, BXE and BXF
direct injection system control unit -J248- via exhaust gas re

circulation valve -N18- (electric-pneumatic) to the exhaust gas
recirculation valve (mechanical).
The electro-pneumatic exhaust gas recirculation valve -N18-
is located in the solenoid valve block.
The cone-shaped plunger in the mechanical exhaust gas re
circulation valve ensures that various cross sectional openings

are possible at different plunger lifts.
Pulsed control enables every conceivable valve position.

do
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2.1.1
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2. Exhaust gas recirculation system
193
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1 - 22 Nm
2 - Intake manifold
take manifold flap motor
-V157- .
to 22 Nm.
3 - Gasket
Renew
4 - Connecting pipe
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8 - Connecting pipe
Tightening sequence:
1. Attach to bypass flap

2. Attach to manifold
3. Tighten to bypass flap
4. Tighten to manifold
AG.
Prote
cted
by
Connector assignment on solenoid valve block, engine codes

BKC, BRU, BXE and BXF
1-
Vacuum connection (on non-return valve for brake servo)
2-
Exhaust gas recirculation valve
3-
Bypass flap
4-
Air filter
5-
Vacuum reservoir
6-
Vacuum unit on turbocharger
194
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11 - 5 Nm
ht
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10 - Bracket
For bypass flap
r
fo
ng
9 - Bypass flap
When activated, directs
exhaust gas to exhaust
gas recirculation cooler
via the electro-pneu
matic exhaust gas recir
culation valve -N18- .
rrectne
s
s
o
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i
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spec
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6 - 10 Nm
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5 - Cooler
lation.

2.1.2
Engine code BJB
Note
direct injection system control unit -J248- via exhaust gas re

circulation valve -N18- (electric-pneumatic) to the exhaust gas
recirculation valve (mechanical).
The electro-pneumatic exhaust gas recirculation valve -N18-
is located in the solenoid valve block.
The cone-shaped plunger in the mechanical exhaust gas re
circulation valve ensures that various cross sectional openings

are possible at different plunger lifts.
Pulsed control enables every conceivable valve position.
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6 - Connecting pipe
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4 - 22 Nm
rrectne
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i
t to the co
n
form
spec
atio
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3 - Gasket
Renew
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2 - From charge air cooler
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1 - Intake manifold
take manifold flap
to 22 Nm.
un
le
195

Pin assignment on solenoid valve block for engine code BJB
1-
Vacuum connection (on non-return valve for brake servo)
2-
Exhaust gas recirculation valve
3-
Intake manifold flap
4-
Air filter
5-
Vacuum reservoir
6-
Vacuum unit on turbocharger
2.1.3
Note
direct injection system control unit -J248- via the exhaust gas
recirculation potentiometer -G212- .

1 - Coolant hose
To connection
2 - Gasket
Renew
4 - Connecting pipe
14 - Vacuum unit
For bypass flap
196
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p

cooler change-over valve N345-
Prote
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by
AG.
10 - Coolant hose
From rear coolant pipe
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9 - 10 Nm
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cooler
rrectne
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i
t to the co
n
form
spec
atio
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7 - To connection for exhaust

gas recirculation valve -N18with exhaust gas recirculation
potentiometer -G212 Assembly overview - in
take manifold
page 176
ility
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6 - 25 Nm
Renew
un
le
5 - From exhaust manifold
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3 - 22 Nm

Renew only together
with exhaust gas recirculation cooler
rrectness of i
t to the co
nform
spec
at
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197
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Prote
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28
Glow plug system
Checking glow plug system
Removing, installing and checking glow plugs page 198

Characteristics of ceramic glow plugs page 199
Removing, installing and checking ceramic glow plugs
page 200
1.1
Removing, installing and checking glow

plugs

Auxiliary measuring set -V.A.G 1594 C-
es, in part or in w
l purpos
hole
ercia
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Diode test lamp -V.A.G 1527 B Jointed spanner -3220-
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Test procedure
Prote
cted
by
Ignition switched off
Pull glow plug connectors off glow plugs.
198
Rep. Gr.28 - Glow plug system
AG.
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Battery voltage at least 11.5 V
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Test requirements

Connect voltage tester -V.A.G 1527 B- cable to battery posi
tive, using clamps from adapter set -V.A.G 1594 C- .
Place probe of diode test lamp -V.A.G 1527 B- on each glow
plug one after the other. If diode lights up, glow plug is OK. If
diode does not light up, replace glow plug.
Remove and install glow plugs using jointed spanner -3220- .
1.2
Characteristics of ceramic glow plugs

WARNING
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and
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f
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Vehicles with 2 valves per cylinder head
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
Visual features of ceramic glow plugs
ility
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The ceramic glow plugs page 199 are sensitive

bending. For this reason a glow plug which has dropped from
a small height (approx. 2 cm) must not be used, even if there
is no obvious damage. It is absolutely necessary to follow the
installation instructions, otherwise the heater pin of the glow
plug can break and cause engine damage.
-A- = Metal glow plug, colour-coded -arrow-.
-B- = Ceramic glow plug with support tube -arrow-, not colourcoded.
Vehicles with 4 valves per cylinder head
-C- = Metal glow plug, colour-coded -arrow-.
Remove and install or check ceramic glow plugs page 200 .

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1. Checking glow plug system
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-D- = Ceramic glow plug with support tube -arrow-, not colourcoded.
199
Prote
cted
by
c
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1.3
Removing, installing and checking ceramic glow plugs

equipment required
Jointed spanner -3220 Torque wrench (550 Nm)
-V.A.G 1331. Volkswagen AG
Hand-held multimeter - kswagen AG

Vol
V.A.G 1526 Aby
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Prote
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Test prerequisites
Engine is cold
Ignition switched off
Procedure
Note
Do not cant ceramic glow plugs when removing and installing.

Remove any components hindering assembly.
Pull connectors off ceramic glow plugs.
Remove ceramic glow plugs using U/J extension and socket,
10 mm -3220- .
note the following:
Before installing the drilling in cylinder head and the threads
must completely cleaned of all deposits.
200
Rep. Gr.28 - Glow plug system
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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en
ole,
cial p
is n
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a
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v
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r
Auxiliary measuring
set ho
ut
a
V.A.G 1594 sCs
does
not
gu
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c

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

glow plugs.
Screw ceramic glow plugs into cylinder head by hand using U/
J extension and socket, 10 mm -3220- .
Then tighten the ceramic glow plugs. Specified torque: 15 Nm.
WARNING
ility
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4-Cylinder Diesel Engine (1.9 L Engine)

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4-Cylinder Diesel Engine (1.9 L Engine)

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4-cylinder diesel engine (1.9 l engine)

Service Department. Technical Information

28 - Glow plug system

23 - Mixture preparation - injection

20 - Fuel supply system

List of Workshop Manual Repair GroupsList of Workshop Manual

Golf 2004 , Golf Plus 2005

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

Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Golf 2004 , Golf Plus 2005

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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

Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts of lubrication system . . . . . . . . . . . .

Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

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

Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Golf 2004 , Golf Plus 2005

Golf 2004 , Golf Plus 2005

Engine number page 1

The engine number (code letters and serial number) can be

Golf 2004 , Golf Plus 2005

Removing and installing engine

Removing and installing engine

Removing engine page 2

Special tools and workshop

Rep. Gr.10 - Removing and installing engine

Drip tray -V.A.G 1306-

Workshop crane -V.A.G

Support clamp -VW 313-

Golf 2004 , Golf Plus 2005

Before carrying out further work, disconnect battery earth

The engine is removed downwards together with the gearbox.

removed must be replaced in the same position when engine

1. Removing and installing engine

Golf 2004 , Golf Plus 2005

When doing any repair work, especially in the engine compart

Two-piece engine cover

Rep. Gr.10 - Removing and installing engine

Golf 2004 , Golf Plus 2005

s Wear eye and hand protection when performing any type

Remove insulation tray General body repairs, exterior; Rep.

Bring lock carrier into service position General body repairs,

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

Remove poly V-belt page 13 .

To facilitate removing and installing engine without opening re

Remove air conditioner compressor Heating, air condition

Secure air conditioner compressor to lock carrier so that re

1. Removing and installing engine

Golf 2004 , Golf Plus 2005

Open all cable guide fasteners -arrows-.

Separate all connecting, coolant, vacuum and intake hoses

Remove slave cylinder for hydraulic clutch. 6-speed manual

Remove selector mechanism from gearbox 6-speed man

Remove subframe Running gear, axles, steering; Rep. Gr.

Support pins must be secured to engine bracket -T10012- as

Rep. Gr.10 - Removing and installing engine

Vehicles with particulate filter

Unbolt pendulum support -arrows-.