Volkswagen Golf Plus 2005 User Manual

Service

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Workshop Manual

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Golf 2004

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Golf Plus 2005

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4-cylinder diesel engine (1.9 l engine)f

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Engine ID

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Edition 01.2009

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Service Department. Technical Information

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Manual Repair GroupsList of Workshopi

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GroupsList of Workshop Manual Repair Groupsi

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00 - Technical data

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10 - Removing and installing engine

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Crankshaft group

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15 - Cylinder head, valve gear

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17 - Lubrication

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19 - Coolingi

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26 - Exhaust system

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28 - Glow plug system

Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg

K0059000420

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																																			Golf 2004 , Golf Plus 2005
																					4-cylinder diesel engine (1.9 l engine) - Edition 01.2009
																							Contents
00 - Technical data												. . . .	.	.	.	.		.	.	.	. . .	.	. . . . .	.	.	.		.		.	.		.	.	.	.		. .	. .	.			.			.			.		. . . . . . . . . . . . . .	1
1		Technical data . .											.	.	.	.	.		.	. .	. . . .	.	. . . . .	.	. .		.	.		.	.	.		. .	.	.	.	. .	. .	.			.	.			.			.	. . . . . . . . . . . . . . . .	1
1.1		Engine number .											. .	.		.	. .		.	. .	. . .	. .	. . . . .	.	.	.	.		.	.	.		.	.	. .	.		. . .	. .		.		.		.		.			.	. . . . . . . . . . . . . . . .	1
1.2		Engine data . . . .											.	.	.	.	.		.	. .	. . . .	.	. . . . .	.	. .		.	.	.		.	.		. .	.	.	.	. .	. .	.			.	.			.			.	. . . . . . . . . . . . . . . .	1
10 - Removing and installing engine .																						.	. . . . .	.	.		.		.	.		.		.	. .		.	. .	.	.		.		.			.				. . . . . . . . . . . . . .	2
1		Removing and installing engine .																				.	. . . . . .	.	.	.		.	. .		.		.	.	. .	.		. .	. .	.	.		.			.		.			. . . . . . . . . . . . . . . . .	2
1.1		Removing engine											.	.		. .	.		.	. .	. . . .	.	. . . . .	.	.	.	.	.	.		.	.		.	. .	.	.	. .	. .		.	.		.			.			.	. . . . . . . . . . . . . . . .	2
1.2		Securing engine to assembly stand																					. . . . .		. .		.	.	. .			.		. .	.	.	.	. .	. .	.		.		.			.			.	. . . . . . . . . . . . . . . .	7
1.3		Notes on installing												.	.	.	. .			. .	. . . .	.	. . . . . .	.	.	.		.	. .		.		.	.	. .	.		. . .	.	.	.	.				.	.				. . . . . . . . . . . . . . . . .	7
1.4		Assembly mountings														.	. .		.	.	. . . .	.	. . . . . .	.	.	.	.		. .		.		.	.	. .	.		. . .	. .		.	.				.	.				. . . . . . . . . . . . . . . . .	10
13 - Crankshaft group . .													.	.	.	.	.		.	.	. . .	.	. . . . .	.	.		.	.	.		.		.	.	.	.		. .	. .	.		.				.		.			. . . . . . . . . . . . . .	12
1		Dismantling and assembling engine . . . .																						.	.	.	.	.	. .			.		.	. .	.		. . .	. .		.	.		.			.			.	. . . . . . . . . . . . . . . .	12
1.1		Assembly overview - poly V-belt drive . . .																						.	.	.		.	. .		.		.	.	.	.	.	. .	. .	.		.		.			.	.			. . . . . . . . . . . . . . . .	12
1.2		Removing and installing poly V-belt																					. . . .	.	. .		.	.	. .			.		. .	.	.	.	. .	. .	.		.		.			.	.			. . . . . . . . . . . . . . . .	13
1.3		Assembly overview - toothed belt drive . .																						.	.	.	.		. .		.		.	.	. .	.		. . .	. .		.	.				.	.				. . . . . . . . . . . . . . . . .	15
1.4		Assembly overview - crankcase .																				.	. . . . . .		. .		.	.	. .		.		.	.	. .		.	. .	. .	.	.	.				.		.			. . . . . . . . . . . . . . . . .	19
2		Removing and installing sealing flange and flywheel																																.	. .	.		. .	. .	.	.	.				.		.			. . . . . . . . . . . . . . . . .	20
2.1		Assembly overview - sealing																			G.V	olks																														20
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																					Aflanges andenflywheel											.		.	. .	.		. . .	.	.	.	.				.		.			. . . . . . . . . . . . . . . .
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		Renewing crankshaftV oil seal - pulley end																						.	.	.	.		. .				g.	.	. .	.		. . .	. .		.	.				.	.				. . . . . . . . . . . . . . . . .
2.3													y																					u																		23
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		Removing andisinstalling sealing flange - pulley end . .a.n.																																			.	. .	. .	.		.		.			.	.			. . . . . . . . . . . . . . . .
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										a																												a
2.5									s		and installing engine speed sender G28																											c														31
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		Removingle																																.	. .	.		. . .	e. .		.	.				.	.				. . . . . . . . . . . . . . . . .
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3		Crankshafte d																																						n												33
												. . . . .	.	.	.	.	.		.	. .	. . . .	.	. . . . . .	.	.	.		.	. .		.		.	.	. .	.		. . .	.	.	y. .					.	.				. . . . . . . . . . . . . . . . .
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3.1		Assemblym								overview - crankshaft																																		b								33
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3.2					p	e	r					dimensions																																		l						38
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4		s	n	o					and conrods																																								i			39
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		Pistonsi														.	. .		.	. .	. . .	. .	. . . . .	.	.	.	.		. .		.		.	.	. .	.		. . .	. .		.	.				.	.			.	. . . . . . . . . . . . . . . .r
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4.1		e																																																	s	39
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	h																																																		e
4.2	w	Separating new conrod																																																	c	40
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	n																.		.	. .	. . .	.	. . . . . .	.	.	.	.		. .		.		.	.	. .	.		. . .	. .		.	.				.	.				. .t. . . . . . . . . . . . . . .
4.3	i	Checking piston projection at TDC																																																	o	41
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																							. . . . .	.	. .		.	.	. .			.	.	.	. .		.	. .	. .	.	.	.					.	.			. .h. . . . . . . . . . . . . . .
	t																																																		e
4.4	r	Piston and cylinder dimensions																																																		42
	a																																																		c
	p																					.	. . . . . .	.	.	.		.	. .		.		.	.	. .	.		. . .	.	.	.	.				.	.				. . .o. . . . . . . . . . . . . .
4.5	n	Piston rings, cylinder bore and piston installation position																																																	r	42
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15 - Cylinder head, valve gear																			.	. .	. . .	.	. . . .	.	.		.	.	.		.		.	.	.	.		. .	. .		.	.					.			.
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	aCylinder head . .												. .	.		. .	.		.	. .	. . . .	.	. . . . . .		. .		.	.	. .		.		.	.	. .		.	. .	. .	.	.	.					.	.			. .n. . . . . . . . . . . . . . .
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1.1																																																			o	45
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	eAssembly overview - cylinder head																						. . . . .	.	.	.		.	. .		.		.	.	. .		.	. .	. .	.		. .					.	.			.r. . . . . . . . . . . . . . .
1.2	m																																																		m	48
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		m
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		Removing and installing cylinder head cover																									.	.	. .		.		.	.	. .		.	. .	. .	.	.	.				.		.			i. . . . . . . . . . . . . . . . .
1.3		o																																															i	n	o	50
		c
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		Removing, installing and tensioning toothed belts																													.		.	.	. .	.		. . .	.	.	.	.				.	t	n.			. . . . . . . . . . . . . . . . .
1.4				o																																																67
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		Removing and installing cylinder head . .																						.	.	.	.	.	. .			.		. .	.	.	.	. .	. .	.		.		d .			.	.			. . . . . . . . . . . . . . . .
1.5							v																																				o									71
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		Checking compression															.		.	. .	. . . .	.	. . . . .	.	.	.	.	.	.		.		.	.	. .	.		. . .	. .		u.				.		.			.	. . . . . . . . . . . . . . . .
								r																																m
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									n																														n
		Valve gear										. . . . .	.	.	.	.	. .			. .	. . . .	.	. . . . . .	.	.	.		.	. .		.		.	.	. .	.		. . .	t.	.	.	.				.	.				. . . . . . . . . . . . . . . . .
									i
2.1									y					- valve gear																								.														74
									p																													C
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		Assembly overviewC																				.	. . . . .	.	. .		.	.	. .			.	.	.	. .		.	p. .	. .	.	.	.					.	.			. . . . . . . . . . . . . . . . .
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2.2		Checking valvegirguides																																	h																	76
																	.		.	. .	. . . .	.	. . . . .	.	.	.	.	.	. .			.		. .	t.	.	.	. .	. .	.		.		.			.			.	. . . . . . . . . . . . . . . .
												y																						b
2.3												p	o																				y																			78
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													c	y																	o
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		Renewing valve stemb seals																			. . . .	.	. . . . . .		. .		.	.	s. .			.		. .	.	.	.	. .	. .	.		.		.			.	.			. . . . . . . . . . . . . . . .
																d												w
																e											a
2.4																	t		et							g																										80
																				or					e
																								n
																							A
		Removing and installingcamshaftP																					. . . ..G. .	.	.	.		.	. .		.		.	.	. .	.		. . .	.	.	.	.				.	.				. . . . . . . . . . . . . . . . .
2.5		Removing and installing camshaft oil seal																						.	.	.		.	. .		.		.	.	. .	.		. . .	.	.	.	.				.		.			. . . . . . . . . . . . . . . . .	84
17 - Lubrication									. .			. . . . .	.	.		.	. .			. .	. . .	.	. . . . .		.	.	.		. .			.		.	. .		.	. .	.	.		.		.			.				. . . . . . . . . . . . . .	86
1		Engine oil										. . . . .	. .	.		. .	.		.	. .	. . . .	.	. . . . .	.	.	.	.	.	. .			.		.	. .	.	.	. .	. .	.		.		.			.			.	. . . . . . . . . . . . . . . .	86
1.1		Oil capacities . . .											.	.	.	.	.		.	. .	. . . .	.	. . . . . .	.	.	.		.	. .		.		.	.	. .	.		. . .	.	.	.	.				.	.				. . . . . . . . . . . . . . . . .	86
1.2		Checking engine oil level																		. .	. . . .	.	. . . . .	.	. .		.	.	. .			.		. .	.	.	.	. .	. .	.		.		.			.	.			. . . . . . . . . . . . . . . .	86

Contents i

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	Golf 2004 , Golf Plus 2005																								nAG.V	olks
																										wagenA			G
																								ge						d	o
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	4-cylinder diesel engine (1.9 l engine) - Edition 01.2009																						w										s
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													i																											n
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2	Parts of lubrication system												th																														e
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		. . .	.		.			.		.	.	.	.a. . . .		.		.	.	.		.		.	.	. . . . . .	. . . . .	. .	.	.	.		.	.	.		.	.	.	.	.					87a
													s																																c
												s																																		c
2.1	Assembly overview - oil pump, sump							. . .l.e																																						e
													. . . . .		.		.	.	.		.		.	.	. . . . . .	. . . . .	. .	.	.	.		.	.	.		.	.	.	.	.					87 p
2.2	Removing and installing sump									e.d	u	n																																	88			t
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		. . .	.		.			.			.	.	. . . . .			.	.	.	.		.		.	.	. . . . .	. . . . .	. .	.	.	.		.	.	.	.		.	.	.	.										y
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3							m	i	t																																				92							i
						r																																														a
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	Oil filter bracket, oil pressure, engine oil cooler and oil supply line .																									. . . . .	. .		.	.	.	.		.	.		.	.	.	.															i
			t	p	e																																																		t
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3.1	Assembly overview - oil filter bracketo				and engine oil cooler																																								92										w
																								.	. . . . . .	. . . . .	. .		.	.	.		.	.	.		.	.	.	.																	i
		s	n																																																							t
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3.2	Checking oil pressure and oil pressure,i								switch																																				93														r
															.		.	.	.	.		.	.	.	. . . . .	. . . . . .	. .		.	.	.		.	.	.		.	.	.	.																			e
3.3		l	to turbocharger																																										94														s
	Assembly overview - oil supply lineo																.	.	.	.		.	.	.	. . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.																			p
		h																																																									e
3.4		w																																											95														c
																																																											t
	Removing and installing oil supplyn line to turbocharger																			.		. .		.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.																			t
		i																																																									o
		r
19 - Cooling		o																																											97														t
																																																											h
		t
																																																											e
		r
		a. .	.		.			.		.		. .	. . . .		.		.	.	.	.		.		.	. . . . .	. . . .	. .		.	.	.		.	.	.			.	.	.																			c
1	Parts of cooling system . . . . .	p																																											97														o
		n																																																									r
																																																											r
		i
		,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .																																																									e
1.1		s																																											98														c
		e																																																									t
																																																											n
	Parts of cooling system, body sides		.		.		.			.	.	.	. . . . .		.		.	.	.	.		.	.	.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.
		o																																																									e
1.2		p																																											99														s
		r																																																									s
	Parts of cooling system, engine uside						.		.	.		. .	. . . .		.	.		. .		. .		.		.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.
		p																																																									o
1.3																																												101															f
		l																																																									i
		a																																																									n
	Coolant hose schematic diagrami .		.		.		.			.	.	.	. . . . .			.	.	.	.	.		.	.	.	. . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.
		c																																																									f
1.4	Draining and filling with coolant																																											102															o
		r
		.e.	.	.		.			.	.		. .	. . . .		.	.		. .		. .		.		.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.																			r
		m																																																									m
																																																											a
1.5	Removing and installing radiator .m																																											105
				.		.			.	.		. .	. . . .		.		.	.	.	.		.	.	.	. . . . .	. . . . . .	. .		.	.	.		.	.	.		.	.	.	.																			it
		o																																										106													i	n	o
		c
			r
1.6	Removing and installing coolant pump									.	.	.	. . . . .			.	.	.	.	.		.		. .	. . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.															t	n
			o
				e
1.7	Removing and installing thermostat																																											108										i	h
					t
					.a.					.	.	.	. . . . .	.	.		.	.	.	.		.	.	.	. . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.													d
1.8	Checking cooling system for leaks						v																																					110								o
								i
								r																																											c
			. . .p. .									.	. . . . .	.	.		.	.	.	.		.	.	.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.										u
1.9	Checking engine oil cooler for leaks									r																																		112					m
										o
											f																																					e
						. . . .g.							. . . . .	.		.	.	.	.	.		.		. .	. . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.
												n																																			n
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													y																																.
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20 - Fuel supply system													o																																o
													C																															p
													th																													y
																																										r
		. . .	.			.			.		.	.		.		.		.	.	.		.		.	. . . . .	. . . .	. . .			.	.		.	.	.			.	.	g.i114
													g																										h
														i																									t
															r
															y																							b
1																p	o	c																			y							114
																																				V
																																			o
	Safety precautions when working on fuel supply systemy																					.	.	.	. . . . . .	. . . . .	. .		.	.	.		.	k.l.			.	.	.	.
																			b		d	e											s
																																w
																															a
2	Rules for cleanliness																						c	et						g														115
																									or				e
																												n
																											A
		. . .	.	.		.	.			.		. .	. . . .	. .		.		. .		. .		.		.	. .P. . . .	. . . . ..	G. . .		.	.		.	.	.	.		.	.	.	.
3	Fuel tank, vehicles with front-wheel drive											.	. . . . .	.		.	.	.	.	.		.	.	.	. . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				116
3.1	Assembly overview - fuel tank	. . .	.	.		.			.	.		. .	. . . .	.	.		.	.	.	.		.	.	.	. . . . .	. . . . . .	. .		.	.	.		.	.	.		.	.	.	.				116
3.2	Emptying fuel tank . . . . . . . . .	. . .	.	.		.	.			.		. .	. . . .	. .		.		.	.	.		. .		.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				117
3.3	Removing and installing fuel tank .		.			. .				.	.	.	. . . . .	.		.	.	.	.	.		.		. .	. . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				121
3.4	Removing and installing fuel delivery unit											.	. . . . .	.		.	.	.		. .		.		. .	. . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				123
3.5	Removing and installing fuel gauge sender												. . . .	.	.		.	.	.	.		.	.	.	. . . . .	. . . . . .	. .		.	.	.		.	.	.		.	.	.	.				124
3.6	Checking fuel pump . . . . . . . .	. . .	.		.	.				.	.	.	. . . . .	.		.	.	.	.	.		.	.	.	. . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				125
4	Fuel tank, vehicles with four-wheel drive											. .	. . . .	.	.		.	.	.	.		.	.	.	. . . . .	. . . . . .	. .		.	.	.		.	.	.		.	.	.	.				127
4.1	Assembly overview - fuel tank	. . .	.	.		.			.	.		. .	. . . .	.	.		.	.	.	.		.	.	.	. . . . .	. . . . . .	. .		.	.	.		.	.	.		.	.	.	.				127
4.2	Emptying fuel tank . . . . . . . . .	. . .	.	.		. .				.		. .	. . . .	. .		.		.	.	.		. .		.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				128
4.3	Removing and installing fuel tank .		.			. .				.	.	.	. . . . .	.		.	.	.	.	.		.		. .	. . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				132
4.4	Removing and installing fuel gauge sender 2 G169																	. .		. .		.		.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				135
4.5	Removing and installing suction-jet pump											.	. . . .	. .		.		. .		. .		.		.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				137
4.6	Checking fuel pump . . . . . . . .	. . .	.		.	. .					.	.	. . . . .	.		.	.	.	.	.		.	.	.	. . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				138
5	Repairing fuel supply system .	. . .	.	.		. .				.		. .	. . . .	.	.	.		.	.	.		.	.	.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				140
5.1	Assembly overview - fuel filter	. . .	.	.		. .				.		. .	. . . .	.	.		.	.	.	.		.	.	.	. . . . .	. . . . . .	. .		.	.	.		.	.	.		.	.	.	.				140
5.2	Removing and installing fuel cooler			.		. .				.		. .	. . . .	.	.		.	.	.	.		.	.	.	. . . . .	. . . . . .	. .		.	.		.	.	.	.		.	.	.	.				141
5.3	Assembly overview - accelerator mechanism . . .													.		.		. .		. .		.		.	. . . . . .	. . . . .	. .		.	.	.		.	.	.		.	.	.	.				142
5.4	Checking tandem pump . . . . .	. . .	.	.		. .				.		. .	. . . .	.	.	.		.	.	.		.	.	.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				143
5.5	Removing and installing tandem pump									.		. .	. . . . .	.		.	.	.		. .		.		.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				147
21 - Turbocharging/supercharging .		. . .	.			. .					.	.	. . . .	.		.		.	.	.		.		.	. . . . .	. . . .	. . .			.	.		.	.	.			.	.	.		151
1	Charge air system with turbocharger					. .				.		. .	. . . .	. .		.		.	.	.		.	.	.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				151
1.1	Safety precautions . . . . . . . . .	. . .	.	.		. .				.		. .	. . . .	.	.	.		.	.	.		.	.	.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				151
1.2	Rules for cleanliness . . . . . . .	. . .	.	.		. .				.		. .	. . . .	. .		.		. .		. .		.		.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				151
1.3	Assembly overview - turbocharger		.		.	. .					.	.	. . . . .	.	.		.	.	.	.		.	.	.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				152
1.4	Removing and installing turbocharger					.				.		. .	. . . .	.	.		.	.	.	.		.	.	.	. . . . .	. . . . . .	. .		.	.	.		.	.	.		.	.	.	.				156
1.5	Assembly overview - parts of charge air cooling .													.		.		. .		. .		.		.	. . . . . .	. . . . .	. .		.	.	.		.	.	.		.	.	.	.				158
1.6	Hose connections . . . . . . . . . .	. . .	.			. .				.		. .	. . . . .	.		.	.	.		. .		.		.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				161
1.7	Checking charge air system for leaks					.				.		. .	. . . .	. .		.		.	.	.		.	.	.	. . . . . .	. . . . .	. .		.	.	.		.	.	.		.	.	.	.				162
1.8	Vacuum hose schematic diagram .		.			. .				.		. .	. . . . .	.		.	.	.		. .		.		.	. . . . . .	. . . . .	. . .		.	.		.	.	.	.		.	.	.	.				164

ii Contents

Downloaded from www.Manualslib.com manuals search engine

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													s	- injection																													c														166
23 - Mixture preparationn																								.	. .		. . .	. . .	. .	.	.	.	. .		.		. .	.			.	.	. .	.t.			.			.		.				. . . . . . . . . . .
												s																																c
											le																																	e
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1										d		injection system																																	a												166
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	Diesel directt																							.	. .		. . .	. . . . .	. .	.	.	.	. . .		.		. . .	.			.	.	. .	. .	.		.					.		.		. . . . . . . . . . . . .
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						m	i																																							y
1.1																																																a									166
																																																				t
	Safety precautionse															.	.	.	.	.	.	.	.	.	. .	.	. . .	. . . . .	.	.	.	.	. . .		.	.	. .	.		.		.	. .	. .	.		.		.							. . . . . . . . . . . . .
					r																																														l
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					p																																														i
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1.2	Rules for cleanliness																.		.	.	.	.	.	.	. .	.	. . .	. . . . .	.	.	. .	.	. .	.		.	. .	.		.		. .	.	. .	.		.		.		.			.	. . . . . . . . . . . . .t		167
			o	t																																																y
		n																																																				i
1.3	Assembly,									overview - unit injector																																										w					167
																										.	. .	. . . . . .	.	.	.	.	. .	.	.		. .	.		.	.	.	. .	.	.	.		.			.		.			e. . . . . . . . . . . . .
	s																																																							r
	i
																																																							h
1.4	e									and installing unit injector																																														e	169
	Removingh																											. . . . .	. .		. .	.	. .	.	.		. .	.		.		. .	.	. .	.	.		.			.			.
	l																																																							s
	o																																																							p
1.5	w								non-contact gap of unit injectors																																															t	171
	Adjustingi																												.	.	. .		. .	.	. .		. .	.		.		. .	.	. .	.	.		.				.		.		. c. . . . . . . . . . . .
	n																																																							t
1.6	Removing and installing O-rings for unit injector																																																							o	172
																															. .		. .		. .	.	.	.	.			. .	.	. .	.			.	.			.				. . . . . . . . . . . . .
	r
	o																																																							t
	t																																																							h
																																																								e
1.7	r																																																								174
	Assembly overview - intake manifold .																											. . . . .	. .		. . .		. .		. .	.	.	.	.			. .	.	. .	.	.		.				.		.		. .r. . . . . . . . . . .
	a																																																							c
	p																																																							o
1.8	n																																																							c	176
	Cleaning the intake manifold flap support, Engine code BLS and BXJ																																															.	.			.
	i																																																							r
	,																																																							e
1.9	s																																																							t	177
	Assembly overview - air filter																							.	. .	.	. . .	. . . . .	. .		. . .		. .		. .	.	.	.	.			. .	.	. .	.	.		.	.					.
	e																																																							n
	s
	o																																																							e
2	p				control unit																																																			s	178
	Enginep															.	.	.	.	.	.	.	.	.	. .	.	. . .	. . . . .	. .		. . .		. .		. .	.	.	.	.			. .	.	. .	.	.		.				.		.		. .f. . . . . . . . . . .
	r																																																							s
2.1	u						and erasing engine control unit fault memory																																																	o	178
	Readingc																																		.	.	.	.	.		.	.	. .	.	.	.		.	.				.		.	. . . . . . . . . . . .f
	l																																																							i
	i																																																							n
2.2	r																																																							o	179
	Adapting functions and components .																											. . . . . .	.		. . .		. .	.	.	.	.	.	.		.	.	.	. .	.	.		.	.				.		.	r. . . . . . . . . . . .
	e																																																							m
2.3	m																																																							a	180
	Removing and installing engine control unit, Golf .																																. .	.	.	. .		.	.		.	.	. .	.	.	.		.	.				.		.	. . . . . . . . . . . .o
	m																																																							t
	c																																																						n	i
2.4	o																																																			t		i			180
	Removing and installing anti-theft engine control unit, Golf																																					.	.			. .	.	. .	.	.		.					n		.	. . . . . . . . . . . .
			r
				o																																																h
2.5	Removing and installing engine control unit, Golf Plus																																																d	s	i						183
																																			.	. .		.	. .			.	. .	.	.	.		.					.		.	. . . . . . . . . . . .
					t
					a
					e
								r																																								o
						v
2.6							i																																								c										183
	Removing and installing anti-theft engine control unit, Golf Plus																																										.	. .	.	.		.				.			. .	. . . . . . . . . . .
									p																																					u
										r																																			m
											f
										o																																		e
											g
												n																																n
26 - Exhaust system												i																															o	t													186
													. .o. .			.	.	.		.	.	.	.	.	.	.	. .	. . . . .	.		. . .		.	.	.	.		.	.			. .		.	.	.		.				.			. .	. . . . . . . . .
													y																														.
													p	C																													C
																																										p
														.																											y
																																									r
1	Exhaust system													t																							b																				186
														. . .ry. .					.	.	.	.	.	.	. .	.	. . .	. . . . .	. .		. . .		. .		. .	. .			g.			. .	.	. .	.	.		.	.					.	. .	. . . . . . . . . . .
														h
															g																							h			i
																i	p																				y	t
1.1																																																									186
	Assembly overview - frontbexhaustd																										pipe with catalyticwsconverter																.	. .	.	.		.				.			. .	. . . . . . . . . . .
																			c	y																V
																																			o
																						e	t										a	kl
																																g
																							c	et							e
1.2	Assembly overview - front exhaust pipe with particulate filter																																						.			.	.	. .	.	.		.				.			. .	. . . . . . . . . . .	187
																									or				A
																									P				.G
1.3	Assembly overview - silencer with mountings (vehicles with front wheel drive) . . . . . . . . . .																																																								189
1.4	Assembly overview - silencer with mountings (vehicles with four-wheel drive) . . . . . . . . . .																																																								191
1.5	Aligning exhaust system free of stress																											. . . . .	.	.	. .		. .	.	.	. .		.	. .			.	. .	.	.	.		.	.				.		. .	. . . . . . . . . . .	192
2	Exhaust gas recirculation system																									.	. .	. . . . . .	.	.	. .		. .	.	.	. .		.	. .			.	. .	.	.	.		.	.				.		. .	. . . . . . . . . . .	193
2.1	Assembly overview - parts of exhaust gas recirculation																																		.	. .		.	.			. .	.	. .	.	.		.				.		.	. .	. . . . . . . . . . .	193
28 - Glow plug system													.	.	.	.	.		.	.	.	.	.	.	.	.	. .	. . . . .	.	.	. .		.	.	.	. .		.	.			.	.	. .	.			.	.				.		. .	. . . . . . . . .	198
1	Checking glow plug system																						.	.	. .	.	. . .	. . . . .	. .		. . .		.	.	.	. .		.	. .			. .	.	. .		.		.	.			.			. .	. . . . . . . . . . .	198
1.1	Removing, installing and checking glow plugs .																														. . .		.	.	. .	.		.	. .			. .	.	. .		.		.	.			.			. .	. . . . . . . . . . .	198
1.2	Characteristics of ceramic glow plugs																											. . . . .	. .		. . .		. .		. .	. .		.	.			. .	.	. .		.		.	.			.			. .	. . . . . . . . . . .	199
1.3	Removing, installing and checking ceramic glow plugs																																		.	. .		.	.			. .	.	. .	.	.		.	.					.	. .	. . . . . . . . . . .	200

Contents iii

Downloaded from www.Manualslib.com manuals search engine

Golf 2004 , Golf Plus 2005

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

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iv Contents

Downloaded from www.Manualslib.com manuals search engine

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

00 – Technical data

1Technical data

Engine number page 1

Engine data page 1

1.1Engine number

The engine number (“code letters” and “serial number”) can be found at the joint between engine and gearbox.

Additionally there is a sticker on the toothed belt guard with “en gine code” and “serial number”.

The engine code is also included on the vehicle data sticker.

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Engine data

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1. Technical data 1

Downloaded from www.Manualslib.com manuals search engine

Golf 2004 , Golf Plus 2005

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

10 – Removing and installing engine

1Removing and installing engine

Removing engine page 2

Securing engine to assembly stand page 7

Notes on installing page 7 .

Assembly mountings page 10 .

1.1Removing engine

Special tools and workshop equipment required

♦Lifting tackle -2024 A-

♦Engine bracket -T10012-

♦Support clamp -VW 313-

♦Engine and gearbox sup port -VW 540-

♦Workshop crane -V.A.G 1202 A-

♦Drip tray -V.A.G 1306-

2Rep. Gr.10 - Removing and installing engine

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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-typeclippliers-VAS 5024-

♦Stepladder -VAS 5085-

♦Guide rods -T10093-

♦Cable ties

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a ♦ Before carrying out further work, disconnect battery earth

i

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

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theft coding first if necessary.

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♦o The engine is removed downwards together with the gearbox.

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oitam

1. Removing and installing engine 3

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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 abruptly

A

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upwards at -arrows-, then pull inner engine cover abruptly up

a

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wards at -arrows-.

e

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– Remove plenum chamber bulkhead.u General body repairs,

th

a

plenum chamber bulk

exterior; Rep. Gr. 50 ; Body - front,s

le

s

head .

u

d

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air mass meter and connecting

– Remove air filter housing withm

i

t

pipe.

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oitam

4Rep. Gr.10 - Removing and installing engine

Downloaded from www.Manualslib.com manuals search engine

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

olksw

very hot (danger of scalding)!.V ag

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♦ The fuel systemV

is also under pressure!oBeforet

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u

Then

b

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a

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r

s

a

the isystem, place cloths around the connections.n

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t

o

e

th

e

carefully loosen connection to release the pressure!o

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p

♦ Wear eye and hand protection when performing any type

u

n

of repair work on the fuel system!

t

d

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t

y

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p

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–

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Removeinsulationtray Generalbodyrepairs,exterior;Rep.i

is

Gr. 50 ; Body - front; Assembly overview

t

h

r

,

e

e

s

l

o

–

Bringlockcarrierintoserviceposition Generalbodyrepairs,

p

h

e

w

exterior; Rep. Gr.

50 ; Body - front; Lock carrier - service po

c

t

n

t

i

o

r

sition .

o

t

h

t

e

r

a

– Drain coolant page 102 .

c

p

o

n

r

r

i

,

Vehicles with air conditioner

e

s

c

e

t

s

n

o

e

p

s

r

s

u

o

p

Note

f

l

i

a

n

i

f

c

o

r

e

r

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

m

m

a

m

it

o

ensure that the lines and hoses are not stretched, kinked or bent.in

o

c

r

o

t

n

e

s

i

h

t

a

v

d

i

rTo facilitate removing and installing engine without opening reo

p

u

c

r

o

frigerant circuit:

m

f

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g

n

n

i

t

y

.

p

C

– Remove poly V-belt page 13 .

o

o

C

p

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y

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t

h

i

g

–

Removegir

h

air condition

air conditioner compressor Heating,t

y

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p

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y

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c

o

ing; Rep. Gr.y

87 ; Removing and installingklcompressor brack

et .

b

d

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– Secure air conditioner compressor to lock carrier so that re

frigerant lines are free of stress.

–

Remove alternator Electrical system; Rep. Gr.

27 ; Re

moving and installing alternator and poly V-belt .

Continuation for all vehicles

–Remove connecting pipes between charge air cooler and en gine.

–Unbolt left and right-hand drive shafts from gearbox Run ning gear, axles, steering; Rep. Gr. 40 ; Removing and installing drive shaft .

–Remove front exhaust pipe page 186 .

–Release connectors on engine control unit and pull them off.

1. Removing and installing engine 5

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Golf 2004 , Golf Plus 2005

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

– Open all cable guide fasteners -arrows-.

o

s

V

lk

y

b

– Removewiringharnessfromcableguideonlongitudinalmem

d

e

is

ber and lay to side on engine.

r

u

o

th

a

s

– Pull off or disconnect all other electrical connectionsn

from en

le

gine and gearbox as necessary and lay to side.

e

d

u

t

m

i

t

– Separate all connecting, coolant, vacuum ande

r intake hoses

from engine.

o

t

p

Vehicles with manual gearbox

s

n

,

i

e

l

–

o

Removeslavecylinderforhydraulicclutch.w 6-speedmanual

h

mechanism; As

gearbox 02S; Rep. Gr. 30 ; Repairing clutchr

n

sembly overview - hydraulics .

i

r

o

t

–

a

Unbolt gear selector mechanism from gearbox. 6-speed

p

n

selector mech

manual gearbox 02S; Rep. Gr. 34 ; Repairinge

i

,

anism .

s

o

s

Vehicles with four-wheel drive:

p

l

r

u

p

–

a

Remove selector mechanism from gearbox 6-speed man

i

c

r

ual gearbox 02Q, four-wheel drive; Rep. Gr. 34 ; Repairing

e

selector mechanism .

m

c

m

o

		r
–	Separate pressure line for hydraulic clutch	control.
		a
		o
		e
		t
		v
–		i
		r
		p
		r
	Removefrontpropshaft Finaldrive02D,0AV;Rep.Gr. 39;
	Assembly overview - repairing propshaft .	o
		f
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Continuation for all vehicles:		p
		o
		C.
		t
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		i
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		p
			o
–	Unbolt pendulum support -arrows-.			c
				y	bd	t
Vehicles with particulate filter					e
–	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- .

en

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6Rep. Gr.10 - Removing and installing engine

Downloaded from www.Manualslib.com manuals search engine

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

–Unboltassemblymountingonenginesidefromenginebracket -arrows-.

Note

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AG

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ge

G

- .

To remove securingobolts, use stepladder -VAS 5085n

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–no

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Unbolt assembly mounting on gearbox side from gearbox

i

i

y

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bracket -arrows-.

w

s

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l

o

– Carefully lower engine with gearbox.

h

w

n

i

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o

Note

p

t

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i

,

Engine with gearbox must be guided carefully when lowered to

s

s

e

prevent damage to bodywork.

p

o

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m

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m

i

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Securing engine to assembly stand

n

o

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i

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t

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Whenpworkingontheengine,secureittosupportclamp-VW313- c

o

d

r

v

i

u

r

of the assembly stand using engine and gearbox support -VW

m

f

540- .

o

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Procedure

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–

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Disconnect gearbox.bd

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A

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– Attach lifting tackle -2024 A- as shown and raise engine out of

engineandgearboxjack-V.A.G1383A-usingworkshophoist

-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

Thehooksandlocatingpinsmustbesecuredwithlockingpins.

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 313using engine and gearbox jack -VW 540- .

1.3Notes on installing

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

1. Removing and installing engine 7

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Golf 2004 , Golf Plus 2005

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

–Checkclutchreleasebearingforwearandrenewifnecessary.

–Lubricate splines of input shaft lightly with G 000 100.

–Checkwhetherdowelsleevesforcentringengineandgearbox 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 paralleltothesupportarm-1-.Dimension-x-mustbeidentical at top and bottom.

Note

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

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8Rep. Gr.10 - Removing and installing engine

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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.

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Install drive shafts Running gear, axles,esteering; Rep. Gr.

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40 ; Removing and installing drive shaftst .

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– Install front exhaust pipe page 186les .

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Vehicles with manual gearbox

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–

clutch

6-speed manual

Install slave cylinder for hydraulice

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sembly overview - hydraulicsis

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Vehicles with four-wheel drive:p

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6-speed manual

Install selector mechanism on gearbox

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lector mechanism .

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–

Install pressure line for

hydraulic clutch control.

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Install front propshaft

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Final drive 02D, 0AV; Rep. Gr. 39 ;

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Assembly overview - repairing propshaft .

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Continuation for all vehicles:

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and installing alternator and poly V- belt .

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Install air conditioner compressor Heating, air conditioning;tceto

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Rep. Gr. 87 ; Removing and installing compressor bracket.

– Install poly V-belt page 13 .

–

Install insulation tray

General body repairs, exterior; Rep.

Gr. 50 ; Body - front; Assembly overview.

– Install engine control unit page 178 .

–

Install plenum chamber bulkhead General body repairs,

exterior; Rep. Gr. 50 ; Body - front; Plenum chamber bulk

head .

– Fill cooling system with coolant page 102 .

– Carry out road test and then read fault memory page 178 .

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1. Removing and installing engine 9

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Golf 2004 , Golf Plus 2005

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

Specified torques

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

1.4Assembly mountings

Engine assembly mounting

A = 20 Nm + 90° (1/4 turn) further 1)

B = 40 Nm + 90° (1/4 turn) further 1)

C = 60 Nm + 90° (1/4 turn) further 1)

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10 Rep. Gr.10 - Removing and installing engine

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

Pendulum support

Alwaysnotethesizeandstrengthclassofbolt.Differentspecified 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

Fortheseandallothergearboxesboltswithstrengthclass10.9 must be used.

If Heli Coil inserts are not fitted in manual gearboxes 02Q, use bolts with strength class 8.8 and the specified torques.

Bolt -A-

M10 x 35 strength class 8.8: turn 40 Nm + 90° further

M10 x 35 strength class 10.9: turn 50 Nm + 90° further

Always renew after removing

Bolt -B-

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1. Removing and installing engine 11

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Assembly overview - poly V-belt drive page 12 Removing and installing poly V-belt page 13 Assembly overview - toothed belt drive page 15 Assembly overview - crankcase page 19

Golf 2004 , Golf Plus 2005

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

13 – Crankshaft group

1Dismantling and assembling engine

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in order to

passages thoroughly and renew the engine oil coolero

prevent further damage from occurring later.

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Assembly overview - polyiV-belt drive

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1 - Belt pulley and vibration

a

damper

Can only be installed in one position, holes are offset.

2 - 25 Nm

3 - Alternator

4 - Bracket

For alternator and air conditionercompressor.

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 installingpage 13 .

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12 Rep. Gr.13 - Crankshaft group

Downloaded from www.Manualslib.com manuals search engine

t r a p n i

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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-

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

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General body repairs,n

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50 ; Body - front; Assembly overviewd

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hoses to side.

– Pull fuel filter out of bracket and lay it withr

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– Swing tensioning element in directiono of arrow to remove ten

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1. Dismantling and assembling engine 13

Downloaded from www.Manualslib.com manuals search engine

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.

1.2.2Installing poly V-belt

– Installation is carried out in the reverse sequence of removal.

Note

♦Before installing poly V-belt, ensure that all ancillaries (alter nator, air conditioner compressor) are secured tightly.

♦When fitting poly V-belt, check direction of belt rotation and ensure proper seating of belt in pulleys.

♦Lastly, place poly V-belt over alternator.

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14 Rep. Gr.13 - Crankshaft group

Downloaded from www.Manualslib.com manuals search engine

s p e c t

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

1.3Assembly overview - toothed belt drive

1 - Toothed belt guard upper

part

2 - 100 Nm

3 - 25 Nm

4 - Camshaft pulley

5 - Hub

With sender wheel

Use counterhold tool -

T10051to loosen and

tighten.

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16 - Crankshaft toothed belt pulley 17 - 120 Nm + 1/4 turn (90°) further

Renew

Use counterhold tool -3099- to loosen and tighten.

Do not additionally oil or grease thread and shoulder.

Turning further can be done in several stages.

18 - 15 Nm

19 - Toothed belt guard lower part

20 - Belt pulley and vibration damper

Can only be installed in one position, holes are offset. 21 - 10 Nm + 1/4 turn (90°) further

Renew

1. Dismantling and assembling engine 15

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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°) furtherRenew

25 - Toothed belt guard centre part

26 - Engine bracket

1.3.1

Removing and installing engineagenAG supportenAGd

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– Remove engine cover.it

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– Todothis,pullenginet p

coverupwardsabruptlyatfrontandright

-arrows A- and thenn

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pull forwards out of rear fastening

-arrow B-.

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Two-piece engine cover

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For two-piece engine cover, first pull outer engine cover abruptly

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upwards at -arrows-,

then pull inner engine cover abruptly up

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wards at -arrows-.

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16 Rep. Gr.13 - Crankshaft group

Downloaded from www.Manualslib.com manuals search engine

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/ 13and take up weight of engine in installation position.

– Remove securing bolts from assembly mounting/engine sup

port -arrows- and remove complete assembly mounting.

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and lowering engine using

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or torn off.

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– Remove noise insulation tray General body repairs, exteri

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or; Rep. Gr. 50 ; Body - front; Assembly overview - noise

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insulation .

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– Remove front right wheel housing liner.

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1. Dismantling and assembling engine

17

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Golf 2004 , Golf Plus 2005

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

G.V

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– Raise engine with support bracket -10-222Ae- until both upper

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– Lower engine with support bracket -10s -222A- until lower bolt

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Caution

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specified torques for the engine

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in the sequence shown

– Tighten bolts for engine

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-1…3- to 40 Nm +

1

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lower engine using support bracket -10 - 222 A- .

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

–Install assembly mounting between engine and body, renew securing bolts page 10 .

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–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

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c o r r e c t n e s s o f i n f o r am

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

1.4Assembly overview - crankcase

1 - Cylinder block

Removing and installing sealing flange and fly wheel page 20 .

Removing and installing crankshaft page 33

Dismantlingandassem bling pistons and con rods page 33

2 - GasketRenew

3 - Oil filter bracket

Dismantlingandassem bling page 92 .

4 - 15 Nm + 1/4 turn (90°) fur ther

Renew

First fit upper left and lower right bolts and thentightenallfourbolts diagonally.

5 - Bracket

6 - 20 Nm

7 - Connection

For thermostat.

8 - 15 Nm

9 - O-ring

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10 - Thermostat

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Removing and installingm

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page 108 .

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position page 108 , removing and installing thermostat.

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Opening liftpat least 7 mm.

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Tighteningsequence and torque specifications Heating, air conditioning; Rep. Gr. 87 ; Removing and

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installing compressor bracket .

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12 - Bracket

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For alternator,mif air conditioner compressor is fitted

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13 - Poly V-belt tensioning element

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14 - 25 Nm

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15 - Sump

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1. Dismantling and assembling engine 19

Golf 2004 , Golf Plus 2005

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2Removing 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 endpage 21 .

Renewing crankshaft sealing flange - flywheel end page 25 .

2.1Assembly overview - sealing flanges and flywheel

Note

G.Volkswage

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Repairing clutch

6-speed manual gearbox 02S; Rep.Gr.e

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30 ;Repairing clutch.

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1 - Seal

e

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 .

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 .

3 - Cylinder block

Removing and installing crankshaft page 33

Dismantlingandassem bling pistons and con rods page 33

4 - 60 Nm + 1/4 turn (90°) fur ther

Renew

5 - Flywheel

To remove and install flywheel, counterhold with 3067.

6 - Intermediate plate

Must be positioned on dowel sleeves.

Do not damage or bend when assembling.

AG

does

not

guarant ee

or a c c

20 Rep. Gr.13 - Crankshaft group

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

7 - 15 NmRenew

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.

2.2Renewing 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-

♦Torque wrench - V.A.G 1332-

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2. Removing and installing sealing flange and flywheel

21

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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.

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– Unscrew inner part oflksoilw seal extractor two turnsoes (approx. 3

g

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mm) out of outerbpart and lock with knurled screw. gu

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– Oil threadedth head of oil seal extractor.

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– Usingugreat pressure, screw oil seal extractor as far as possi

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seal.

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knurled screw and turn inner part against crankshaft

– Loosenp

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oil seal is pulled out.

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The oil seal sealing lip must not be additionally oiled or greased.

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– Remove oilo residue from crankshaft journal using clean cloth.oC

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– Place guide sleevery

-T10053/1- onto crankshaft journal.b

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– Slide oil seal over guidecsleeve onto crankshafte

journal.

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22 Rep. Gr.13 - Crankshaft group

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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 .

2.3Removing 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

♦ Siliconesealant-D176404

A-

agen

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A

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♦

Flat scraper

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belt. page 50

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2. Removing and installing sealing flange and flywheel 23

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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.

–Removesealantresiduefromcylinderblockwithaflatscraper.

–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.

2.3.2	is
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Installing

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♦ Install sealing flange within 5 minutes of applying the silicone
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♦ Sealant bead must not be wider than 2...3 mm, because oth

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erwise excess sealant can enter sump and clog strainer in oil

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pump suction pipeoas well as drip onto crankshaft oil seal.

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♦ Beforeapplyingsealantrybead,coversealingsurfaceofoilsealb

with a clean cloth.

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c o r r e c t n e s s o f

24 Rep. Gr.13 - Crankshaft group

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