4-Cylinder Diesel Engine (1.9 l Engine)

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

Workshop Manual Golf 2004 ➤ Golf Plus 2005 ➤

4-cylinder diesel engine (1.9 l engine)

Engine ID

BJB

BKC BRU

BLS

r fo ng

Edition 01.2009 ht rig py Co t.

un le

Service

BXE

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Service Department. Technical Information

BXF

BXJ

un le

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

Service

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Repair Group 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling

r fo ng

c o p yri gh t . C op yi

21 - Turbocharging/supercharging Prote cted by

28 - Glow plug system

AG.

26 - Exhaust system

agen lksw Vo by

23 - Mixture preparation - injection

ht rig py Co t.

20 - Fuel supply system

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

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

1

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1

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

2

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 .............................. agenflywheel AG. Volksw AG do age kswseal - pulley end . . . .es. n.o.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing crankshaft oil l o gu yV db Removing and iinstalling sealing flange - pulley end . a.ra.nt. . . . . . . . . . . . . . . . . . . . . . . . . . . se r e ho Renewing crankshaft sealing flange - flywheel end . . . . .e o. r .a . . . . . . . . . . . . . . . . . . . . . . . ut a 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 . . . . . . . . . . . . . . . . . . . . . . . . . . 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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

ility ab y li an pt ce

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

r fo ng

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

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

i

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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

ht rig py Co t.

c o p yri gh t. C op yi

1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 agen lksw Vo by

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AG.

Prote cted by

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

87 88 92 92 93 94 95

rrectness of i t to the co nform spec at i h re o n wit in t his

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ility ab y li an pt ce

2 2.1 2.2 3 3.1 3.2 3.3 3.4

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o e h t u ra . .a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o87 c s s

AG. Volkswagen AG d agen oes Golf 2004 ➤ , Golf Plus 2005 ➤ ksw no l o V gu l engine) - Edition 01.2009 4-cylinder diesel enginet (1.9 by ara d e nte is r o eo h ut ra a c s s

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

rrectness of i t to the co nf o r m spec atio h re n in wit

Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . thi sd o cu m en

ht rig py Co t.

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

ility ab y li an pt ce

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 Prote cted by c o p yri gh t. C op yi

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . agen lksw Vo by

AG.

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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Contents

do c um en

iv

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 r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

00 –

Technical data

1

Technical data

Engine number ⇒ page 1 Engine data ⇒ page 1

1.1

Engine number

The engine number (“code letters” and “serial number”) can be found at the joint between engine and gearbox. Additionally there is a sticker on the toothed belt guard with “en‐ gine code” and “serial number”. The engine code is also included on the vehicle data sticker.

un le

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

r fo ng

79.5 95.5 2 19.0 DIN EN 590 1-3-4-2 yes yes

Prote cted by c o py rig ht . C op yi

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

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

Torque

l kW at rpm Nm at rpm

10.03 ▸ EU3 standard 1.9 77/ 4000 250/ 1900

ility ab y li an pt ce

Manufactured Emissions fulfil

agen lksw Vo by

Engine code

Capacity Output

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o e o BXE BJB BKC BRU BLS h ut ra a c s s

Engine data

79.5 95.5 2 18.5 DIN EN 590 1-3-4-2 yes yes

ht rig py Co t.

1.2

yes

yes

yes

yes no

yes no

yes no

1. Technical data

1

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

10 –

Removing and installing engine

1

Removing and installing engine

Removing engine ⇒ page 2 Securing engine to assembly stand ⇒ page 7 Notes on installing ⇒ page 7 . Assembly mountings ⇒ page 10 .

1.1

Removing engine

Special tools and workshop equipment required ♦ Lifting tackle -2024 A♦ Engine bracket -T10012♦ Engine and gearbox sup‐ port -VW 540un le pe rm itte d

AG.

Rep. Gr.10 - Removing and installing engine

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

2

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

♦ Drip tray -V.A.G 1306-

ility ab y li an pt ce

♦ Workshop crane -V.A.G 1202 A-

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ht rig py Co t.

♦ Support clamp -VW 313-

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ♦ 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.

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

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

thi sd o cu m en

♦ 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

3

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 G. Volkswagen AG d n Aabruptly oes wage s upwards at -arrows-, then pull inner engine cover abruptly up‐ k not l Vo gu y b ara wards at -arrows-. d e

nte eo ra c

is or

r fo ng

AG.

Prote cted by

Rep. Gr.10 - Removing and installing engine

agen lksw Vo by

c o p yri gh t . C op yi

4

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Remove air filter housing with air mass meter and connecting pipe.

ht rig py Co t.

un le

ility ab y li an pt ce

th – Remove plenum chamber bulkhead. au ⇒ General body repairs, ss plenum chamber bulk‐ exterior; Rep. Gr. 50 ; Body - front, head .

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Remove bolt -arrow A- and pull air filter housing upwards out of mounting. – Remove battery and battery tray. – Disconnect fuel supply and return lines as well as coolant line on cylinder head. WARNING

♦ The fuel and the fuel lines in the fuel system can become very hot (danger ofAscalding)! G. Volkswagen AG do e

n wage

s no ks ♦ The fuel ysystem is also under pressure! Before opening t gu Vol b ara d the system, place cloths around the connections. nte Then ir se eo carefully loosen connection to release the pressure! ho ut r

ac

sa

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

ility ab y li an pt ce

♦ s Wear eye and hand protection when performing any type of repair work on the fuel system!

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

– 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 .

ht rig py Co t.

r fo ng

To facilitate removing and installing engine without opening re‐ frigerant circuit: c o p yri gh t . C op yi

– Remove air conditioner compressor ⇒ Heating, air condition‐ ing; Rep. Gr. 87 ; Removing and installing compressor brack‐ et . agen lksw Vo by

AG.

Prote cted by

– 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.

1. Removing and installing engine

5

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte Remove wiring harness from cable guide on longitudinal mem‐ is r o eo h ber and lay to side on engine. ut ra a c s s

– 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 ng

– 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- .

6

Rep. Gr.10 - Removing and installing engine

AG.

Vehicles with particulate filter

agen lksw Vo by

– Unbolt pendulum support -arrows-.

Prote cted by c o p yri gh t. C op yi

Continuation for all vehicles:

ht rig py Co t.

– Remove front propshaft ⇒ Final drive 02D, 0AV; Rep. Gr. 39 ; Assembly overview - repairing propshaft .

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

ility ab y li an pt ce

– Pull off or disconnect all other electrical connections from en‐ gine and gearbox as necessary and lay to side.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Unbolt assembly mounting on engine side from engine bracket -arrows-. Note olkswagen AG en AG. V

gu ara nte eo ra c

pe rm itte d

y db ise r tho au s s

es, in part or in w l purpos hole ercia , is n m ot com

– Carefully lower engine with gearbox. Note

Engine with gearbox must be guided carefully when lowered to prevent damage to bodywork.

r te o iva r rp fo g n

1.2

Securing engine to assembly stand

agen lksw Vo by

c o p yri gh t. C op yi

– Disconnect gearbox.

ht rig py Co t.

Procedure

do c um en

When working on the engine, secure it to support clamp -VW 313of the assembly stand using engine and gearbox support -VW 540- .

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Unbolt assembly mounting on gearbox side from gearbox bracket -arrows-.

ility ab y li an pt ce

un le

does waguse stepladder -VAS To remove securingVbolts, 5085. not olks

AG.

Prote cted by

– 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:

1. Removing and installing engine

7

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

r fo ng

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Rep. Gr.10 - Removing and installing engine

ht rig py Co t.

8

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

Distance -a- = 10 mm can also be checked with a metal rod of suitable size, or similar.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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.

un le

Vehicles with manual gearbox

ility ab y li an pt ce

–

pe rm itte d

–

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b Install drive shafts ⇒ Running gear, axles, esteering; Rep. Gr. d ran ir s tee 40 ; Removing and installing drive shafts . o h t or u ac a s s Install front exhaust pipe ⇒ page 186 .

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

– 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.

Prote cted by

– Install air conditioner compressor ⇒ Heating, air conditioning; Rep. Gr. 87 ; Removing and installing compressor bracket.

agen lksw Vo by

c o p yri gh t . C op yi

– Install alternator ⇒ Electrical system; Rep. Gr. 27 ; Removing and installing alternator and poly V- belt .

ht rig py Co t.

– On vehicles with particulate filter install subframe ⇒ Running gear, axles, steering; Rep. Gr. 40

do c um en

Continuation for all vehicles:

r te o iva r rp fo g n

– 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 .

1. Removing and installing engine

9

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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) n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

ility ab y li an pt ce

Gearbox assembly mounting

un le

Renew

pe rm itte d

A = 40 Nm + 90° (1/4 turn) further 1)

AG.

Prote cted by

Rep. Gr.10 - Removing and installing engine

agen lksw Vo by

c o p yri gh t . C op yi

10

do c um en

r te o iva r rp fo g n

Renew

rrectness of i t to the co nform spec a t i h re o n in wit thi s

1)

es, in part or in w l purpos hole ercia , is n m ot com

B = 60 Nm + 90° (1/4 turn) further 1)

ht rig py Co t.

1)

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 en AG. V

do ag M10 x 75 strength class 8.8:oturn lksw 40 Nm + 90° further es not

yV db

M10 x 75 strength class ise 10.9: turn 50 Nm + 90° further or h ut

Bolt -C-

M14 x 1.5 x 70

rrectness of i t to the co nform spec at i h re o n wit in t his

100 Nm + turn 90° further Tighten only if pendulum support is bolted to gearbox Always renew after removing

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

a Always renew after ss removing

gu ara nte eo ra c

1. Removing and installing engine

11

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

13 –

Crankshaft group

1

Dismantling and assembling engine

Assembly overview - poly V-belt drive ⇒ page 12 Removing and installing poly V-belt ⇒ page 13 Assembly overview - toothed belt drive ⇒ page 15

Note

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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

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

thi sd o cu m en

4 - Bracket ❑ For alternator and air conditioner compressor.

AG.

3 - Alternator

agen lksw Vo by

2 - 25 Nm

Prote cted by c o py rig ht . C op yi

1 - Belt pulley and vibration damper ❑ Can only be installed in one position, holes are offset.

ht rig py Co t.

1.1

rrectness of i t to the co nf o r m spec atio h re n in wit

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.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

un le

pe rm itte d

ility ab y li an pt ce

– 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 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

– Mark direction of rotation of poly V-belt.

– Swing tensioning element in direction of arrow to remove ten‐ sion from poly V-belt.

do c um en

ht rig py Co t.

r te o iva r rp fo g n

The open-end spanner 16 mm -T 10241- is particularly well suited to relieve tension.

agen lksw Vo by

AG.

1. Dismantling and assembling engine

13

Prote cted by

c o p yri gh t . C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 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

ility ab y li an pt ce

Belt drive without air conditioner compressor

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

Belt drive with air conditioner compressor

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Rep. Gr.13 - Crankshaft group

thi sd o cu m en

14

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.3

Assembly overview - toothed belt drive

1 - Toothed belt guard upper part 2 - 100 Nm 3 - 25 Nm 4 - Camshaft pulley

pe rm itte d

un le

ility ab y li an pt ce

5 - Hub ❑ With sender wheel ❑ Use counterhold tool T10051- to loosen and AG. Volkswagen AG d tighten. agen oes ksw not l o V gu ❑ To remove,byuse puller ara d nte T10052ise r o eo h t u ra ❑ Removing and installing a c s ⇒ spage 80 , removing and installing camshaft.

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

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‐ ther r te o iva r rp fo g n

agen lksw Vo by

c o p yri gh t. C op yi

14 - Idler roller

15 - Coolant pump ❑ Removing and installing ⇒ page 106 .

ht rig py Co t.

13 - 20 Nm

do c um en

12 - Tensioning roller ❑ Remove engine support in order to remove and install ⇒ page 16 .

AG.

Prote cted by

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 1. Dismantling and assembling engine

15

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 Removing and installing engine support n AG. V doe wage

s no t gu ara nte eo ra c

olks

V by Special tools and workshop equipment required ed is or

♦ Support bracket -10 - 222 A- auth un le

pe rm itte d

ility ab y li an pt ce

ss

♦ Torque wrench -V.A.G 1331– Remove engine cover.

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

– To do this, pull engine cover upwards abruptly at front and right -arrows A- and then pull forwards out of rear fastening -arrow B-.

Two-piece engine cover

r te o iva r rp fo g n

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Rep. Gr.13 - Crankshaft group

ht rig py Co t.

16

do c um en

For two-piece engine cover, first pull outer engine cover abruptly upwards at -arrows-, then pull inner engine cover abruptly up‐ wards at -arrows-.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 o r m spec atio h re n in wit

WARNING

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 e ng

supported with support bracket 10-222A!

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

1. Dismantling and assembling engine

17

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 AG. Volkswagen A

can be loosened and removed.

ility ab y li an pt ce

–

G do es n ot g ua ran tee or ac

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

–

n wage olks V by Raise engine with support bracket -10-222Aed until both upper ris removed. bolts of engine support can be loosenedhand o t au ss Lower engine with support bracket -10-222Auntil lower bolt

– Remove engine support upwards.

rrectness of i t to the co nf o r m spec atio h re n in wit

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 cted by c o py rig ht . C op yi

– 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

Rep. Gr.13 - Crankshaft group

AG.

Before installing assembly mounting, tighten all engine support bolts to prescribed torque.

agen lksw Vo by

Note

ht rig py Co t.

II: Engine support with greater clearance to engine

thi sd o cu m en

– Tighten bolts for engine support in the sequence shown -1…3- to 40 Nm + 1/2 turn (180 °) further. To do this, raise or lower engine using support bracket -10 - 222 A- .

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.4

Assembly overview - crankcase

1 - Cylinder block ❑ Removing and installing sealing flange and fly‐ wheel ⇒ page 20 . ❑ Removing and installing crankshaft ⇒ page 33 ❑ Dismantling and assem‐ bling pistons and con‐ rods ⇒ page 33 2 - Gasket ❑ Renew 3 - Oil filter bracket ❑ Dismantling and assem‐ bling ⇒ page 92 . 4 - 15 Nm + 1/4 turn (90°) fur‐ ther ❑ Renew ❑ First fit upper left and lower right bolts and then tighten all four bolts diagonally. 5 - Bracket 6 - 20 Nm 7 - Connection ❑ For thermostat.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

9 - O-ring ❑ Renew

un le

8 - 15 Nm

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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

10 - Thermostat ❑ Removing and installing ⇒ 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 r fo ng

AG.

Prote cted by c o p yri gh t. C op yi

16 - 15 Nm

agen lksw Vo by

15 - Sump ❑ Clean sealing surface before fitting. ❑ Install with silicone sealant -D 176 404 A2- .

ht rig py Co t.

14 - 25 Nm

1. Dismantling and assembling engine

19

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2

Removing and installing sealing flange and flywheel

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

Assembly overview - sealing flanges and flywheel Note

20

Rep. Gr.13 - Crankshaft group

AG.

6 - Intermediate plate ❑ Must be positioned on dowel sleeves. ❑ Do not damage or bend when assembling.

agen lksw Vo by

5 - Flywheel ❑ To remove and install flywheel, counterhold with 3067.

Prote cted by c o py rig ht . C op yi

4 - 60 Nm + 1/4 turn (90°) fur‐ ther ❑ Renew

rrectness of i t to the co nform spec at i h re o n wit in t his

3 - Cylinder block ❑ Removing and installing crankshaft ⇒ page 33 ❑ Dismantling and assem‐ bling pistons and con‐ rods ⇒ page 33

do c um en

2 - Sealing flange ❑ Must be positioned on dowel sleeves. ❑ Removing and installing ⇒ page 23 . ❑ Install with silicone seal‐ ant -D 176 404 A2⇒ page 23 .

ility ab y li an pt ce

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 .

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Repairing clutch ⇒ 6-speed manual gearbox

AG. Volkswagen AG d agen oes ksw not l o V gu y30 b ara 02S; Rep. Gr. ; Repairing clutch. d e nte is r o eo h ut ra a c s s

ht rig py Co t.

2.1

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 7 - 15 Nm ❑ Renew 8 - Sealing flange with oil seal ❑ Renew complete with oil seal and sender wheel only. ❑ Removing and installing ⇒ page 25 . 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

Special tools and workshop equipment required ♦ Counterhold tool -3099♦ Oil seal extractor -3203♦ Assembly tool -T10053♦ Torque wrench V.A.G 1331-

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Removing

– Remove toothed belt. ⇒ page 50

do c um en

r te o iva r rp fo g n

2.2.1

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

♦ Torque wrench V.A.G 1332-

ht rig py Co t.

agen lksw Vo by

2. Removing and installing sealing flange and flywheel

21

AG.

Prote cted by

c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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

AG do gen – Unscrew inner part oflkoil es n(approx. 3 swaseal extractor two turns o o y V and lock with knurled screw.t gua mm) out of outerd bpart

ran tee or ac

e ris

ho – Oil threaded ut head of oil seal extractor.

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

ility ab y li an pt ce

a ss

– 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. ht rig py Co t.

– Remove oil residue from crankshaft journal using clean cloth. c o p yri gh t. C op yi

– Place guide sleeve -T10053/1- onto crankshaft journal. agen lksw Vo by

Prote cted by

– Slide oil seal over guide sleeve onto crankshaft journal.

Rep. Gr.13 - Crankshaft group

AG.

22

thi sd o cu m en

Note

rrectness of i t to the co nf o r m spec atio h re n in wit

– Loosen knurled screw and turn inner part against crankshaft until oil seal is pulled out.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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

Special tools and workshop 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 AG. Volkswagen AG d Aagen o

es n ot g ua ran tee or ac

w olks yV b ed ris ho t au

♦ Flat scraper

Prote cted by c o py rig ht . C op yi

– Remove toothed belt. ⇒ page 50

ht rig py Co t.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

rrectness of i t to the co nform spec at i h re o n wit in t his

Removing

do c um en

2.3.1

ility ab y li an pt ce

ss

2. Removing and installing sealing flange and flywheel

23

agen lksw Vo by

AG.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 c o py rig ht . C op yi

♦ Before applying sealant bead, cover sealing surface of oil seal

Rep. Gr.13 - Crankshaft group

AG.

24

agen lksw Vo by

with a clean cloth.

ht rig py Co t.

erwise excess sealant can enter sump and clog strainer in oil pump suction pipe as well as drip onto crankshaft oil seal.

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 e ng

Installing

rrectness of i t to the co nf o r m spec atio h re n in wit

2.3.2

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 agen o

es n ot g ua ran tee or ac

w olks yV b ed ris ho t au

Special tools and workshop equipment required ♦ Assembly tool -T10134-

♦ Vernier gauge

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

♦ Socket -V.A.G 1332/11-

ss

ility ab y li an pt ce

♦ 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 lksw Vo by

Prote cted by c o py rig ht . C op yi

– Remove intermediate plate.

ht rig py Co t.

– Remove flywheel.

thi sd o cu m en

removed.

2. Removing and installing sealing flange and flywheel

25

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 cted by c o py rig ht . C op yi

agen lksw Vo by

AG.

turned after removal from packaging.

ht rig py Co t.

♦ 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

Rep. Gr.13 - Crankshaft group

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 ot p om c r erm o e t a itte riv du p or nl f e g n

– Screw three M6 x 35 mm bolts into threaded holes -arrows- of sealing flange.

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2.4.3

. Volkswagen AG gen AG d

swa sender wheeloes no A - Assembling seal olkwith t gu yV b ara d nte on assembly tool ise -T10134r o e

h ut

rrectness of i t to the co nform spec a t i h re o n in wit thi s

un le

pe rm itte d es, in part or in w l purpos hole ercia , is n m ot com

or ac ility ab y li an pt ce

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 rig py Co t.

Inner part of assembly tool and assembly housing must be at same height.

do c um en

Note

r te o iva r rp fo g n

– Press assembly housing -C- downwards so that it lies on hex‐ agon nut -B- -arrow-.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

– 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.

2. Removing and installing sealing flange and flywheel

27

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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-.

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

–

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran 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

Rep. Gr.13 - Crankshaft group

Prote cted by

Crankshaft flange must be free of oil and grease.

AG.

•

agen lksw Vo by

c o p yri gh t . C op yi

B - Attaching assembling tool -T10134with sealing flange on crankshaft flange

ht rig py Co t.

2.4.4

do c um en

When installing sealing flange, ensure that sender wheel remains fixed in assembly device.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 ara nte eo ra c

ks Vol by d e ris tho u a ss

rrectness of i t to the co nform spec a t i h re o n in wit thi s

2.4.5

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

– To guide sealing flange, screw two M7 × 35 mm bolts -A- into n AG. Volkswagen AG do 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-.

agen lksw Vo by

c o p yri gh t . C op yi

– Hand-tighten both hexagon socket head bolts of assembly tool.

ht rig 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 r 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.

2. Removing and installing sealing flange and flywheel

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 iv r du rp o nl f e ng

ility ab y li an pt ce

2.4.6

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d ➤ , Golf Plus 2005 ➤ e nte is r o eo diesel engine (1.9 l engine)uth- Edition 01.2009 ra a c s 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 o py 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

Rep. Gr.13 - Crankshaft group

AG.

– Screw the three knurled screws -B- out of sealing flange.

agen lksw Vo 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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s 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

ility ab y li an pt 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 lksw Vo by

Prote cted by c o p yri gh t. C op yi

– 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-

Special tools and workshop equipment required

2. Removing and installing sealing flange and flywheel

31

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ♦ Hexagon key extension, 4 mm -T10370-

♦ Or commercially available ball-ended hexagon key socket, 5 . Volkswagen AG mm gen AG does swa

ss

not gu ara nte eo ra c ility ab y li an pt ce

un le

Note

olk yV db e ris tho au

– Remove noise insulation tray ⇒ General body repairs, exteri‐ or; Rep. Gr. 50 ; Body - front; Assembly overview - noise 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.

Rep. Gr.13 - Crankshaft group

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

32

ht rig py Co t.

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

urposes, in part or in wh 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.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

3

Crankshaft

Assembly overview - crankshaft ⇒ page 33 Crankshaft dimensions ⇒ page 38 .

3.1

Assembly overview - crankshaft

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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

ility ab y li an pt ce

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 rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

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: 0.07…0.17 mm, wear limit: 0.37 mm ❑ Check radial clearance with Plastigage new: 0.03...0.08 mm, wear limit: 0.17 mm ❑ Do not rotate crankshaft when checking radial clearance. ❑ Crankshaft dimensions ⇒ page 38 . 7 - Thrust washer ❑ For cylinder block, bearing 3

3. Crankshaft

33

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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 ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s 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 t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Rep. Gr.13 - Crankshaft group

thi sd o cu m en

34

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 1 - -1- Kukko 21/2 2 - Centring mandrel -3176-

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

Puller -T10055- with adapter -T10055/3Gearbox is unscrewed from engine. AG.

Prote cted by

Pulling needle bearing out:

agen lksw Vo by

c o p yri gh t. C op yi

•

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 ab y li an pt ce

un le

3 - Drift -VW 207 C-

3. Crankshaft

35

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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.

Rep. Gr.13 - Crankshaft group

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

a ss

ht rig py Co t.

V by

ed Special tools, testers, measuring instruments and ris ho required t u

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

3 - Drift -VW 207 C-

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

agen lksw Vo by

AG.

Prote cted by c o p yri 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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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

Rep. Gr.13 - Crankshaft group

47.80

Conrod journal ∅ -0.022 -0.042

AG.

Honing dimen‐ sion

agen lksw Vo by

(Dimensions in mm)

r fo ng

Crankshaft dimensions

Prote cted by c o p yri gh t. C op 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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Driving depth: Dimension -a- = 1.5 to 1.8 mm.

ht rig py Co t.

•

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

un le

Renew bearing, if driving depth is too deep.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

4

Pistons and conrods

Assembly overview - pistons and conrods ⇒ page 39 . Separating new conrod ⇒ page 40 . Checking piston projection at TDC ⇒ page 41 Piston and cylinder dimensions ⇒ page 42 . AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Piston rings, cylinder bore and piston installation position ⇒ page 42

Assembly overview - pistons and conrods es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

rrectness of i t to the co nform spec at i h re o n wit in t his do c um en

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

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

ility ab y li an pt ce

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 .

ht rig py Co t.

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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ❑ ❑ ❑ ❑ ❑

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 ❑ Note installation position. ❑ 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. n AG. Volkswagen AG do es n wage s k l ❑ Use old bolt for measuring radial clearance. ot g Vo

ua ran tee

– 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 cted by

Rep. Gr.13 - Crankshaft group

agen lksw Vo by

c o p yri gh t . C op yi

40

ht rig py Co t.

r fo ng

– 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 h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

Separating new conrod

or ac ility ab y li an pt ce

4.2

by ed ris o th au ss

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

4.3

Checking piston projection at TDC

Special tools and workshop equipment required ♦ Measuring bridge -VW 382/7-

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

rrectness of i t to the co nform spec a t i h re o n in wit thi s

♦ Dial gauge Test procedure Note

If different values are determined during the projection measure‐ ment, use the largest dimension for selecting the gasket.

Note

do c um en

r te o iva r rp fo g n

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:

ht rig py Co t.

Turn engine clockwise to measure piston projection at TDC. c o p yri gh t . C op yi

Piston projection

AG.

Prote cted by

0.91 mm ... 1.00 mm 1.01 mm ... 1.10 mm 1.11 mm ... 1.20 mm

agen lksw Vo by

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

♦ End dimension plate -VW 385/17-

Identification Holes/notches 1 2 3

4. Pistons and conrods

41

Golf 2004 ➤ , Golf Plus 2005 ➤ olkswagen AG en AG. V01.2009 does 4-cylinder diesel engine (1.9 l engine) -agEdition n lksw

ot g ua ran tee or ac

un le

ility ab y li an pt ce

o yV db e Cylinder head gasket identification horis t au ♦ Part number = arrow 1 ss pe rm itte d

♦ 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

r te o iva r rp fo g n

Cylinder bore ∅

Piston rings, cylinder bore and piston in‐ stallation position AG.

Special tools and workshop equipment required ♦ 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

Special tools and workshop equipment required ♦ Feeler gauges

42

Rep. Gr.13 - Crankshaft group

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

Checking piston ring gap

do c um en

Basic dimen‐ sion Stage I Stage II

Piston ∅

ht rig py Co t.

Honing dimension

4.5

rrectness of i t to the co nform spec a t i h re o n in wit thi s

4.4

es, in part or in w l purpos hole ercia , is n m ot com

♦ Holes = arrow 3

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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

Special tools and workshop equipment required ♦ 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 swa k not , l o mounted on a repair stand with engine support bracket -VW 540V gu y b ara d be e as measurements may then incorrect. nt ris

un le

and allocation of piston to cylinder

pe rm itte d

Piston in cylinders 1 and 2: Piston in cylinders 3 and 4:

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

Larger inlet valve chamber towards flywheel -arrows-.

ee or ac ility ab y li an pt ce

Piston installation

tho au s 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

do c um en

ht rig py Co t.

r te o iva r rp fo g n

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

4. Pistons and conrods

43

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

15 –

Cylinder head, valve gear

1

Cylinder head Note

♦ When installing an exchange cylinder head with fitted cam‐

shaft, the contact surfaces between the bucket tappets and the cam must be oiled before installing the cylinder head cov‐ er.

♦ The plastic protectors fitted to protect the open valves must be

removed only immediately before the cylinder head is fitted.

♦ If the cylinder head is replaced, all the coolant in the system

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Rep. Gr.15 - Cylinder head, valve gear

ht rig py Co t.

44

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 ab y li an pt ce

un le

must also be renewed.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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

ility ab y li an pt ce

un le

7

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara - Hub d nte ise r o eo h ❑ With sender wheel t u ra a c s s ❑ Use counterhold tool pe rm itte d

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

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 c um en

r te o iva r rp fo g n

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) . agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

14 - Fuel supply line

ht rig py Co t.

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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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

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

25 - Unit injector ❑ Removing and installing ⇒ page 169 .

gen AG does not gu ara nte eo ra c ility ab y li an pt ce

AG. agen ksw l o yV db ise r tho au s s

rrectness of i t to the co nf o r m spec atio h re n in wit

27 - Central connector ❑ For unit injector 28 - From brake servo

29 - Tandem pump ❑ For fuel and vacuum supply ❑ Checking ⇒ page 147 . ❑ Removing and installing ⇒ page 147 . ❑ Must not be dismantled.

Prote cted by

34 - 20 Nm 35 - Cylinder head ❑ Removing and installing ⇒ page 67 . ❑ After renewing, renew entire coolant 36 - Cylinder head gasket ❑ Renew ❑ Note marking ⇒ page 47 ❑ After renewing, renew entire coolant

46

Rep. Gr.15 - Cylinder head, valve gear

AG.

33 - Bracket

agen lksw Vo by

c o p yri gh t. C op yi

32 - Gasket ❑ Renew

ht rig py Co t.

31 - Return hose ❑ To fuel filter ❑ Blue or with blue marking. ❑ Check for secure seating. ❑ Secure with spring-type clips.

thi sd o cu m en

30 - Supply hose ❑ From fuel filter. ❑ White or with white marking. ❑ Check for secure seating. ❑ Secure with spring-type clips.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 y li an pt ce

♦ Straight edge

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

Special tools and workshop equipment required

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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 o py rig ht . C op yi

♦ Piston projection at TDC must be determined when installing

agen lksw Vo by

AG.

new pistons or a short engine. ⇒ page 41

ht rig py Co t.

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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.2

Removing and installing cylinder head cover

Special tools and workshop equipment required ♦ 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 agen oes

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 o wards at -arrows-. h t au ss

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

– Remove upper toothed belt guard.

not gu ara nte eo ra c

– Disconnect crankcase breather hose at union of rear of charge air pipe.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Rep. Gr.15 - Cylinder head, valve gear

do c um en

48

rrectness of i t to the co nform spec at i h re o n wit in t his

– Unbolt bracket from exhaust gas recirculation valve.

ht rig py Co t.

Two-piece engine cover

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 . Volkswagen AG Continuation for all vehicles gen AG d

wa olks

oes not gu ara nte eo ra c

yV – Remove cylinder d b head cover. e ris tho u a ss

un le

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 n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

Cylinder head cover, engine codes: BJB, BKC, BRU, BXE, BXF

Note

ht rig py Co t.

r fo ng

Installation is carried out in the reverse sequence of removal. In the process, note the following:

c o p yri gh t. C op yi

♦ Renew cylinder head cover gasket and seal for bolts if dam‐ agen lksw Vo by

Prote cted 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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Cylinder head cover, engine codes: BJB, BKC, BRU, BXE, BXF – Screw on cylinder head cover hand-tight in the sequence -1 to 13.-

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

pe rm itte d

ility ab y li an pt ce

un le

– Tighten bolts to 10 Nm in the sequence -1...13-.

es, in part or in w l purpos hole ercia , is n m ot com

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

Rep. Gr.15 - Cylinder head, valve gear

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 lksw Vo by

Prote cted by c o p yri gh t. C op yi

♦ From 05.05 a modified engine support has been introduced, it

do c um en

Note

r te o iva r rp fo g n

Removing, installing and tensioning toothed belts ht rig py Co t.

1.3

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

1.3.1

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 ab y li an pt ce

un le

-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)

Special tools and workshop equipment required ♦ Pin wrench -T10020- or hexagon wrench c o p yri gh t. C op yi

♦ Crankshaft stop -T10050AG.

Prote cted by

♦ Torque wrench V.A.G 1332-

agen lksw Vo by

♦ Torque wrench V.A.G 1331-

ht rig py Co t.

♦ Locking pin -T10115-

do c um en

r te o iva r rp fo g n

♦ Locking pin -3359-

1. Cylinder head

51

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ♦ 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 ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Note

rrectness of i t to the co nform spec at i h re o n wit in t his

Removing

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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.

– Remove poly V-belt ⇒ page 13 .

Prote cted by

– Remove lower and centre parts of toothed belt guard.

52

Rep. Gr.15 - Cylinder head, valve gear

AG.

– Remove belt pulley with vibration damper.

agen lksw Vo by

c o p yri gh t . C op yi

– Remove front right wheel housing liner.

ht rig py Co t.

– Remove tensioning element for poly V-belt.

do c um en

– Remove engine cover. ⇒ page 4

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 agen oes connected). n lksw

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 r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

ss

ot g ua ran tee or ac

o yV db e ris tho au

– 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.

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

AG.

– Remove refrigerant line securing clamp from longitudinal member.

ht rig py Co t.

– Lower engine with support bracket -10-222A- until both lower bolts of engine bracket can be loosened.

do c um 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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 – Turn crankshaft to TDC No. 1 cylinder.

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 nthe does w ge not belt guard must line up with the markingy Von olksthe camshaft sender gu b ara d wheel -arrow-. e n is

Note

rrectness of i t to the co nform spec at i h re o n wit 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 – Turn crankshaft to TDC No. 1 cylinder.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Rep. Gr.15 - Cylinder head, valve gear

ht rig py Co t.

54

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

– Lock hub using locking . To do this, slide locking pin through the free elongated hole on left into hole in cylinder head.

tee or ac ility ab y li an pt ce

r ho ut a pinss-3359-

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Note

Turn crankshaft until marking on crankshaft pulley and tooth seg‐ 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 pin through the free elongated hole on left into hole in cylinder head. – Lock crankshaft toothed belt pulley with crankshaft stop T10100- . To do this, push crankshaft stop into teeth of toothed . Volkswagen AG gen AG does belt pulley from its face side. swa

ss

not gu ara nte eo ra c

Continuation for all vehicles – 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.

Prote cted by c o p yri gh t. C op yi

– Turn pin wrench -T10020- anti-clockwise until toothed belt tensioning roller can be locked with locking pin -T10115- .

agen lksw Vo by

AG.

Note

ht rig py Co t.

r fo ng

– Loosen tensioning roller securing nut.

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

The marks on the crankshaft toothed belt pulley and the crank‐ shaft stop must align. At the same time, the crankshaft stop pin must engage in the drilling in the sealing flange.

ility ab y li an pt ce

un le

Note

olk yV db e ris tho au

A hexagon key can be used to tension or relieve tension on the tensioner.

1. Cylinder head

55

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 by d e crankshaft stop -T10100- . ris

•

au pin Tensioning roller locked with locking ss cured to right stop.

ility ab y li an pt ce

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

Note

pe rm itte d

un le

tho

n AG. Volkswagen AG do es n wage ot g ua ran tee or ac -T10115- and se‐

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. – 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

Rep. Gr.15 - Cylinder head, valve gear

AG.

– Loosen tensioning roller securing nut and pull out locking pin -T10115- .

agen lksw Vo by

c o p yri gh t. C op yi

Ensure that tensioning roller seats correctly in rear toothed belt guard -arrow-.

ht rig py Co t.

Note

do c um en

r te o iva r rp fo g n

– Then fit toothed belt on coolant pump toothed belt pulley.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 AG.of – Turn crankshaft two rotations in engine direction does agen ksw not l o until crankshaft is just before TDC No. 1 cylinder. gu yV b ed

ara nte e

ris Vehicles with round crankshaft belt ho pulley

rrectness of i t to the co nform spec at i h re o n wit in t his

– Check whether crankshaft can be locked with crankshaft stop -T10050- . If crankshaft cannot be locked

ht rig py Co t.

c o p yri gh t. C op yi

– Loosen securing bolts -1- for camshaft toothed belt pulley.

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

– Lock hub with locking pin -3359- whilst turning engine in di‐ rection of rotation.

or ac ility ab y li an pt ce

t au ss

agen lksw Vo by

AG.

Prote cted by

– 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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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:

ility ab y li an pt ce

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

un le

– Loosen securing bolts -1- for camshaft

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte toothed belt is pulley. r o eo h ut ra a c s s

– 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

Rep. Gr.15 - Cylinder head, valve gear

AG.

– Remove locking pin -3359- and crankshaft stop -T10050- .

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

– In this position, tighten camshaft toothed belt pulley securing bolts -1- to 25 Nm.

do c um en

– 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.

ht rig py Co t.

Continuation for all vehicles

r te o iva r rp fo g n

– Now turn crankshaft in engine direction of rotation until crank‐ shaft stop pin engages in sealing flange from rotational move‐ ment.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 does not gu ara nte eo ra c

– 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)

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

– Install centre and lower parts of toothed belt guard.

ility ab y li an pt ce

ris tho u a ss

– Install belt pulley vibration damper (renew securing bolts). – Install poly V-belt ⇒ page 13 . – Install toothed belt guard upper part.

rrectness of i t to the co nform spec at i h re o n wit in t his

Specified torque: 10 Nm + 90° (1/4 turn)

– 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.

agen lksw Vo by

1. Cylinder head

do c um en

ht rig py Co t.

AG.

Prote cted by

c o p yri gh t . C op yi

– Fit engine cover.

59

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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. Special tools and workshop equipment required ♦ Diesel injection pump lock‐ ing pin -3359♦ Locking pin -T10060 A♦ Crankshaft stop -T10100♦ Counterhold tool -T10172♦ Special wrench, long reach -T10264-

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

AG.

Prote cted by

Rep. Gr.15 - Cylinder head, valve gear

agen lksw Vo by

c o p yri gh t. C op yi

60

ht rig py Co t.

r fo ng

– 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 n wit i n thi sd o c um en

Removing

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

ility ab y li an pt ce

un le

♦ Locking tool -T10265-

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

agen lksw Vo by

c o p yri gh t. C op yi

– Disconnect fuel supply line -3- and return line -2- by pulling release tabs.

ht rig py Co t.

r fo ng

– 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 n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

– Remove bolt -1-.

61

AG.

Prote cted by

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 poly V-belt ⇒ page 13 . – Remove tensioning element for poly V-belt.

– Remove upper toothed belt guard, to do this, loosen retaining clips -arrows-. – Remove front right wheel housing liner. – Remove belt pulley with vibration damper. – Remove lower and centre parts of toothed belt guard. AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

r fo ng

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Rep. Gr.15 - Cylinder head, valve gear

ht rig py Co t.

62

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

– Turn crankshaft to TDC No. 1 cylinder.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Note

Turn crankshaft until marking on crankshaft pulley and tooth seg‐ 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 pin through the free elongated hole on left into hole in cylinder 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

The marks on the crankshaft toothed belt pulley and the crank‐ shaft stop must align. When doing this, the pin of the crankshaft stop must insert in the drilling of the sealing flange. – Mark direction of rotation of toothed belt.

ility ab y li an pt ce

– Loosen tensioning roller securing nut -1-.

ht rig py Co t.

r 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 o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

–

n AG. Volkswagen AG do es n wage s k l ot g o Loosen securing bolts -1- of camshaft toothed belt pulley y Vuntil ua b ran camshaft pulley can be moved within the elongatedisholes. ed tee r o h t or u ac a ss

agen lksw Vo by

1. Cylinder head

63

AG.

Prote cted by

c o p yri gh t . C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 olks cured to right stop with securing nut. gu yV

ara nte e

or ac

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

ility ab y li an pt ce

Note

b ed ris o th au ss

rrectness of i t to the co nf o r m spec atio h re n in wit

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. – 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

Rep. Gr.15 - Cylinder head, valve gear

AG.

– Loosen tensioning roller securing nut -1-.

agen lksw Vo by

c o p yri gh t . C op yi

– 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 o cu m en

Note

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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. – Remove locking pin -3359- and crankshaft stop -T10100- . – Turn crankshaft two rotations in engine direction of rotation 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- .

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

ht rig py Co t.

r fo ng

– 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 n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

If crankshaft cannot be locked

1. Cylinder head

65

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 AG. Volkswagen AG d agen oes

lksw – Turn crankshaft slightly against engine direction rotation oof yV b d just before the 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 ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

ss of rotation until crank‐ – Now turn crankshaft in engine direction shaft stop pin engages in sealing flange whilst turning.

not gu ara nte eo ra c

– 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 -T10100- .

– Repeat check and adjustment if necessary.

– Install poly V-belt ⇒ page 13 .

– 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

Rep. Gr.15 - Cylinder head, valve gear

AG.

Specified torque: 10 Nm + 90° (1/4 turn)

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

– 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 en

– Turn crankshaft two rotations in engine direction of rotation until crankshaft is just before TDC No. 1 cylinder.

Golf 2004 ➤ , Golf Plus 2005 ➤ G. Volkswagen AG d gen Aengine 4-cylinderkdiesel (1.9 l engine) a oes - Edition 01.2009 w s n

1.4

ol yV db e ris tho au

ot g ua ran tee or ac

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 r 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 ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Special tools and workshop equipment required

ility ab y li an pt ce

ss

♦ Water drainage container V.A.G 1390/1-

♦ Retainer -T10014- (only ve‐ hicles ▸ 05.05)

thi sd o cu m en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Special tools and workshop equipment required ♦ Support bracket -10-222A- with adapters -10-222A/13- (only vehicles ▸ 05.05)

1. Cylinder head

67

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 en AG. V ag ksw Vol y db ise WARNINGuthor a ss

does not gu ara nte eo ra c

♦ Ensure that there is sufficient clearance to all moving or 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 .

agen lksw Vo by

AG.

c o p yri gh t. C op yi

– Remove two-piece engine cover ⇒ page 4 Prote cted by

– Remove plenum chamber bulkhead. ⇒ General body repairs, exterior; Rep. Gr. 50 ; Body - front, plenum chamber bulk‐ head .

– Remove air filter housing with air mass meter and connecting pipe.

68

Rep. Gr.15 - Cylinder head, valve gear

ht rig py Co t.

– 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 c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

rrectness of i t to the co nform spec at i h re o n wit in t his

♦ 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.

ility ab y li an pt ce

When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐ tions:

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Remove bolt -arrow A- and pull air filter housing upwards out of mounting. – Remove insulation tray. ⇒ General body repairs, exterior; Rep. Gr. 50 ; Body - front; Assembly overview . – 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 . n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o From 05.05 a modified engine support has been introduced, itoris h t u ac a no longer necessary to remove the engine support and supporting ss

Note

pe rm itte d

un le

ility ab y li an pt ce

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) ht rig py Co t.

c o p yri gh t . C op yi

Note

do c um en

r te o iva r rp fo g n

– Separate all connection, coolant, vacuum and intake hoses from cylinder head.

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

– Remove toothed belt. ⇒ page 50

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

agen lksw Vo by

AG.

Prote cted by

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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. Continuation for all vehicles

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

ility ab y li an pt ce

un le

– 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

Rep. Gr.15 - Cylinder head, valve gear

AG.

♦ Carefully remove remains of emery and abrasives.

agen lksw Vo by

c o p yri gh t. C op yi

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.

ht rig py Co t.

r fo ng

♦ Always renew cylinder head bolts.

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Maintain sequence when loosening cylinder head bolts.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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-

ility ab y li an pt ce

Stage II = 60 Nm

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Stage I = 35 Nm

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

Turn further with rigid spanner:

Stage III = 1/4 turn (90°)

Note

rrectness of i t to the co nform spec at i h re o n 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 .

agen lksw Vo by

– Install poly V-belt ⇒ page 13 .

Prote cted by c o py rig ht . C op yi

– Install toothed belt ⇒ page 50 .

ht rig py Co t.

– Install hub for camshaft toothed belt pulley ⇒ page 147 , Re‐ moving and installing camshaft.

do c um 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 . – Fill cooling system with coolant ⇒ page 102 . – 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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Special tools and workshop equipment required

V.A.G 1331-

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

ility ab y li an pt ce

♦

♦ Adapter -V.A.G 1381/12-

rrectness of i t to the co nf o r m spec atio h re n in wit

♦ Compression tester V.A.G 1763-

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

•

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

Rep. Gr.15 - Cylinder head, valve gear

thi sd o cu m en

Test prerequisite

ht rig py Co t.

♦

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte Jointed spanner -3220- oris eo h ut ra a c s Torque wrench s

Golf 2004 ➤ , Golf Plus 2005 ➤ AG. Volkswagen does 01.2009 agen(1.9 l engine) -AG 4-cylinder diesel oengine Edition no lksw

ility ab y li an pt ce

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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

t gu ara nte eo ra c

V by ed s i glowthplugs or or u a ss

– Check compression using compression tester -V.A.G 1763- .

rrectness of i t to the co nform spec at i h re o n wit 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 cted by

– Read fault memory of engine control unit. ⇒ page 178

agen lksw Vo by

c o p yri gh t . C op yi

Specified torque: 15 Nm.

ht rig py Co t.

– 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

Golf 2004 ➤ , Golf Plus 2005 ➤ AG. Volkswagen AG d 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 agen oes ksw n

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

Rep. Gr.15 - Cylinder head, valve gear

AG.

2 - Rocker arm shaft ❑ Do not interchange.

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

1 - 20 Nm + 1/4 turn (90°) fur‐ ther ❑ Renew ❑ Note sequence when loosening and tighten‐ ing ⇒ page 80 , Re‐ moving and installing camshaft.

r fo ng

Assembly overview - valve gear

ht rig py Co t.

2.1

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Note

ss

ot g ua ran tee or ac ility ab y li an pt ce

un le

2

ol yV db e ris tho au

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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). ❑ Removing and installing ⇒ page 84 . 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 ht rig py Co t.

agen lksw Vo by

AG.

17 - Camshaft ❑ Checking axial clearance ⇒ page 76 . ❑ Removing and installing ⇒ page 80 . ❑ 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 ❑ Removing and installing ⇒ page 169 .

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ss

gen AG does not gu ara nte eo ra c

ility ab y li an pt ce

11 - Valve guide ❑ Checking ⇒ page 76 .

AG. agen ksw l o yV db ise r tho au

Prote cted by c o py rig ht . C op yi

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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Checking camshaft axial clearance

Special tools and workshop equipment required ♦ 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

Special tools and workshop equipment required

76

Rep. Gr.15 - Cylinder head, valve gear

AG.

35.95 6.980 89.95 45

agen lksw Vo by

2.2

mm mm mm ∠°

Exhaust valve

Prote cted by c o py rig ht . C op yi

∅a ∅b c α

Inlet valve

ht rig py Co t.

Dimension

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

Wear limit: max. 0.15 mm

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d removed andisewith first, third and last nte r o eo h ut ra a c s s

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

♦ 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

ht rig py Co t.

r fo ng

– Cylinder head must be renewed if the rock is greater than the wear limit.

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

♦ Universal dial gauge bracket -VW 387-

2. Valve gear

77

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

Renewing valve stem seals

Special tools and workshop 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

Rep. Gr.15 - Cylinder head, valve gear

AG.

Removing

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

2.3.1

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦ Fitting tool -3129-

ility ab y li an pt ce

♦ Puller -3047 A-

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ht rig py Co t.

2.3

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Installing

rrectness of i t to the co nf o r m spec atio h re n in wit

2.3.2

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

– 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.

thi sd o cu m en

ht rig py Co t.

agen lksw Vo by

2. Valve gear

79

AG.

Prote cted by

c o p yri gh t . C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ AG. Volkswagen AG d agen oes w01.2009 4-cylinder diesel engine (1.9 l engine) - Edition s k no l o

Removing and installing camshaft

ility ab y li an pt ce

Special tools and workshop equipment required

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

2.4

t gu ara nte eo ra c

yV db ir se ho ut a ss

♦ Puller -T10052-

rrectness of i t to the co nf o r m spec atio h re n in wit

♦ Counterhold tool -T10051-

♦ Torque wrench (5…50 Nm) -V.A.G 1331♦ Torque wrench (40…200 Nm) -V.A.G 1332-

♦ Sealant -AMV 174 004 01-

Prote cted by

– Pull camshaft toothed belt pulley off hub.

80

Rep. Gr.15 - Cylinder head, valve gear

AG.

– Remove securing bolts for camshaft toothed belt pulley -1-.

agen lksw Vo by

c o p yri gh t . C op yi

– Remove toothed belt. ⇒ page 50

ht rig py Co t.

Removing

thi sd o cu m en

2.4.1

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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-. agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

AG.

Note

ht rig py Co t.

– Remove rocker arm shafts.

rrectness of i t to the co nform spec at i h re o n wit in t his

– Apply puller -T10052- and screw securing bolts -1- into hub.

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

ss

s no t gu ara nte eo ra c

ks Vol by d e ris ho t au

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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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 m ot com

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Oil bearing shell running surfaces.

ility ab y li an pt ce

un le

♦

n AG. Volkswagen AG do es n wage s k l ot g Vo (mark). Do not interchange used bearing dshells ua by ran ir se tee o 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.

agen lksw Vo by

c o p yri gh t . C op yi

– Install camshaft oil seal. ⇒ page 84

Prote cted by

– 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

Rep. Gr.15 - Cylinder head, valve gear

AG.

– Fit hub onto camshaft.

ht rig py Co t.

– Tighten bearing caps 5, 1 and 3 likewise to 8 Nm +1/4 turn (90°).

do c um en

r te o iva r rp fo g n

♦ Bearing cap 5 must align flush with outer edge of cylinder

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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. n AG. Volkswagen A

G do es n ot g ua d ran e ris o Screw new adjustment screws into rocker arms hand-tight andtee o h t ra fit lock nut. ss au c ge swa

k 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 .

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

Note

ht rig py Co t.

r fo ng

– Install cylinder head cover.

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Fit the dial gauge onto the adjustment screw of the unit injector as shown.

ility ab y li an pt ce

un le

–

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.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2.5

Removing and installing camshaft oil seal

Special tools and workshop equipment required ♦ Fitting sleeves -10-203♦ Oil seal extractor -3240♦ Torque wrench -V.A.G 1331♦ Torque wrench -V.A.G 1332♦ Bolt M12×1.5 × 65

Removing

– Remove toothed belt. ⇒ page 50 – 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.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Rep. Gr.15 - Cylinder head, valve gear

ht rig py Co t.

84

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 e ng

rrectness of i t to the co nf o r m spec atio h re n in wit

2.5.1

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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

rrectness of i t to the co nf o r m spec atio h re n in wit

Note

Installing

ility ab y li an pt ce

2.5.2

AG. Volkswagen AG d agen oes ksw not l o V y b Golf 2004 ➤ g, uGolf ara Plus 2005 ➤ d nte ise r o 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 eo h t u ra a c s s

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 .

thi sd o cu m en

2. Valve gear

85

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

1

Engine oil Note

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

Lubrication

rrectness of i t to the co nf o r m spec atio h re n in wit

17 –

ility ab y li an pt ce

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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

agen lksw Vo by

Oil capacities

Prote cted by c o py rig ht . C op yi

1.1

thi sd o cu m en

Checking engine oil level ⇒ page 86

ht rig py Co t.

Oil capacities ⇒ page 86

Golf 2004 ➤ , Golf Plus 2005 ➤ - 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 fo ng

AG.

2 - Sealing flange ❑ With seal. ❑ Must be positioned on dowel sleeves. ❑ Removing and installing ⇒ 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 .

agen lksw Vo by

1 - 15 Nm

Assembly overview - oil pump, sump ht rig py Co t.

2.1

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Caution

ility ab y li an pt ce

un le

2

AG. Volkswagen AG d agen 4-cylinder diesel oeengine (1.9 l engine) s no ksw l o t gu V by ara d e nte ris eo ho t u ra a c s s

Prote cted by c o p yri gh t. C op yi

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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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

n AG 15 - Oil drain plug, 30 Nm wage olks V ❑ Renew ed by is or

16 - 10 Nmauth

18 - Seal ❑ Renew

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

17 - Oil level and oil temperature sender -G266❑ Black connector, 3-pin.

ility ab y li an pt ce

ss

does not gu ara nte eo ra c

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 r fo ng

2.2

AG.

Note

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

25 - Oil spray jet ❑ For piston cooling

Removing and installing sump

Special tools and workshop equipment required

88

Rep. Gr.17 - Lubrication

ht rig py Co t.

24 - 25 Nm ❑ Insert without sealant.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ♦ Torque wrench -V.A.G 1331-

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

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 ab y li an pt ce

un le

♦ Hexagon key extension, 5 mm -3249-

♦ Hand drill with plastic brush attachment ♦ Silicone sealant -D176404A2-

♦ Flat scraper

Removing

– Remove insulation tray. ⇒ General body repairs, exterior; Rep. Gr. 50 ; Body - front; Assembly overview . agen lksw Vo by

AG.

Note

Prote cted by c o py rig ht . C op yi

– Drain engine oil.

do c um en

2.2.1

ht rig py Co t.

♦ Eye protection

r te o iva r rp fo g n

♦ 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.

2. Parts of lubrication system

89

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Remove sealant residue on sump using a rotating brush, e.g. an electric drill with a plastic brush attachment (wear safety goggles). – Clean sealing surfaces. They must be free of oil and grease.

2.2.2

Installing

Note ♦ Observe expiry date of sealing compound. ♦ The oil sump must be installed within 5 minutes of applying

silicone sealing compound.

– Cut off tube nozzle at forward marking (approx. 3 mm nozzle ∅). – Apply silicone sealing compound, as shown, to clean sealing surface on sump. Sealing compound bead must be: ♦ 2…3 mm thick. ♦ Run bead along inner side of bolt holes -arrows-. Note

The sealant bead must not be thicker, otherwise excess sealing compound will enter the oil sump and may block the oil suction n AG. Volkswagen AG do es n wage line strainer. o olks

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Rep. Gr.17 - Lubrication

thi sd o cu m en

90

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

ility ab y li an pt ce

ss

t gu ara nte eo ra c

yV db ise r tho au

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

– 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.

thi sd o cu m en

Note

rrectness of i t to the co nf o r m spec atio h re n in wit

– 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.)

ility ab y li an pt ce

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

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ht rig py Co t.

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

Further assembly is basically the reverse of the dismantling se‐ quence.

2. Parts of lubrication system

91

AG.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

3

Oil filter bracket, oil pressure, engine oil cooler and oil supply line

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

3.1

Assembly overview - oil filter bracket and engine oil cooler

1 - Oil filter bracket

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

4 - Seal ❑ Renew

rrectness of i t to the co nform spec at i h re o n wit in t his

3 - Gasket ❑ Renew

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

ility ab y li an pt ce

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. ❑ Removing and installing ⇒ 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

Rep. Gr.17 - Lubrication

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 .

agen lksw Vo by

c o p yri gh t . C op yi

10 - Plug, 10 Nm ❑ If seal is leaking, nip open and renew.

do c um en

9 - Oil filter element ❑ Ensure "Top" is upper‐ most when fitting

ht rig py Co t.

8 - Seal ❑ Renew

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ❑ Checking engine oil cooler for leaks ⇒ page 112 15 - Gasket ❑ Renew. 17 - 10 Nm

♦ Voltage tester V.A.G 1527 B-

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

3.2.1

do c um en

r te o iva r rp fo g n

♦ Auxiliary measuring set V.A.G 1594 A-

es, in part or in w l purpos hole ercia , is n m ot com

♦ Oil pressure tester V.A.G 1342-

rrectness of i t to the co nform spec a t i h re o n in wit thi s

Special tools and workshop equipment required

pe rm itte d

un le

Checking oil pressure and oil pressure switch

ility ab y li an pt ce

3.2

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ht rig py Co t.

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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Remove oil pressure switch -F1- and screw into tester. – Screw tester into oil filter bracket in place of oil pressure AG. Volkswagen AG d agen oes switch. n lksw o yV

b ed wire of tester to earth (-). – Connect brown ris

tho

ot g ua ran tee o ac battery positive r(+)

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

ility ab y li an pt ce

u – 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 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

– At 0.55…0.85 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 cted by c o py rig ht . C op yi

4 - 10 Nm

5 - Bracket

8 - Union nut, 22 Nm

94

Rep. Gr.17 - Lubrication

AG.

7 - 10 Nm

agen lksw Vo by

6 - Union nut, 22 Nm

ht rig py Co t.

r fo ng

3 - Oil supply line ❑ To turbocharger.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

3.4

Removing and installing oil supply line to turbocharger

Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-

3.4.1 –

Removing

AG. Volkswagen AG d agen oes ksw not l o Remove engine cover. ⇒ page 4 To do this, pull V engine cover gu by ara d e upwards abruptly at front -arrows A- and then pull forwards out nte is r o eo h of rear fastening -arrow B-. ut ra a c s s

– Remove bolt -arrow A- and pull air filter housing upwards out of mounting. – Remove insulation tray. ⇒ General body repairs, exterior; Rep. Gr. 50 ; Body - front; Assembly overview . – Loosen securing bolts for retaining clips. – Loosen oil supply line union nuts on oil filter bracket and tur‐ bocharger.

agen lksw Vo by

AG.

Installing

Prote cted by c o p yri gh t. C op yi

3.4.2

ht rig py Co t.

r fo ng

– Remove oil supply line.

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

ility ab y li an pt ce

– Remove air filter housing with air mass meter and connecting 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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

– 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

Rep. Gr.17 - Lubrication

ht rig py Co t.

– Start union nuts for oil supply line on connections.

thi sd o cu m en

– Loosen securing nut -2- from retainer -5-.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

19 –

Cooling

1

Parts of cooling system 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.

Note ♦ When the engine is warm, the cooling system is under pres‐

AG. Volkswagen AG d sure. If necessary, release pressure before beginning agen repair oes ksw not l o work. gu yV b ed

ara nte e

ris In case of repair, ♦ Hoses are secured with spring-type clips. ho

t au ss

un le

ility ab y li an pt ce

♦ Spring-type clip pliers -VAS 5024- or hose clip pliers -

or ac

pe rm itte d

V.A.G 1921- are recommended for fitting spring-type clips.

♦ When installing coolant hoses, route stress-free so that they

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

do not come into contact with other components (observe markings on coolant connection and hose).

ht rig py Co t.

only use spring-type clips.

1. Parts of cooling system

97

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Perform leakage test of cooling system using cooling system test‐ er -V.A.G 1274- and adapters adapter -V.A.G 1274/8- and adapt‐ er -V.A.G 1274/9- . n AG. Volkswagen A

G do es n ot g ua ran tee or ac

ge swa

k Vol . Parts of cooling system - body side ⇒ pageby98 d se

i or page 99 Parts of cooling system - engine sideth⇒ au

un le

ility ab y li an pt ce

ss page 101 Coolant hose schematic diagram ⇒

pe rm itte d

Draining and filling with coolant ⇒ page 102 es, in part or in w l purpos hole ercia , is n m ot com

Removing and installing radiator ⇒ page 105 .

rrectness of i t to the co nform spec a t i h re o n in wit thi s

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 r te o iva r rp fo g n

Prote cted by

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

agen lksw Vo by

c o p yri gh t. C op yi

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.

ht rig py Co t.

3 - Cooler ❑ Removing and installing ⇒ page 105 . ❑ After renewing, renew entire coolant

do c um en

2 - O-ring ❑ Renew if damaged.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 15 - Retaining clip ❑ Check for secure seating. 16 - Radiator outlet coolant temperature sender -G83-

1.2

Parts of cooling system, engine side

1 - To top of expansion tank ❑ Coolant hose schematic diagram ⇒ page 101

11 - 40 Nm 12 - T-piece

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

10 - To heat exchanger ❑ Coolant hose schematic diagram ⇒ page 101

do c um en

9 - 10 Nm

Prote cted by

8 - Connection

AG.

7 - To exhaust gas recircula‐ tion cooler ❑ Coolant hose schematic diagram ⇒ page 101

agen lksw Vo by

6 - Coolant temperature send‐ er -G62❑ With coolant tempera‐ ture display sender -G2-

rrectness of i t to the co nform spec at i h re o n wit in t his

5 - Retaining clip ❑ Check for secure seat‐ ing.

c o p yri gh t. C op yi

4 - O-ring ❑ Renew.

ility ab y li an pt ce

3 - To bypass flap ❑ Coolant hose schematic diagram ⇒ page 101

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

ht rig py Co t.

2 - Upper coolant pipe ❑ Bolted to cylinder head cover

13 - To bypass flap ❑ Coolant hose schematic diagram ⇒ page 101 14 - T-piece 15 - To top of radiator ❑ Coolant hose schematic diagram ⇒ page 101 16 - 15 Nm 17 - To bottom of expansion tank ❑ Coolant hose schematic diagram ⇒ page 101 18 - Coolant pipe 19 - To bottom of radiator ❑ Coolant hose schematic diagram ⇒ page 101

1. Parts of cooling system

99

22 - To heat exchanger ❑ Coolant hose schematic diagram ⇒ page 101 . 24 - 10 Nm

25 - To auxiliary heater ❑ Coolant hose schematic diagram ⇒ page 101 .

28 - Engine oil cooler ❑ Removing and installing ⇒ page 92 . 29 - Coolant pump ❑ Check for ease of movement. ❑ Note installation position. ❑ Removing and installing ⇒ page 106 .

100

Rep. Gr.19 - Cooling

AG.

27 - To exhaust gas recirculation cooler ❑ Coolant hose schematic diagram ⇒ page 101 .

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

26 - Coolant pipe

ht rig py Co t.

23 - Rear coolant pipe

rrectness of i t to the co nform spec at i h re o n wit in t his

21 - Thermostat ❑ Removing and installing ⇒ 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.

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

20 - Connection ❑ For thermostat.

ility ab y li an pt ce

Golf 2004 4-cylinder

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo ➤ , Golf Plus 2005 ➤uth ra a c s diesel engine (1.9 l sengine) - Edition 01.2009

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.3

Coolant hose schematic diagram

1 - Expansion tank 2 - Bypass flap 3 - Exhaust gas recirculation cooler

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

4 - Heat exchanger for heater unit

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

5 - Cylinder head/cylinder block

rrectness of i t to the co nform spec at i h re o n wit in t his

6 - Gearbox oil cooler ❑ For gear oil ❑ Only on vehicles with automatic gearbox 7 - Upper coolant hose 8 - Cooler

9 - Lower coolant hose 10 - Engine oil cooler

11 - Coolant pump and ther‐ mostat

do c um en

12 - Auxiliary heater ❑ Vehicles with optional equipment only.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Note

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

1. Parts of cooling system

101

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.4

Draining and filling with coolant

Special tools and workshop equipment required ♦ Refractometer -T10007-wagen AG. Volkswagen AG doe

s no t gu ara nte eo ra c

ks Vol

y ♦ Drip tray -V.A.G e1306db is or

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

ility ab y li an pt ce

th pliers ♦ Spring-typeauclip s VAS 5024s A-

♦ Cooling system charge unit -VAS 6096-

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

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. – Remove insulation tray. ⇒ General body repairs, exterior; Rep. Gr. 50 ; Body - front; Assembly overview .

102

Rep. Gr.19 - Cooling

thi sd o cu m en

1.4.1

rrectness of i t to the co nf o r m spec atio h re n in wit

♦ Adapter -V.A.G 1274/8-

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 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 r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

do c um en

1. Parts of cooling system

103

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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 n AG. Volkswagen AG do the current anti-freeze concentration. e wage

s no t gu ara nte eo ra c

ks Vol

by ♦ 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 t to the co nform spec at i h re o n wit in t 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; Rep. Gr. 50 ; Body - front; Assembly overview . – 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

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Rep. Gr.19 - Cooling

ht rig py Co t.

104

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Recommended mixture ratios:

ility ab y li an pt ce

au ss

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.5

Removing and installing radiator

Special tools and workshop 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 wage

s no t gu ara nte eo ra c

ks Vol

y ♦ Cooling system d b charge unit ise r -VAS 6096ho

ht rig py Co t.

agen lksw Vo by

c o p yri gh t. C op yi

Removing

thi sd o cu m en

AG.

Prote cted by

1.5.1

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

ility ab y li an pt ce

t au ss

– Bring lock carrier into service position. ⇒ General body re‐ pairs, exterior; Rep. Gr. 50 ; Body - front; Lock carrier service position . – Drain coolant. ⇒ page 102 – Pull coolant hoses off radiator. – Separate connector for radiator fan. – Remove radiator securing bolts. – Remove radiator downwards.

1.5.2

Installing

Installation is carried out in the reverse order. When installing, note the following: – Fill with coolant. ⇒ page 102

1. Parts of cooling system

105

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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 ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

♦ Spring-type clip pliers VAS 5024 A-

Prote cted by c o p yri gh t. C op yi

Removing

Note

Always renew seals and gaskets. – Drain coolant ⇒ page 102 . – Remove poly V-belt ⇒ page 13 . – Remove toothed belt ⇒ page 50 .

106

Rep. Gr.19 - Cooling

do c um en

1.6.1

rrectness of i t to the co nform spec at i h re o n wit in t his

♦ Torque wrench V.A.G 1331-

AG.

♦ Drip tray -V.A.G 1306-

agen lksw Vo by

♦ Refractometer -T10007-

ility ab y li an pt ce

Special tools and workshop equipment required

ht rig py Co t.

1.6

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Remove securing bolts -1- for coolant pump -2- and carefully remove coolant pump.

1.6.2

Installing

Installation is carried out in the reverse order. When 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 . – Install poly V-belt ⇒ page 13 .

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

do c um en

ht rig py Co t.

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 ab y li an pt ce

un le

– Fill cooling system with coolant ⇒ page 102 .

agen lksw Vo by

AG.

1. Parts of cooling system

107

Prote cted by c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.7

Removing and installing thermostat

Special tools and workshop 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 l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Removing

rrectness of i t to the co nform spec at i h re o n wit in t his

1.7.1

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Always renew seals and gaskets. – Drain coolant. ⇒ page 102

– Remove alternator. ⇒ Electrical system; Rep. Gr. 27 ; Re‐ moving and installing alternator with poly V-belt . – Pull coolant hose off connection.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Rep. Gr.19 - Cooling

do c um en

108

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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

Installation is carried out in the reverse order. When installing, note the following: – Moisten new O-ring -3- with coolant. – Insert thermostat -4- into connection -2- and turn 1/4 turn (90 °) to right. Note

The brace on the thermostat must be almost vertical. olksw –

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

un le

ility ab y li an pt ce

– Replenish coolant. ⇒ page 102

ht rig py Co t.

–

agen AG AG. V does agen ksw not l o V gu y Insert connection -2- with thermostat -4- in cylinder ara block. db e nte is r o eo h Tightenut securing bolts -1- to 15 Nm. ra a c s s

1. Parts of cooling system

109

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.8

Checking cooling system for leaks

Special tools and workshop 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

Rep. Gr.19 - Cooling

AG.

•

agen lksw Vo by

c o p yri gh t. C op yi

Test prerequisite

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

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

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

ht rig py Co t.

♦ Adapter for cooling system tester -V.A.G 1274/8-

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 ab y li an pt ce

of max. 1.6 bar.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

–

. Volkswagen AG gen AG doe swa k not l o Attach cooling system tester -V.A.G 1274- withscooling V gu system y b ara d-V.A.G tester adapter 1274/9to cap. e nte is r o eo h t upump ra a Use hand on cooling system tester to create a pressure c s s

rrectness of i t to the co nform spec at i h re o n wit in t his

– 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 c um en

1. Parts of cooling system

111

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 Edition 01.2009 olkswagen- A AG.l Vengine)

1.9

n wage olks V by ed ris o th au

G do es n ot g ua ran tee or ac

Checking engine oil cooler for leaks ss

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

ility ab y li an pt ce

Special tools and workshop equipment required ♦ Refractometer -T10007-

rrectness of i t to the co nf o r m spec atio h re n in wit

♦ Hose clamps up to Ø 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-

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

♦ Torque wrench -V.A.G 1331-

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

112

Rep. Gr.19 - Cooling

thi sd o cu m en

Special tools and workshop equipment required

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ♦ Cap -1J0 121 324♦ Coolant hose -251 265 056♦ Screw clamp Test prerequisite: •

Engine cold

Test procedure – Remove noise insulation tray ⇒ General body repairs, exteri‐ or; Rep. Gr. 50 ; Body - front; Assembly overview - noise 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. G. Volkswagen nA wage

AG do es n ot g ua b d ran e tee ris Attach cooling system tester -V.A.G 1274with cooling system o h t or 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.

ility ab y li an pt ce

rrectness of i t to the co nform spec at i h re o n wit in t his

If pressure drops:

– Renew oil cooler.

Assembly is carried out in the reverse order, note the following: – Check coolant level, if necessary replenish coolant.

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

olksmarking. – Fill expansion tank up to “Max” yV

1. Parts of cooling system

113

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

20 –

Fuel supply system

1

Safety precautions when working on fuel supply system 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

ility ab y li an pt ce

WARNING

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

rrectness of i t to the co nf o r m spec atio h re n in wit

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. ♦ The fuel and the fuel lines in the fuel system can become 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.

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

When removing and installing fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel tank, observe the following:

ht rig py Co t.

♦ Wear eye and hand protection when performing any type of repair work on the fuel system!

thi sd o cu m en

♦ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2

Rules for cleanliness

When working on the fuel supply and injection systems, pay care‐ ful attention to the following “6 rules” for cleanliness: ♦ Thoroughly clean all unions and adjacent areas before dis‐ n AG. Volkswagen AG do connecting. e wage s no t

ks Vol

gu y ara ♦ Place removed parts eon d b a clean surface and cover. Do not use nte s i r fluffy cloths! o e h

t au

un le

pe rm itte d

es, in part or in w l purpos hole ercia , is n m ot com

♦ When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely nec‐ essary.

do c um en

ht rig py Co t.

r te o iva r rp fo g n

♦ 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 t to the co nform spec a t i h re o n in wit thi s

♦ 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 ac ility ab y li an pt ce

♦ Carefully coverss opened components or seal if repairs cannot be carried out immediately.

2. Rules for cleanliness

115

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

3

Fuel tank, vehicles with front-wheel drive

Observe safety precautions ⇒ page 114 . Observe rules for cleanliness ⇒ page 115 . Assembly overview - fuel tank ⇒ page 116 . Emptying fuel tank ⇒ page 117 . Removing and installing fuel tank ⇒ page 121 . Removing and installing fuel delivery unit ⇒ page 123 . Removing and installing fuel gauge sender ⇒ page 124 . Checking fuel pump ⇒ page 125 .

3.1

Assembly overview - fuel tank

1 - Sealing cap 2 - 1.5 Nm 3 - Earth connection AG. Volkswagen AG d ❑ Check for secure seat‐ agen oes ksw not l ing. o V g 4 - 10 Nm un le

ua ran tee

or ac ility ab y li an pt ce

5 - Wiring duct

y db ise r tho au s s

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

8 - Clamping washer

Prote cted by

11 - Seal ❑ Renew if damaged. ❑ Moisten with fuel when installing

116

Rep. Gr.20 - Fuel supply system

AG.

10 - Heat shield ❑ For fuel tank.

agen lksw Vo by

c o p yri gh t. C op yi

9 - Securing strap ❑ Note installation posi‐ tion.

ht rig py Co t.

r fo ng

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 s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

6 - Fuel tank ❑ When removing, sup‐ port using engine and gearbox jack -V.A.G 1383/A- . ❑ Removing and installing ⇒ page 121 .

AG. Volkswagen does Plus 2005 ➤ agen Golf 2004 ➤A,GGolf ksw not l o V gu 01.2009 4-cylinder ddiesel engine (1.9 l engine) - Edition by ara e nte is r o eo h ut ra a c s s

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 r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

12 - Fuel delivery unit ❑ With fuel gauge sender (G). ❑ Note installation position of flange on fuel tank ⇒ page 117 . ❑ Removing and installing ⇒ page 123 . ❑ Checking fuel pump ⇒ page 125 . ❑ 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- . ❑ Specified torque: 110 Nm.

ht rig py Co t.

agen lksw Vo by

AG.

15 - Return line ❑ From fuel cooler ❑ Blue or with blue marking. ❑ Clipped onto fuel tank ❑ Check for secure seating. ❑ To pull off flange, press release button on connecting piece.

do c um en

14 - Supply line ❑ To fuel filter ❑ Clipped onto fuel tank ❑ Check for secure seating. ❑ Black ❑ To pull off flange, press release button on connecting piece. Prote cted by c o py rig ht . C op yi

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

Special tools and workshop equipment required

3. Fuel tank, vehicles with front-wheel drive

117

olkswagen AG en AG. V does not gu ara nte eo ra c

wag Golf 2004 ➤ , Golf Plus 2005 ➤ olks yV b d 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 se

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

ility ab y li an pt ce

♦ Fuel extractor -VAS 5190-

ri ho ut a 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

Special tools and workshop equipment required ♦ 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

Rep. Gr.20 - Fuel supply system

AG.

Emptying fuel tank if more than 3/4 full ⇒ page 120

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

Emptying fuel tank, bleeding fuel system when fuel pump is intact ⇒ page 118 .

ht rig py Co t.

– Note safety precautions before beginning work ⇒ page 114 .

thi sd o cu m en

♦ Torque wrench (40…200 Nm) -V.A.G 1332-

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Pull off supply line -arrow- and catch escaping fuel with a cloth.

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

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

– Connect fuel extractor -VAS 5190- with adapter for fuel ex‐ tractor -VAS 5190 /3 - to fuel supply line.

agen lksw Vo by

c o p yri gh t. C op yi

The fuel pump is being activated when engine is not running.

ht rig py Co t.

Note

thi sd o cu m en

– Connect a diagnostic tester.

AG.

Prote cted by

– 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.

– Connect a diagnostic tester. – Perform the function “Bleeding fuel system” in “guided func‐ tions”.

3. Fuel tank, vehicles with front-wheel drive

119

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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-.

– Remove filler cap from fuel tank filler neck. – Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel n AG. Volkswagen AG do filler neck. e wage

s no t gu ara nte eo ra c

ks Vol

y – Push extraction hose into fuel tank until marking eon d b hose s i r -arrow- coincides with shaft end. tho

Note

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 r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

au ss

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.

Prote cted by c o p yri gh t. C op yi

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

Rep. Gr.20 - Fuel supply system

AG.

⇒ page 120

agen lksw Vo by

♦ If the fuel tank has to be drained fully, proceed as follows:

ht rig py Co t.

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

do c um en

Note

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Remove cover from fuel delivery unit. 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. – Pull connector and fuel lines off flange. Note

Press buttons on hose couplings to do this. – Open locking ring using fuel tank sender wrench -T10202- . – Lift sender flange. – Insert extraction hose of fuel extractor -VAS 5190- as deeply as possible into fuel tank and extract fuel. If fuel tank needed only to be emptied, reinstall sender flange.

3.3

Removing and installing fuel tankgen AG. Volkswagen AG a lksw

Special tools and workshop equipment requiredby Vo ed ris o h t au ss

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 ab y li an pt ce

un le

♦ Torque wrench -V.A.G 1331-

does not gu ara nte eo ra c

do c um en

ht rig py Co t.

r te o iva r rp fo g n

♦ Engine and gearbox jack -V.A.G 1383/A-

agen lksw Vo by

AG.

3. Fuel tank, vehicles with front-wheel drive

121

Prote cted by

c o p yri gh t. C op yi

Removing

ility ab y li an pt ce

3.3.1

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) -

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or Edition 01.2009 u ac a ss

– Note safety precautions before beginning work ⇒ page 114 .

Note

rrectness of i t to the co nform spec at i h re o n wit in t his

Observe rules for cleanliness ⇒ page 115 .

♦ 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

Press buttons on hose couplings to do this. – 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

Installation is carried out in the reverse sequence of removal. In the process, note the following:

122

Rep. Gr.20 - Fuel supply system

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 lksw Vo by

– Pull connector off flange.

c o p yri gh t . C op yi

– Remove cover from fuel delivery unit.

do c um en

– 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

ht rig py Co t.

– Empty fuel tank ⇒ page 117 .

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ♦ Install breather and fuel hoses free of kinks. ♦ 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). ♦ Clip fuel lines onto fuel tank.

3.4

Removing and installing fuel delivery unit

Special tools and workshop equipment required ♦ Fuel tank sender unit tool -T10202-

♦ Torque wrench -V.A.G 1332-

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

Removing

rrectness of i t to the co nf o r m spec atio h re n in wit

3.4.1

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

– Note safety precautions before beginning work ⇒ page 114 . Observe rules for cleanliness ⇒ page 115 . – First check whether a coded radio is fitted. If so, obtain antitheft coding. – With the ignition switched off, disconnect battery earth strap. – The fuel tank must not be more than 3/4 full when removing the suction-jet pump. Drain fuel tank if necessary ⇒ page 117 . – Fold rear seats forwards.

c o p yri gh t . C op yi

agen lksw Vo by

– Pull connector and fuel lines off flange.

ht rig py Co t.

– Remove cover from fuel delivery unit.

thi sd o cu m en

– 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

3. Fuel tank, vehicles with front-wheel drive

123

AG.

Prote cted by

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Note

Press buttons on hose couplings to do this. WARNING

♦ The fuel and the fuel lines in the fuel system can become 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 of repair work on the fuel system! – 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 ol s V of removal. by

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Note

ility ab y li an pt ce

ed ris ho t au ss

does not gu ara nte eo ra c

♦ 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.

♦ Ensure that fuel hose connections are tight. ♦ 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 cted by

Rep. Gr.20 - Fuel supply system

agen lksw Vo by

124

c o p yri gh t . C op yi

– Remove fuel delivery unit. ⇒ page 123

do c um en

Removing

ht rig py Co t.

3.5

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran voltage supply of fuel pump ir se -G6- ⇒ page 125 tee o h t or u ac a current consumption sof fuel pump -G6⇒ page 126 s

ility ab y li an pt ce

3.6.1

Checking fuel pump

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

3.6

Checking function and voltage supply

Special tools and workshop equipment required

rrectness of i t to the co nf o r m spec atio h re 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.

agen lksw Vo by

c o p yri gh t . C op yi

•

ht rig py Co t.

Test prerequisites

thi sd o cu m en

♦ Auxiliary measuring set -V.A.G 1594 C-

AG.

Prote cted by

– Fold rear seats forwards. – 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 – Remove cover from fuel delivery unit. – 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.

3. Fuel tank, vehicles with front-wheel drive

125

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 n AG. Volkswagen AG do e wage

s no olks 1527 B- to outer contacts – Connect diode test lamp -V.A.G tof gu yV b d 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): – Remove fuel delivery unit. ⇒ page 123 – 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

– Pull 4-pin connector off fuel delivery unit flange. r fo ng

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

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: – Renew fuel delivery unit. ⇒ page 123

126

Rep. Gr.20 - Fuel supply system

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 h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

If LED does not light up

ra c ility ab y li an pt ce

s The LED must light up for about 2 seconds. – Switch on ignition.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

4

Fuel tank, vehicles with four-wheel drive

Observe safety precautions ⇒ page 114 . Observe rules for cleanliness ⇒ page 115 . Assembly overview - fuel tank ⇒ page 127 . Emptying fuel tank ⇒ page 128 . Removing and installing fuel tank ⇒ page 132 . Removing and installing fuel gauge sender 2 -G169⇒ page 135 . Removing and installing suction jet pump ⇒ page 137 Checking fuel pump ⇒ page 125 .

4.1 1

Assembly overview - fuel tank Volkswa

2 - Return line ❑ Blue ❑ Check for secure seat‐ ing. 3 - Seal ❑ Renew if damaged. ❑ When installing, fit dry in fuel tank opening ❑ Moisten with fuel only when installing flange.

r fo ng

ht rig py Co t.

4 - Fuel delivery unit ❑ Removing and installing ⇒ page 123 . ❑ Checking fuel pump ⇒ page 125 . ❑ Note installation posi‐ tion on fuel tank ⇒ page 128 . ❑ With fuel gauge sender -G❑ Removing and installing fuel gauge sender ⇒ page 124 .

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

❑ Check for secure seat‐ ing.

gen AG does not gu ara nte eo ra c ility ab y li an pt ce

AG. agen ksw l o yV db - Supply line ise r tho ❑ Black au s s

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

5 - Locking ring, 110 Nm ❑ Check for secure seat‐ 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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 7 - Cap ❑ Renew if damaged. 8 - Securing bolt ❑ Tighten to 1.5 Nm. 9 - Earth connection ❑ Check for secure seating. 10 - 10 Nm

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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

rrectness of i t to the co nf o r m spec atio h re n in wit

12 - Fuel gauge sender 2 -G169-

ility ab y li an pt ce

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- . ❑ Removing and installing ⇒ page 132 . 14 - Securing strap ❑ Note installation position.

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

Special tools and workshop equipment required ♦ Fuel extractor -VAS 5190-

128

Rep. Gr.20 - Fuel supply system

AG.

Note

agen lksw Vo by

c o p yri gh t. C op yi

The marking on the flange must align with the marking on the fuel tank -arrow-.

ht rig py Co t.

Installation position of flange for fuel delivery unit and fuel gauge sender 2 -G169-

thi sd o cu m en

16 - Heat shield ❑ Riveted to exhaust pipe mounting

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ♦ Fuel tank sender unit tool -T10202-

♦ Torque wrench (40…200 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

Special tools and workshop equipment required ♦ Diagnostic tester ♦ Fuel extractor -VAS 5190-

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.

ht rig py Co t.

r fo ng

– Pull off supply line -arrow- and catch escaping fuel with a cloth.

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

WARNING

un le

♦ Adapter for fuel extraction -VAS

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o 5190 /3 eo h t u ra a c s s

agen lksw Vo by

AG.

4. Fuel tank, vehicles with four-wheel drive

129

Prote cted by

c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Connect fuel extractor -VAS 5190- with adapter for fuel ex‐ AG. Volkswagen AG d agen oes tractor -VAS 5190 /3 - to fuel supply line. n lksw

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Note

rrectness of i t to the co nform spec at i h re o n wit in t his

– Connect a diagnostic tester.

ility ab y li an pt ce

ss

ot g ua ran tee or ac

o yV db e ris tho au

The fuel pump is being activated when engine is not running. – Switch on ignition.

– Remove filler cap from fuel tank filler neck.

2) Low-pressure section

•

Fuel tank filled.

– Connect a diagnostic tester. – 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

Rep. Gr.20 - Fuel supply system

AG.

Bleeding fuel system

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

– Operate shut-off tap on fuel extractor -VAS 5190- , until the fuel tank is emptied.

ht rig py Co t.

If the fuel tank is emptied, “stop” the function to prevent the fuel pump from running “dry”.

do c um en

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

Golf 2004 ➤ , Golf Plus 2005 ➤ n AG. Volkswagen AG do els engine) wage diesel engine (1.9 4-cylinder - Edition 01.2009 s k no l o

ility ab y li an pt ce

–

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

–

t gu ara nte eo ra c

V by ed s i r 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 t to the co nf o r m spec atio h re n in wit

– Remove filler cap from fuel tank filler neck. – 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.

thi sd o cu m en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

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

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

4. Fuel tank, vehicles with four-wheel drive

131

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Pull connector and fuel lines off flange. Note

Press buttons on hose couplings to do this. – Open locking ring using

If fuel tank needed only to be emptied, reinstall sender flange.

4.3

Removing and installing fuel tank

Special tools and workshop equipment required

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

♦ Engine and gearbox jack -V.A.G 1383 A-

Remove fuel tank ⇒ page 132 .

4.3.1

Removing fuel tank

– Note safety precautions before beginning work ⇒ page 114 .

132

Rep. Gr.20 - Fuel supply system

ht rig py Co t.

r fo ng

♦ Torque wrench (5…50 Nm) -V.A.G 1331-

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Insert extraction hose of fuel extractor -VAS 5190- as deeply as possible into fuel tank and extract fuel.

ility ab y li an pt ce

un le

– Lift sender flange.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte fuel tank is sender wrench -T10202- . r o eo h ut ra a c s s

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Note

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

un le

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 ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Special tools and workshop equipment required

♦ Engine and gearbox jack -V.A.G 1383 A-

do c um en

r te o iva r rp fo g n

♦ Torque wrench (5…50 Nm) -V.A.G 1331-

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

– First check whether a coded radio is fitted. If so, obtain antitheft coding. Before disconnecting battery, open fuel tank flap and if necessary remove wheel lock adapter from luggage compartment. – With the ignition switched off, disconnect battery earth strap. ⇒ 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

4. Fuel tank, vehicles with four-wheel drive

133

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Unscrew filler neck from body -arrows- and unclip electrical wire from filler neck. – Remove bench seat ⇒ General body repairs, interior; Rep. 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 s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

– Remove centre and rear silencers.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

– 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

Rep. Gr.20 - Fuel supply system

AG.

– Pull off adapter cable on four-wheel drive control unit -J492- .

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

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.

ht rig py Co t.

WARNING

do c um en

Continuation for all vehicles:

r te o iva r rp fo g n

– Remove complete propshaft ⇒ Propshaft and rear final drive; Rep. Gr. 39 ; Repairing propshaft - Golf .

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 m ot p o c erm or e t a itte iv r du rp o nl f e ng

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw l o t gu axle. V The filler neck must beby“guided 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 a c s s

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

– 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. ♦ Do not interchange supply line and return line (return line blue or with blue marking, supply line black). ♦ 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

4. Fuel tank, vehicles with four-wheel drive

135

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Note ♦ Ensure that the fuel gauge sender is not bent. ♦ If necessary, drain fuel tank using fuel extractor -VAS 5190- .

⇒ page 128

♦ Note safety precautions before starting work ⇒ page 114 . ♦ Observe rules for cleanliness ⇒ page 115 . Removing: – First check whether a coded radio is fitted. If so, obtain antitheft coding. – With the ignition switched off, disconnect nbattery swagenstrap. . Volkearth AG do ge AG es n ⇒ Electrical system; Rep. Gr. 27 o; lkDisconnecting and con‐ swa ot g V y ua necting batteries . b d r 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 lksw Vo by

Prote cted by c o py rig ht . C op yi

Caution

When installing do not bend fuel gauge sender 2 -G169- float arm.

136

Rep. Gr.20 - Fuel supply system

AG.

– Place fuel gauge sender 2 -G169- in fuel tank.

ht rig py Co t.

Installing:

do c um en

r te o iva r rp fo g n

– Open locking ring using wrench -T10202- .

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

ility ab y li an pt ce

un le

– 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 r rp fo g 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 rig py Co t.

c o p yri gh t . C op yi

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. agen lksw Vo by

Prote cted by

♦ 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.

4. Fuel tank, vehicles with four-wheel drive

137

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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

Special tools and workshop equipment required ♦ 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

– Fold rear seats forwards. – 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 – Remove cover from fuel delivery unit. – Switch on ignition. Fuel pump must be heard to run. – Switch off ignition. If the fuel pump does not start:

AG.

Prote cted by

Rep. Gr.20 - Fuel supply system

agen lksw Vo by

c o p yri gh t. C op yi

138

ht rig py Co t.

r fo ng

– Pull 4-pin connector off fuel delivery unit flange.

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

4.6.2

not gu ara nte eo ra window heating, c

ility ab y li an pt ce

•

AG. Volkswagen AG d agen oes

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

•

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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): – Remove fuel delivery unit. ⇒ page 123 – 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

4.6.3

Checking current draw of fuel pump

– Pull 4-pin connector off fuel delivery unit flange. – 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 agen o –

.

un le

– Start engine and run at idling speed.

es n ot g ua ran tee or ac ility ab y li an pt ce

ksw Vol by d e 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

– Renew fuel delivery unit. ⇒ page 123

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Measure current draw of fuel pump: Specification: max. 7.5 Amperes.

agen lksw Vo by

4. Fuel tank, vehicles with four-wheel drive

139

AG.

Prote cted by

c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

5

Repairing fuel supply system

n AG. Volkswagen AG do es n ot g V ua by d ran e Removing and installing 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. ❑ Check for secure seat‐ ing. 2 - 8 Nm

r fo ng

Prote cted by

6 - Supply line ❑ To tandem pump ❑ White or with white marking. ❑ Check for secure seat‐ ing. 7 - Return line ❑ From tandem pump ❑ Blue marking ❑ Check for secure seat‐ ing. 8 - Fuel filter upper part 9 - Fuel temperature sender -G8110 - Seal ❑ Renew. 11 - Filter insert ❑ Observe change intervals. 12 - Seal ❑ Renew.

140

Rep. Gr.20 - Fuel supply system

AG.

5 - Seal ❑ Renew.

agen lksw Vo by

c o p yri gh t. C op yi

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 ❑ Check for secure seat‐ 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 c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Checking tandem pump ⇒ page 143

ility ab y li an pt ce

un le

gepage 140 . wa⇒ Assembly overview - fuel filter olks

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 his

17 - Retaining clip ❑ Check for secure seating.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

16 - Seal ❑ Renew.

ility ab y li an pt ce

15 - Bracket

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

18 - Return line ❑ With connection for fuel temperature sender -G8119 - From tandem pump

5.2

Removing and installing fuel cooler

Special tools and workshop equipment required

do c um en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

♦ Torque wrench -V.A.G 1331-

c o p yri gh t. C op yi

Removing – Note safety precautions before beginning work ⇒ page 114 . Observe rules for cleanliness ⇒ page 115 . 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 Installation is carried out in the reverse sequence of removal. In the process, note the following: ♦ Tighten fuel cooler securing nuts to 15 Nm.

5. Repairing fuel supply system

141

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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 l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Removing

rrectness of i t to the co nform spec at i h re o n wit in t his

5.3.1

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

Special tools and workshop equipment required

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Rep. Gr.20 - Fuel supply system

do c um en

142

ht rig py Co t.

♦ Release tool -T10238-

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Before removing accelerator pedal module, remove cover in footwell by removing plastic nuts -arrows-. – Lever out cap ⇒ Item 4 (page 142) using a screwdriver. – Remove bolt ⇒ Item 3 (page 142) .

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r Releasing accelerator pedal moduleho eo ut ra a c s – To remove accelerator pedals module, push release tool pe rm itte d

un le

ility ab y li an pt ce

T10238- (for right-hand drive vehicles release tool -T10240- ) into openings provided to stop.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

5.3.2

es, in part or in w l purpos hole ercia , is n m ot com

– Separate electrical connection and pull wire guide off accel‐ erator pedal module.

Installing

Installation is carried out in the reverse order. When installing, note the following: – Push electrical connector -1- onto accelerator pedal module. – Insert centring pin -6- into hole in floor of vehicle.

agen lksw Vo by

AG.

5.4

Prote cted by c o p yri gh t. C op yi

– Install steering column trim.

ht rig py Co t.

– Secure accelerator pedal module with bolt -2-, specified tor‐ que 10 Nm and fit cap -3-.

do c um en

r te o iva r rp fo g n

– 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

Special tools and workshop equipment required ♦ Vehicle diagnosis, testing and information system -VAS 5051-

5. Repairing fuel supply system

143

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 . Volkswage

ility ab y li an pt ce

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

♦

n AG d AG agen oes ksw not l o gu yV Diagnosis cable, 3 m withd bvoltage supply -VAS 5051/1- or di‐ ara nte ise voltage supply -VAS 5051/3agnosis cable, 5 m without r o eo h t u ra a c s s

♦ Tandem pump tester -VAS 5187-

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

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

Rep. Gr.20 - Fuel supply system

ht rig py Co t.

♦ Torque wrench -V.A.G 1331-

thi sd o cu m en

♦ Banjo bolt -5187/1A-

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Procedure – Remove plug -arrow-.

– Connect tandem pump tester -VAS 5187- as shown. – Start engine and run at idling speed. – 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 do agemeasured

es n ot g ua ran tee or ac

w olks

V by number block (key pad) and – Enter display group “1” using ed s i r confirm entry with Q key. ho

t au

– Increase engine speed to 4,000 rpm. – Observe pressure indicated on pressure gauge.

rrectness of i t to the co nf o r m spec atio h re n in 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:

agen lksw Vo by

Prote cted by

c o p yri gh t . C op yi

Note

ht rig py Co t.

– Renew tandem pump. ⇒ page 147

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 e ng

ility ab y li an pt ce

– Read engine idlingssspeed in display zone “1”.

After removing pressure tester, tighten plug to 25 Nm. Always renew seal.

5. Repairing fuel supply system

145

AG.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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. Special tools and workshop equipment required ♦ 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.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Rep. Gr.20 - Fuel supply system

do c um en

146

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 r erm o e t a itte riv du p or nl f e g n

– Seal fuel return union on tandem pump with a plug. Secure sealing plug with a spring-type clamp.

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage s k l ot g o Procedure yV ua b ran ed s i tee r hose (white marking) and fuel return hose – Pull fuel supply o h t or u ac a (blue marking) off tandem pump. ss

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Connect compressed air hose -1- (compressed air source) to charge air system tester -V.A.G 1687- . Note olkswagen AG en AG. V

does wag drain at water drain If there is water in the sight -6-. ksglass, nscrew ot Vol

– Open

gu ara nte eo ra c

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 o n wit in t his

The maximum test pressure is 1.3 bar and this must not be exceeded.

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

– Adjust pressure to 1.0 bar with pressure regulating valve -2-.

ility ab y li an pt ce

y db ise r valve -3-. tho au s s

5. Repairing fuel supply system

147

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Special tools and workshop 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 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

rrectness of i t to the co nf o r m spec atio h re n in wit

Removing Prote cted by c o p yri gh t. C op yi

– Connect hand vacuum pump with accessories -V.A.G 1390and water drainage container -V.A.G 1390/1- to return hose -2-.

agen lksw Vo by

AG.

– Operate hand vacuum pump until no more fuel comes out of return hose. Be careful that no fuel is sucked into hand vacuum pump. – Remove air filter housing with air mass meter and connecting pipe.

148

Rep. Gr.20 - Fuel supply system

ht rig py Co t.

– Pull supply hose (white marking) and return hose (blue mark‐ ing) off fuel filter.

thi sd o cu m en

5.5.1

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Remove bolt -arrow A- and pull air filter housing upwards out 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. . Volkscylinder AGfrom n – Remove tandem pump -4doe wage

s no t gu ara nte eo ra c

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

Installing

Installation is carried out in the reverse order. When 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 sd o cu m en

– Tighten lower securing bolts to 10 Nm.

rrectness of i t to the co nf o r m spec atio h re n in wit

5.5.2

ility ab y li an pt ce

ks Vol by d e ris tho u a ss

– Attach return hose (blue marking) to return connection -3- of tandem pump. ht rig py Co t.

c o p yri gh t. C op yi

– Attach supply hose (white marking) to supply connection -2and vacuum hose from brake servo -1- to tandem pump -4-. agen lksw Vo by

Prote cted by

– Connect supply hose (white marking) to fuel filter.

5. Repairing fuel supply system

149

AG.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Rep. Gr.20 - Fuel supply system

do c um en

150

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 r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

21 –

Turbocharging/supercharging

1

Charge air system with turbocharger

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

1.1

Safety precautions AG. Volkswagen AG d agen oes

ksw WARNING Vol

not gu by ara d e nte ris o eo When doinguthany repair work, especially in the engine compart‐ ra c ment, payss aattention to the following due to the cramped condi‐ pe rm itte d

un le

ility ab y li an pt ce

tions:

es, in part or in w l purpos hole ercia , is n m ot com

♦ Ensure that there is sufficient clearance to all moving or 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

Rules for cleanliness

When working on the turbocharger, pay careful attention to the following rules for cleanliness:

do c um en

r te o iva r rp fo g n

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 h re o n in wit thi s

♦ 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.

ht rig py Co t.

c o p yri gh t . C op yi

♦ Thoroughly clean all unions and adjacent areas before dis‐ connecting. agen lksw Vo by

AG.

Prote cted by

♦ Place removed parts on a clean surface and cover. Do not use fluffy cloths! ♦ Carefully cover opened components or seal if repairs cannot be carried out immediately. ♦ Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.). ♦ 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

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ♦ When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely nec‐ 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.

Observe rules for cleanliness ⇒ page 151 . Observe safety precautions ⇒ page 151 .

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Rep. Gr.21 - Turbocharging/supercharging

do c um en

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 m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Engine codes BJB, BKC, BRU, BXE and BXF ⇒ page 153 Engine codes BLS and BXJ ⇒ page 155

1.3.1

Engine codes BJB, BKC, BRU, BXE and BXF

1 - 10 Nm 2 - Union nut, 22 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 ❑ Removing and installing ⇒ page 95 . 4 - Union nut, 22 Nm 5 - Gasket ❑ Renew. ❑ Note installation posi‐ 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 ng

14 - Connection, 40 Nm

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

13 - Seal ❑ Renew.

agen lksw Vo by

12 - Gasket ❑ Renew.

Prote cted by c o p yri gh t. C op yi

11 - Connecting piece

ht rig py Co t.

10 - Connecting pipe ❑ Air filter/turbocharger

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

9 - 40 Nm ❑ First hand tighten all bolts

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

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.

1. Charge air system with turbocharger

153

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 19 - 20 Nm ❑ First hand tighten all bolts 20 - 20 Nm ❑ Renew. 21 - Heat shield 22 - Gasket ❑ Renew. ❑ Note installation position. 23 - Clamp, 7 Nm 24 - Front exhaust pipe

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 r erm o e t a itte riv du p or nl f e g n

27 - Connecting pipe ❑ To bypass flap

ility ab y li an pt ce

25 - Bracket AG. Volkswagen AG d agen oes ❑ For oil supply line ⇒ Item 3 (page 153) . ksw not l o V gu y b ara d ❑ Before installing, secure oil supply line. rise nte o eo h t u ra a 26 - 22 Nm c s s ❑ Renew.

28 - Connection, 30 Nm ❑ Renew. ❑ Coat threads and bolt head seating surface with “G 052 112 A3”.

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Rep. Gr.21 - Turbocharging/supercharging

do c um en

154

2 - Bracket

Engine codes BLS and BXJ

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 r erm o e t a itte riv du p or nl f e g n

1.3.2

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or Golf 2004 u ac ➤ , Golf Plus 2005 ➤ a ss 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

6 - Vacuum hose

do c um en

5 - Turbocharger ❑ Can only be renewed with exhaust manifold. ❑ Removing and installing ⇒ page 156 . 7 - Gasket ❑ Renew. ❑ Note installation posi‐ 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 14 - Connecting pipe ❑ 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 1. Charge air system with turbocharger

155

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ❑ 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 rm itte d

1.4

ility ab y li an pt ce

un le

24 - 10 Nm

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

Removing and installing turbocharger

rrectness of i t to the co nform spec a t i h re o n in wit thi s

♦ Torque wrench -V.A.G 1331-

es, in part or in w l purpos hole ercia , is n m ot com

Special tools and workshop equipment required

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Rep. Gr.21 - Turbocharging/supercharging

ht rig py Co t.

156

do c um en

♦ Tool set -T10395-

r te o iva r rp fo g n

♦ Lambda probe open ring spanner set -3337-

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 oe s no t

olks

V gu by housing, air filter element and intake ♦ Check airedfilter ara hoses nte s i r for soiling. o e h

t au

or a

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 – Remove noise insulation tray ⇒ General body repairs, exteri‐ or; Rep. Gr. 50 ; Body - front; Noise insulation . – Remove subframe and the right drive shaft ⇒ Running gear, axles, steering; Rep. Gr. 40 . Engine codes BLS and BXJ – 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 rig py Co t.

Continuation for all vehicles:

do c um en

– Remove particulate filter.

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 r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

c ♦ Check complete charged air routing and charge air cooler ss for foreign objects.

Prote cted by c o py rig ht . C op yi

– Disconnect fasteners -arrows- of coolant pipes for auxiliary heater, if part of original equipment.

1. Charge air system with turbocharger

157

agen lksw Vo by

AG.

un le

– 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

Rep. Gr.21 - Turbocharging/supercharging

Prote cted by

Note

AG.

Assembly overview - parts of charge air cooling

agen lksw Vo by

1.5

c o p yri gh t . C op yi

Torque setting of pendulum support ⇒ page 10 .

ht rig py Co t.

Note

r fo ng

– Installation is carried out in the reverse sequence of removal.

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Unbolt pendulum support -arrows-.

ility ab y li an pt ce

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) -

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a s s Edition 01.2009

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Engine codes BJB, BKC, BRU, BXE and BXF ⇒ page 159 Engine codes BLS and BXJ ⇒ page 160 Installing hose connections with connector couplings ⇒ page 161

1.5.1

Engine codes BJB, BKC, BRU, BXE and BXF

1 - 8 Nm ❑ Fitting location ⇒ page 160 2 - Bracket ❑ Note installation posi‐ tion. 3 - Charge air cooler 4 - Connecting hose 5 - 8 Nm

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r Connecting pipe ho eo ut ra a c s s To intake connecting pipe.

6 - To turbocharger.

ility ab y li an pt ce

8-

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

7-

9 - Vacuum reservoir 10 - 15 Nm

rrectness of i t to the co nform spec at i h re o n wit in t his

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 c um en

ht rig py Co t.

1. Charge air system with turbocharger

159

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

1.5.2

ility ab y li an pt ce

Golf 2004 4-cylinder

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ➤ , Golf Plus 2005 ➤ ut ra a c s diesel engine (1.9 l engine) - Edition 01.2009 s

Engine codes BLS and BXJ

rrectness of i t to the co nform spec at i h re o n wit in t his

1 - 8 Nm

Fitting location ⇒ page 160 2 - Bracket ❑ Note installation posi‐ 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

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

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

12 - Connecting hose ❑ To intake manifold flap motor -V157❑ Assembly overview - in‐ take manifold ⇒ page 174 13 - 8 Nm 14 - Connecting hose ❑ To turbocharger. Securing bolts for charge air cooler To loosen or tighten securing bolts -arrow-, bumper cover must be removed.

160

Rep. Gr.21 - Turbocharging/supercharging

ht rig py Co t.

5 - 3 Nm

do c um en

4 - Sealing strip ❑ Pushed onto top and bottom of charge air cooler

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.6

Hose connections

Installing hose connections with connector couplings ⇒ 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 doe wage

ks Vol

ris tho u a ss

s no t gu ara nte eo ra c ility ab y li an pt ce

un le

by – Push charge airedhose into coupling to stop.

ht rig py Co t.

r fo ng

– Check if connector coupling seats correctly and is properly engaged by pulling hose.

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Bring securing clip to locking position -2- and then push charge air hose again.

1. Charge air system with turbocharger

161

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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 le

Checking charge air system for leaks

ility ab y li an pt ce

1.7

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

♦ 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.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

– 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

Rep. Gr.21 - Turbocharging/supercharging

ht rig py Co t.

r fo ng

Prepare charge air system tester -V.A.G 1687- as follows:

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Special tools and workshop equipment required

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o h 4-cylindere odiesel ut ra a c ss

Golf 2004 ➤ , Golf Plus 2005 ➤ engine (1.9 l engine) - Edition 01.2009

do c um en

un le

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 ab y li an pt ce

– 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- . ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

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.

1. Charge air system with turbocharger

163

Golf 2004 ➤ , Golf Plus 2005 ➤ AG. Volkswagen AG d agen oes 4-cylinder diesel engine (1.9 lwengine) - Edition 01.2009 no olks

1.8

yV db ise r tho au s s

Vacuum hose schematic diagram un le

ility ab y li an pt ce

Vehicles with particulate filter ⇒ page 164

t gu ara nte eo ra c

pe rm itte d

Vehicles without particulate filter ⇒ page 165

Vehicles with particulate filter

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

1.8.1

1 - Turbocharger

2 - Connecting pipe air filter/ turbocharger 3 - Non-return valve ❑ Note installation posi‐ tion. 4 - To brake servo

Prote cted by

10 - Cooler ❑ For exhaust gas recircu‐ lation. 11 - Exhaust gas recirculation valve -N1812 - Exhaust gas recirculation cooler change-over valve N34513 - Non-return valve ❑ Note installation posi‐ tion. 14 - Vacuum unit ❑ Turbocharger

164

Rep. Gr.21 - Turbocharging/supercharging

AG.

9 - Bypass flap ❑ For exhaust gas recircu‐ lation cooler.

agen lksw Vo by

c o p yri gh t. C op yi

8 - Intake manifold

do c um en

7 - Cylinder head/cylinder block

ht rig py Co t.

6 - Air filter

r te o iva r rp fo g n

5 - Charge pressure control solenoid valve -N75-

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.8.2

Vehicles without particulate filter

1 - Solenoid valve block 2 - Non-return valve ❑ Note installation posi‐ tion. 3 - To brake servo

11 - Exhaust gas recirculation valve -N1812 - Turbocharger 13 - Non-return valve ❑ Note installation posi‐ tion.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

10 - Cooler ❑ For exhaust gas recircu‐ lation.

rrectness of i t to the co nform spec at i h re o n wit in t his

9 - Bypass flap ❑ For exhaust gas recircu‐ lation cooler.

do c um en

AG.

8 - Vacuum reservoir

ility ab y li an pt ce

7 - Cylinder head/cylinder block

agen lksw Vo by

6 - Intake manifold

Prote cted by c o py rig ht . C op yi

5 - Air filter

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ht rig py Co t.

4 - Connecting pipe air filter/ turbocharger

1. Charge air system with turbocharger

165

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

23 –

Mixture preparation - injection

1

Diesel direct injection system

The diesel direct injection system control unit is equipped with a fault memory. Read fault memory before and after making repairs or adjustments. Safety precautions ⇒ page 166 Rules for cleanliness ⇒ page 167 . Assembly overview - unit injector ⇒ page 167 Removing and installing unit injector ⇒ page 169 Adjusting non-contact gap of unit injectors ⇒ page 171 Removing and installing O-rings for unit injector ⇒ page 172 Repairing intake manifold flap ⇒ page 174 Assembly overview - air filter ⇒ page 177 .

1.1

Safety precautions WARNING

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 and 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. 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

agen lksw Vo by

c o p yri gh t. C op yi

166

ht rig py Co t.

r fo ng

♦ 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 s o f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

♦ Test and measuring instruments must be secured to rear seat and operated by a second person from this location.

ility ab y li an pt ce

ag ksw Vol y db se Observe followingthiforitest and measuring au during a road test: ss

Rules for cleanliness

ility ab y li an pt ce

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

1.2

AG. Volkswagen doesPlus 2005 ➤ agen Golf 2004 ➤ A, GGolf ksw not l o V engine (1.9 l engine) - Edition 4-cylinder diesel gu01.2009 y b ara d nte ise r o eo h t u ra a c s s

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

♦ Thoroughly clean all unions and adjacent areas before dis‐ connecting. ♦ Place removed parts on a clean surface and cover. Do not use fluffy cloths! ♦ Carefully cover opened components or seal if repairs cannot be carried out immediately. ♦ Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.). ♦ When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely nec‐ essary.

Assembly overview - unit injector

agen lksw Vo by

AG.

Prote cted by

♦ Always renew seals and O-rings

c o p yri gh t. C op yi

♦ Observe rules for cleanliness ⇒ page 167 .

ht rig py Co t.

1.3

thi sd o cu m en

♦ 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 om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte Golf 2004 ➤ ,oGolf Plus 2005 ➤ ris eo h ut ra 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 ❑ Removing and installing ⇒ 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

Rep. Gr.23 - Mixture preparation - injection

AG.

9 - O-ring ❑ Renew ⇒ page 172 .

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

8 - O-ring ❑ Renewing ⇒ page 172

ht rig py Co t.

7 - O-ring ❑ Renewing ⇒ page 172

do c um en

6 - Unit injector ❑ Removing and installing ⇒ page 169 .

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.4

Removing and installing unit injector

Special tools and workshop equipment required ♦ Universal dial gauge brack‐ et -VW 387-

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

thi sd o cu m en

AG.

Prote cted by c o py rig ht . C op yi

1.4.1

rrectness of i t to the co nf o r m spec atio h re n in wit

♦ Torque wrench V.A.G 1331-

agen lksw Vo by

♦ Puller -T10055-

ility ab y li an pt ce

♦ Special wrench, long reach -T10054-

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

ht rig py Co t.

♦ 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.

1. Diesel direct injection system

169

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 es n wage s k l ot g o taps. V y u

or ac

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

rrectness of i t to the co nf o r m spec atio h re n in wit

1.4.2

ara nte e

ility ab y li an pt ce

ss

b ed ris o th au

Installing

Note

Prote cted by c o py rig ht . C op yi

♦ New unit injectors are supplied with O-rings and heat shield agen lksw Vo by

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

Rep. Gr.23 - Mixture preparation - injection

ht rig py Co t.

unit injector, the adjustment screw in the rocker arm and also the unit injector ball stud must be renewed.

thi sd o cu m en

♦ Each time work is performed which requires adjustment of the

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Dimension “a”

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b ran 0.8 mmised tee r o h t or 0.8 amm u ac ss

Cylinder

rrectness of i t to the co nform spec at i h re o n wit 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 .

agen lksw Vo by

c o p yri gh t . C op yi

AG.

Prote cted by

– Fit dial gauge onto adjustment screw of unit injector as shown.

ht rig py Co t.

Adjusting non-contact gap of unit injec‐ tors

do c um en

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 .

1. Diesel direct injection system

171

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.6

Removing and installing O-rings for unit injector

Special tools and workshop equipment required ♦ 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

ility ab y li an pt ce

Note

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

1.6.2

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

♦ 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.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Rep. Gr.23 - Mixture preparation - injection

ht rig py Co t.

172

do c um en

– Remove assembly sleeve.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Place assembly sleeve -T10056/2- onto stop on unit injector. – Slide the middle, thinner O-ring carefully onto assembly sleeve and into seat on unit injector. – Remove assembly sleeve.

– Place assembly sleeve -T10056/3- onto stop on unit injector. – Push the lower O-ring carefully onto the assembly sleeve and into the seat of the unit injector. – Remove assembly sleeve. – Fit new heat shield seal together with securing clip.

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 r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

do c um en

ht rig py Co t.

agen lksw Vo by

1. Diesel direct injection system

173

AG.

Prote cted by

c o p yri gh t . C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

Assembly overview - intake manifold

Engine codes BKC, BRU, BXE and

ility ab y li an pt ce

Engine code BJB ⇒ page 175

un le

1.7

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo BXF ⇒uthpage 174 ra a c s s

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

Rep. Gr.23 - Mixture preparation - injection

AG.

7 - Connecting pipe ❑ To exhaust gas recircu‐ lation cooler.

agen lksw Vo by

6 - 10 Nm

Prote cted by c o py rig ht . C op yi

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.

ht rig py Co t.

4 - 10 Nm

r fo ng

3 - Intake connecting pipe ❑ With exhaust gas recir‐ culation valve

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

1.7.1

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

Engine codes BLS and BXJ ⇒ page 176

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.7.2

Engine code BJB

1 - Intake manifold ❑ Tighten securing bolts to 22 Nm. 2 - O-ring ❑ Renew. 3 - Intake connecting pipe ❑ With exhaust gas recir‐ culation valve and in‐ take manifold flap 4 - 10 Nm 5 - Gasket ❑ Renew.

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

un le

pe rm itte d

ility ab y li an pt ce

6 - Connecting pipe ❑ To exhaust gas recircu‐ lation cooler.

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

7 - 10 Nm

8 - Bracket 9 - Vacuum unit 10 - To solenoid valve block

do c um en

ht rig py Co t.

r te o iva r rp fo g n

11 - 22 Nm

1. Diesel direct injection system

175

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

ility ab y li an pt ce

un le

Engine codes BLS and BXJ

pe rm itte d

1.7.3

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d Golf 2004 ➤ , Golf Plus 2005 ➤ e nte is r o eo h 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ut ra a c s s

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

1 - Gasket ❑ Renew. 2 - Intake manifold ❑ Tighten securing bolts to 22 Nm 3 - Seal ❑ Renew 4 - Connection

r te o iva r rp fo g n

AG.

8 - Exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer G212❑ Assembly overview - ex‐ haust gas recirculation ⇒ page 196

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

7 - 10 Nm

ht rig py Co t.

6 - From charge air cooler

do c um en

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 10 - Connecting pipe ❑ For exhaust gas recircu‐ 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

Rep. Gr.23 - Mixture preparation - injection

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 AG do agen -N18- and the – Remove the exhaust gas recirculation in‐es n wvalve ot g olks V take manifold flap motor -V157y. ua b d e ris

un le

– 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 cted by

9 - Air duct ❑ To lock carrier.

c o p yri gh t . C op yi

8 - Filter element

agen lksw Vo by

7 - Vacuum hose ❑ To solenoid valve block

ht rig py Co t.

6 - 8 Nm

r fo ng

5 - Air filter upper part

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

– Wipe off intake manifold flap support using a lint-free cloth.

ran tee or ac ility ab y li an pt ce

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

1. Diesel direct injection system

177

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2

Engine control unit

Reading and clearing engine control unit fault memory ⇒ page 178

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte engine control unit, Golf ⇒ page 180 . ris o eo h ut ra a anti-theft engine control unit, Golf ss c

Adapting functions and components ⇒ page 179 .

ility ab y li an pt ce

Removing and installing ⇒ page 180 .

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Removing and installing

Removing and installing engine control unit, Golf Plus ⇒ page 183 .

2.1

rrectness of i t to the co nform spec at i h re o n wit in t his

Removing and installing anti-theft engine control unit Golf Plus ⇒ page 183 .

Reading and erasing engine control unit fault memory

Special tools and workshop equipment required

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

agen lksw Vo by

AG.

Prote cted by c o py rig ht . C op yi

Rep. Gr.23 - Mixture preparation - injection

ht rig py Co t.

178

do c um en

– Connect vehicle diagnostic, testing and information system VAS 5051- as follows:

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Push diagnosis cable connector onto diagnosis connector. – Start engine and run at idling speed. 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

Special tools and workshop equipment required

ility ab y li an pt ce

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 r erm o e t a itte riv du p or nl f e g n

♦

AG. Volkswagen AG d agen oes ksw not l o Vehicle diagnostic, testing and information system -VAS 5051gu yV b ara d e nte is r o eo h ut ra a c s s

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”.

agen lksw Vo by

– Select “Engine management”.

Prote cted by c o py rig ht . C op yi

– Select “01-Systems capable of self-diagnosis”.

2. Engine control unit

do c um en

– Select “Engine code”.

ht rig py Co t.

– Select “Drive train”.

179

Golf 2004 ➤ , Golf Plus 2005 ➤ AG. Volkswagen AG do n es n wage 4-cylinder diesel engine (1.9 o 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 – Switch off ignition.

– 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. c o p yri gh t . C op yi

agen lksw Vo by

AG.

Prote cted 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 . Special tools and workshop equipment required ♦ Electric cutter -V.A.G 1561 A♦ Saw set -V.A.G 1561/14-

180

Rep. Gr.23 - Mixture preparation - injection

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 ot p o c erm or e t a itte iv r du rp o nl f e ng

2.3

t gu ara nte eo ra c ility ab y li an pt ce

yV db ir se ho ut a ss

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

Note

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

ility ab y li an pt ce

un le

♦ 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 – Switch off ignition. 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 . agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

– 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-.

2. Engine control unit

181

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 . Volkswagen AG gen AG does not gu ara nte eo ra c

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 n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

ris tho u a 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

Rep. Gr.23 - Mixture preparation - injection

AG.

– Tighten new shear-head bolts -1- evenly until heads shearhead off.

agen lksw Vo by

c o p yri gh t. C op yi

– Push protective housing onto bracket.

ht rig py Co t.

– Press catch -1- against engine control unit.

do c um en

– Push engine control unit onto bracket.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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: – Switch off ignition. – Remove plenum chamber bulkhead ⇒ General body repairs; Rep. Gr. 50 ; Body - front; Plenum chamber bulkhead . – Loosen securing nuts -arrows-. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

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 ab y li an pt ce

un le

– 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

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

– Install plenum chamber bulkhead ⇒ General body repairs; Rep. Gr. 50 ; Body - front; Plenum chamber bulkhead .

ht rig py Co t.

– Fit connectors and lock in position.

do c um en

r te o iva r rp fo g n

– Push bracket onto engine control unit.

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

Special tools and workshop equipment required ♦ Grip pliers

2. Engine control unit

183

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 – Switch off ignition. – 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 r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

a unit bracket -arrows-. – Then remove securing nuts for control ss

does not gu ara nte eo ra c

– Release connectors on engine control unit and pull off con‐ nector.

184

Rep. Gr.23 - Mixture preparation - injection

AG.

– Fit connectors to engine control unit and lock in position.

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

– Push engine control unit onto control unit bracket until it en‐ gages in catches.

ht rig py Co t.

Installing

do c um en

– Press catches -1- and -2- outwards. Then pull engine control unit off control unit bracket in direction of arrow.

– Tighten

n AG. Volkswagen AG do Golf 2004 ➤ , Golf Plus 2005 ➤ es n wage s k l ot g o 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 yV u b ara ed nte ris o eo 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; Rep. Gr. 50 ; Body - front; Plenum chamber bulkhead .

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 e ng

ility ab y li an pt ce

– Install cover of protective housing.

2. Engine control unit

185

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t . C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

26 –

Exhaust system

1

Exhaust system

Assembly overview - front exhaust pipe with catalytic converter ⇒ page 186 . Assembly overview - front exhaust pipe with particulate filter ⇒ page 187 Assembly overview - silencer with mountings (vehicles with front wheel drive) ⇒ page 189 . Assembly overview - silencer with mountings (vehicles fourgen AG G. Volkswawith nA does wage wheel drive) ⇒ page 191 . no olks

t gu ara nte eo ra c

yV db ise r tho au s s

Assembly overview - front exhaust pipe with catalytic converter ility ab y li an pt ce

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

1.1

1 - Front exhaust pipe with cat‐ alytic converter 2 - 40 Nm

rrectness of i t to the co nf o r m spec atio h re n in 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 cted by

Rep. Gr.26 - Exhaust system

agen lksw Vo by

186

c o p yri gh t. C op yi

10 - Clip

thi sd o cu m en

9 - Gasket ❑ Note installation posi‐ tion.

ht rig py Co t.

8 - 7 Nm

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Installation position of clamp Position clamp at distance -a- = 5 mm from marking on front ex‐ haust pipe.

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

1.2

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

rrectness of i t to the co nform spec at i h re o n wit in t his

Assembly overview - front exhaust pipe with particulate filter

Special tools and workshop equipment required ♦ Lambda probe open ring spanner set -3337-

do c um en

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

♦ 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

Golf 2004 ➤ , Golf Plus 2005 ➤ n AG. Volkswagen AG do es n wage s k l ot g o 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 yV

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

AG.

Prote cted by

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 ❑ Note installation position.

188

Rep. Gr.26 - Exhaust system

thi sd o cu m en

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-

agen lksw Vo by

5 - Control line, 45 Nm

c o p yri gh t . C op yi

4 - 10 Nm

rrectness of i t to the co nf o r m spec atio h re n in wit

3 - Bracket ❑ For control lines

ility ab y li an pt ce

2 - Exhaust gas pressure sen‐ sor 1 -G450-

or ac

ht rig py Co t.

1 - 8 Nm

ua ran tee

b ed ris o th au ss

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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. ht rig py Co t.

agen lksw Vo by

AG.

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

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 e ng

rrectness of i t to the co nf o r m spec atio h re n in wit

1.3

ex‐

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o gu y V of clamp Installation position b ara d e nte is r o eo h – Position ut double clamp -a- = 5 mm from marking on front ra a c s haust s pipe of particulate filter.

Prote cted by c o py rig ht . C op yi

4 - Rear silencer 5 - Mounting ❑ Renew if damaged.

1. Exhaust system

189

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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

Special tools and workshop equipment required AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

♦ Eye protection Procedure

WARNING

Wear eye protection.

– Cut exhaust pipe at right angles at separating point -arrow 2-.

AG.

Rep. Gr.26 - Exhaust system

agen lksw Vo by

Prote cted by c o py rig ht . C op yi

190

ht rig py Co t.

r fo ng

– When installing, position repair double clamp -4- at side mark‐ ings -arrow 1- and -arrow 3-.

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

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

ility ab y li an pt ce

un le

♦ Pneumatic sabre saw -V.A.G 1523 A-

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – 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 Specified torque, M10: 40 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

ility ab y li an pt ce

6 - Rear silencer

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

5 - Retaining ring ❑ Renew if damaged.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

7 - Mounting ❑ Renew if damaged.

rrectness of i t to the co nform spec at i h re o n wit in t his do c um en

ht rig py Co t.

4 - 25 Nm

1. Exhaust system

191

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 Installation position of clamp – Install clamp so that ends of bolts do not protrude beyond bot‐ tom of clamp.

AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s

Aligning exhaust system free of stress

Engine must be cold

Procedure

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 r erm o e t a itte riv du p or nl f e g n

Prerequisite

ility ab y li an pt ce

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.

Specified torque, M10: 40 Nm – Once clamp has been tightened, check distance -a- and cor‐ rect if necessary.

192

Rep. Gr.26 - Exhaust system

AG.

Specified torque, M8: 25 Nm

agen lksw Vo by

Prote cted by c o p yri gh t. C op yi

– With parts in this position, tighten bolted connections of clamp.

ht rig py Co t.

– 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.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2

Exhaust gas recirculation system

2.1

Assembly overview - parts of exhaust gas recirculation

Engine codes BKC, BRU, BXE and BXF ⇒ page 193 AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d BXJ ⇒ page 196 e nte is r o eo h ut ra a c s s

Engine code BJB ⇒ page 195 Engine codes BLS and

rrectness of i t to the co nform spec at i h re o n wit in t his

♦ The exhaust gas recirculation system is activated by the diesel

ility ab y li an pt ce

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. ♦ Renew self-locking nuts.

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

2.1.1

ht rig py Co t.

2. Exhaust gas recirculation system

193

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 1 - 22 Nm 2 - Intake manifold ❑ With exhaust gas recir‐ culation valve and in‐ take manifold flap motor -V157- . ❑ Tighten securing bolts to 22 Nm. 3 - Gasket ❑ Renew 4 - Connecting pipe

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

un le

7 - Exhaust manifold 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

Rep. Gr.26 - Exhaust system

agen lksw Vo by

c o p yri gh t . C op yi

11 - 5 Nm

ht rig py Co t.

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 f i t to the co n form spec atio h re n wit i n thi sd o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

6 - 10 Nm

ility ab y li an pt ce

5 - Cooler ❑ For exhaust gas recircu‐ lation.

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2.1.2

Engine code BJB

Note ♦ The exhaust gas recirculation system is activated by the diesel

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.

r fo ng

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

AG.

Prote cted by

6 - Connecting pipe

agen lksw Vo by

5 - Exhaust manifold

c o p yri gh t. C op yi

4 - 22 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

3 - Gasket ❑ Renew

ht rig py Co t.

2 - From charge air cooler

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

ility ab y li an pt ce

1 - Intake manifold ❑ With exhaust gas recir‐ culation valve and in‐ take manifold flap ❑ Tighten securing bolts to 22 Nm.

un le

♦ Renew self-locking nuts.

2. Exhaust gas recirculation system

195

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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

Engine codes BLS and BXJ

Note ♦ The exhaust gas recirculation system is activated by the diesel

direct injection system control unit -J248- via the exhaust gas recirculation potentiometer -G212- .

♦ Renew self-locking nuts. 1 - Coolant hose ❑ To connection 2 - Gasket ❑ Renew 4 - Connecting pipe

13 - Connecting pipe 14 - Vacuum unit ❑ For bypass flap

196

Rep. Gr.26 - Exhaust system

r fo ng

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

12 - Exhaust gas recirculation cooler change-over valve N345-

Prote cted by

11 - Connecting hose

AG.

10 - Coolant hose ❑ From rear coolant pipe

agen lksw Vo by

9 - 10 Nm

c o p yri gh t . C op yi

8 - Exhaust gas recirculation cooler

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

7 - To connection for exhaust gas recirculation valve -N18with exhaust gas recirculation potentiometer -G212❑ Assembly overview - in‐ take manifold ⇒ page 176

ility ab y li an pt ce

6 - 25 Nm ❑ Renew

un le

5 - From exhaust manifold

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

ht rig py Co t.

3 - 22 Nm

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 ❑ Renew only together with exhaust gas recirculation cooler

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 r erm o e t a itte riv du p or nl f e g n

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

do c um en

2. Exhaust gas recirculation system

197

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by

c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

28 –

Glow plug system

1

Checking glow plug system

Removing, installing and checking glow plugs ⇒ page 198 Characteristics of ceramic glow plugs ⇒ page 199 Removing, installing and checking ceramic glow plugs ⇒ page 200

1.1

Removing, installing and checking glow plugs

Special tools and workshop equipment required ♦ Auxiliary measuring set -V.A.G 1594 C-

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

ility ab y li an pt ce

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

rrectness of i t to the co nf o r m spec atio h re n in wit

♦ Diode test lamp -V.A.G 1527 B♦ Jointed spanner -3220-

c o p yri gh t. C op yi

Test procedure

Prote cted by

Ignition switched off

– Pull glow plug connectors off glow plugs.

198

Rep. Gr.28 - Glow plug system

AG.

•

agen lksw Vo by

Battery voltage at least 11.5 V

ht rig py Co t.

•

thi sd o cu m en

Test requirements

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 – Connect voltage tester -V.A.G 1527 B- cable to battery posi‐ tive, using clamps from adapter set -V.A.G 1594 C- . – Place probe of diode test lamp -V.A.G 1527 B- on each glow plug one after the other. If diode lights up, glow plug is OK. If diode does not light up, replace glow plug. – Remove and install glow plugs using jointed spanner -3220- . Specified torque: 15 Nm.

1.2

Characteristics of ceramic glow plugs WARNING

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s to jolts and s

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

Vehicles with 2 valves per cylinder head

rrectness of i t to the co nf o r m spec atio h re n in wit

Visual features of ceramic glow plugs

ility ab y li an pt ce

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 . ht rig py Co t.

agen lksw Vo by

AG.

1. Checking glow plug system

thi sd o cu m en

-D- = Ceramic glow plug with support tube -arrow-, not colourcoded.

199

Prote cted by

c o p yri gh t. C op yi

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1.3

Removing, installing and checking ceramic glow plugs

Special tools and workshop equipment required ♦ Jointed spanner -3220♦ Torque wrench (5…50 Nm) -V.A.G 1331. Volkswagen AG

♦ Hand-held multimeter - kswagen AG Vol V.A.G 1526 Aby d ise

r fo ng

ht rig py Co t.

agen lksw Vo by

AG.

Prote cted by c o p yri gh t. C op yi

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- . Installation is carried out in the reverse order. When installing, 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 o c um en

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

un le

ility ab y li an pt ce

r ♦ Auxiliary measuring set ho ut a V.A.G 1594 sCs

does not gu ara nte eo ra c

Golf 2004 ➤ , Golf Plus 2005 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 01.2009 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 ab y li an pt ce

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

♦

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara After installing and before the engine is started, salways d nte i e r o perform a resistance test on all ceramic glowthplugs when eo u ra a engine is cold. c s s

♦ If the defective ceramic glow plug is broken, remove all fragments from the engine, otherwise these can cause damage to the engine.

rrectness of i t to the co nf o r m spec atio h re n in wit

♦ Specification: max. 1 Ω

– If the specification is exceeded, renew the defective ceramic glow plug.

thi sd o cu m en

ht rig py Co t.

agen lksw Vo by

AG.

1. Checking glow plug system

201

Prote cted by

c o p yri gh t. C op yi