Diesel Engine 4 Cylinder (1 9 L Engine)

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Service Department. Technical Information

This is the cut pages sample. Download all 207 page(s) at: ManualPlace.com
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00 - Technical data
10 - Removing and installing engine

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13 - Crankshaft group

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15 - Cylinder head, valve gear

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17 - Lubrication

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19 - Cooling
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20 - Fuel supply system

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21 - Turbocharging/supercharging
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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

 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 - sealingn flanges AG. Volksw and
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2.2 Renewing crankshaft ooil
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2.4 Renewing crankshaft
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2.5 Removingssand installing engine speed sender G28 . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . 31
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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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4.3 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5 Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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1.3 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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2.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.3 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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2.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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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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2 Parts of lubrication system . . . . . . . . . . . . . .a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o87
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2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . s
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2.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

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3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line . . . . . . . . . . . . . . . . . . 92

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3.1 Assembly overview - oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 92

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3.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

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3.3 Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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3.4 Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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1.1 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.3 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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1.4 Draining and filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

1.5 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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1.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

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1.7 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

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1.8 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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1.9 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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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
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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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1 Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

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1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

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1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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1.4 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

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1.5 Adjusting non-contact gap of unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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1.6 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.7 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.8 Cleaning the intake manifold flap support, Engine code BLS and BXJ . . . . . . . . . . . . . . . . 176

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1.9 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

2.1 Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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2.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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2.3 Removing and installing engine control unit, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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2.4 Removing and installing anti-theft engine control unit, Golf . . . . . . . . . . . . . . . . . . . . . . . . 180
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2.5 Removing and installing engine control unit, Golf Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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2.6 Removing and installing anti-theft engine control unit, Golf Plus . . . . . . . . . . . . . . . . . . . . 183
r
rp

cu
o

m
f

en
ng

t.
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
yi Co
Cop py
t. rig
1 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
gh ht
pyri by
Vo
o
1.1 Assembly overview - front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . . .
by c
186
lksw
cted agen
Prote
1.2 Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . 187
AG.

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

n AG. Volkswagen AG do
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iv Contents
 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.

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1.2 Engine data yV
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Engine code BJB
ut
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BKC BRU BLS e o BXE BXF BXJ
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Manufactured s10.03 ▸ 10.03 ▸ 04.04 ▸ 02.06 ▸ 03.06 03.06 11.07
ce
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un

Emissions fulfil EU3 EU4 EU4 EU4 EU4 pt EU4 EU4

an
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standard standard standard standard standard y li standard standard

erm

ab
Capacity l 1.9 1.9 1.9 1.9 1.9 ility
1.9 1.9
ot p

wit
Output kW at 77/ 77/ 66/ 77/ 77/ 66/ 66/
is n

h re

rpm 4000 4000 4000 4000 4000 4000 4000

ole,

spec

Torque Nm at 250/ 250/ 210/ 250/ 250/ 210/ 210/

urposes, in part or in wh

rpm 1900 1900 1800...250 1900 1900 1800 1800...250

t to the co

0 0
Bore ∅ mm 79.5 79.5 79.5 79.5 79.5 79.5 79.5
rrectne

Stroke mm 95.5 95.5 95.5 95.5 95.5 95.5 95.5

Valves per cylinder 2 2 2 2 2 2 2
ss

Compression ratio 19.0 19.0 19.0 18.5 18.5 19.0 19.0

o
cial p

f in

Fuel accord‐ DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN

form
mer

ing to 590 590 590 590 590 590 590

atio
m

Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

o

n
c

i
or

Catalytic converter yes yes yes yes yes yes yes

thi
te

sd
va

Exhaust gas recircu‐ yes yes yes yes yes yes yes
i

o
pr

cum
r

lation
fo

en
ng

t.
yi
Turbocharging/super‐ yes yes yes yes yes yes yes
Co
op py
charging
. C rig
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rig by
py
Charge air cooler yes yes yes yes yes yes yes
co Vo
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Particulate filter no
Prote
no no yes no no no
AG.

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-
♦ Support clamp -VW 313-
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♦ Engine and gearbox sup‐ olksw not
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port -VW 540- d by ara
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or eo
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♦ Workshop crane -V.A.G s aut ra
c
1202 A- s

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pt
♦ Drip tray -V.A.G 1306-

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tion in
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thi
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Prote AG.

2 Rep. Gr.10 - Removing and installing engine

 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

AG. Volkswagen AG d
agen oes
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Note
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♦ Before carrying out further work, disconnect battery earth

nf
ercia

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

o

theft coding first if necessary.

rm
m

atio
m

♦ The engine is removed downwards together with the gearbox.

o

n in
or c

thi

♦ All cable ties which are opened or cut through when engine is
te

sd
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removed must be replaced in the same position when engine

o
r
rp

cu

is installed.
o

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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

1. Removing and installing engine 3

 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 n Aabruptly
G. Volkswagen AG d
upwards at -arrows-, then pull inner engine cover lks wage
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– Remove plenum chamber bulkhead. au ⇒ General body repairs,
th ra
exterior; Rep. Gr. 50 ; Body - front,
ss plenum chamber bulk‐ c
ce

head .
le
un

pt
an
d
itte

– Remove air filter housing with air mass meter and connecting
y li
erm

ab

pipe.
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
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fo

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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.

4 Rep. Gr.10 - Removing and installing 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
very hot (danger ofAscalding)!
G. Volkswagen
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♦ The fuel ysystem
Vol
ks is also under pressure!
s no
Before
t gu opening
the system,
ir se
d b
place cloths around the connections.
ara
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carefully
ut
ho loosen connection to release the pressure! eo
r
sa ac
♦ s Wear eye and hand protection when performing any type

ce
le

of repair work on the fuel system!

un

pt
an
d
itte

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ab
ility
ot p

– Remove insulation tray ⇒ General body repairs, exterior; Rep.

wit
Gr. 50 ; Body - front; Assembly overview
is n

h re
ole,

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

spec
urposes, in part or in wh

exterior; Rep. Gr. 50 ; Body - front; Lock carrier - service po‐

t to the co
sition .
– Drain coolant ⇒ page 102 . rrectne
Vehicles with air conditioner
ss o

Note
cial p

f inform
mer

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

atio
m

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

n
c

i
or

n thi
te

sd

To facilitate removing and installing engine without opening re‐

iva

o
r

frigerant circuit:
p

cum
r
fo

en
ng

– Remove poly V-belt ⇒ page 13 .

t.
yi Co
Cop py
. rig
– Remove air conditioner compressor ⇒ Heating, air condition‐
t
gh ht
yri by
ing; Rep. Gr. 87 ; Removing and installing compressor brack‐
cop Vo
by lksw
et . cted agen
Prote AG.

– 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
– Open all cable guide fasteners -arrows-. agen oes
olksw not
V gu
by ara
– Remove wiring harness from cable guide on longitudinal mem‐rised
nte
ber and lay to side on engine. aut
ho eo
ra
ss c
– Pull off or disconnect all other electrical connections from en‐

ce
le
un
gine and gearbox as necessary and lay to side.

pt
an
d
itte

y li
– Separate all connecting, coolant, vacuum and intake hoses

erm

ab
from engine.

ility
ot p

wit
is n
Vehicles with manual gearbox

h re
ole,

spec
– Remove slave cylinder for hydraulic clutch. ⇒ 6-speed manual

urposes, in part or in wh
gearbox 02S; Rep. Gr. 30 ; Repairing clutch mechanism; As‐

t to the co
sembly overview - hydraulics .
– Unbolt gear selector mechanism from gearbox. ⇒ 6-speed

rrectne
manual gearbox 02S; Rep. Gr. 34 ; Repairing selector mech‐
anism .

ss
Vehicles with four-wheel drive:

o
cial p

f in
– Remove selector mechanism from gearbox ⇒ 6-speed man‐

form
mer

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

atio
selector mechanism .
om

n
c

i
or

n
– Separate pressure line for hydraulic clutch control.

thi
te

sd
va

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

i

o
pr

cum
r

Assembly overview - repairing propshaft .

fo

en
ng

t.
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Continuation for all vehicles: Cop py
t. rig
gh ht
pyri by
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– Unbolt pendulum support -arrows-. by c lksw
cted agen
Prote AG.
Vehicles with particulate filter
– 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

 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
To remove securingVbolts,
olks
waguse stepladder -VAS 5085-
does
not .
y gu
db ara
rise nte
tho eo
s au ra
c
s

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un

pt
an
d
itte

y li
rm

ab
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ility
– Unbolt assembly mounting on gearbox side from gearbox
ot

wit
, is n

bracket -arrows-.

h re
hole

spec
– Carefully lower engine with gearbox.
es, in part or in w

t to the co
Note

rrectness of i
Engine with gearbox must be guided carefully when lowered to
prevent damage to bodywork.
l purpos

nform
mercia

a
com

tion in
1.2 Securing engine to assembly stand
r
te o

thi
s
iva

When working on the engine, secure it to support clamp -VW 313-

do
r
rp

of the assembly stand using engine and gearbox support -VW

um
fo

en

540- .
ng

t.
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op py
Procedure t. C rig
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– Disconnect gearbox.
co lksw
by
cted agen
Prote AG.
– 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

Distance -a- = 10 mm can also be checked with a metal rod of

suitable size, or similar.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

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le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
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fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

8 Rep. Gr.10 - Removing and installing engine

 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. swage

n AG. Volkswagen AG do
es n
olk ot g
yV
– Install drive shafts ⇒ Running gear, axles, esteering;
d b Rep. Gr. ua
ran
ir s
40 ; Removing and installing drive shafts tho . tee
or
au ac
– Install front exhaust pipe ⇒ page 186 .
ss

ce
le
un

pt
Vehicles with manual gearbox

an
d
itte

y li
rm

– Install slave cylinder for hydraulic clutch ⇒ 6-speed manual

ab
pe

ility
gearbox 02S; Rep. Gr. 30 ; Repairing clutch mechanism; As‐
ot

wit
sembly overview - hydraulics .
, is n

h re
hole

– Remove selector mechanism from gearbox ⇒ 6-speed man‐

spec
ual gearbox 02S; Rep. Gr. 34 ; Repairing selector mecha‐
es, in part or in w

t to the co
nism .
Vehicles with four-wheel drive:

rrectness of i
– Install selector mechanism on gearbox ⇒ 6-speed manual
gearbox 02Q, four-wheel drive; Rep. Gr. 34 ; Repairing se‐
l purpos

lector mechanism .
– Install pressure line for hydraulic clutch control.

nform
ercia

– Install front propshaft ⇒ Final drive 02D, 0AV; Rep. Gr. 39 ;

m

a
com

t
Assembly overview - repairing propshaft .

ion in
r
te o

Continuation for all vehicles:

thi
s
iva

do
r

– On vehicles with particulate filter install subframe ⇒ Running

rp

cum
fo

gear, axles, steering; Rep. Gr. 40

en
ng

t.
yi Co
op
– Install alternator ⇒ Electrical system; Rep. Gr. 27 ; Removing C py
t. rig
and installing alternator and poly V- belt .
gh ht
pyri by
Vo
co lksw
by
– Install air conditioner compressor ⇒ Heating, air conditioning; cted agen
Prote AG.
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 .

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 M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm

1.4 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)
1) Renew
n AG. Volkswagen AG do
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Gearbox assembly mounting ss

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A = 40 Nm + 90° (1/4 turn) further 1)

an
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itte

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rm

ab
B = 60 Nm + 90° (1/4 turn) further 1)
pe

ility
ot

wit
1)
, is n

Renew

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

10 Rep. Gr.10 - Removing and installing engine

 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 -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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en AG. V
M10 x 75 strength class 8.8:oturn
lksw 40 Nm + 90° further es not
ag do
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M10 x 75 strength class
or
ise 10.9: turn 50 Nm + 90° further nte
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Always renew after
ss removing
a c
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nl

Bolt -C-
pt
du

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M14 x 1.5 x 70
erm

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ility
ot p

100 Nm + turn 90° further

wit
, is n

h re

Tighten only if pendulum support is bolted to gearbox

hole

spec

Always renew after removing

es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

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ate

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for

en
ng

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gh ht
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Prote AG.

1. Removing and installing engine 11

 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
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Assembly overview - crankcase ⇒ page 19 lksw
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If large quantities of metal particles or other deposits (caused, for

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example, by partial seizure of the crankshaft or conrod bearings)
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are found in the engine oil when making repairs, clean the oil
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passages thoroughly and renew the engine oil cooler in order to
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1.1 Assembly overview - poly V-belt drive
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1 - Belt pulley and vibration

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❑ Can only be installed in
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one position, holes are

offset.

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2 - 25 Nm

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3 - Alternator
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4 - Bracket

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❑ For alternator and air

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5 - Poly V-belt tensioning ele‐ . Cop py
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❑ Swing with ring spanner
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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

 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-

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1.2.1 Removing poly V-belt autho tee
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– Remove insulation tray. ⇒ General body repairs, exterior;

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

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– Pull fuel filter out of bracket and lay it with hoses to side.
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– Mark direction of rotation of poly V-belt.
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– Swing tensioning element in direction of arrow to remove ten‐
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sion from poly V-belt.
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The open-end spanner 16 mm -T 10241- is particularly well suited
to relieve tension.
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1. Dismantling and assembling engine 13

Diesel Engine 4 Cylinder (1 9 L Engine)
Full download: http://manualplace.com/download/diesel-engine-4-cylinder-1-9-l-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.

1.2.2 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.
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– Start engine and check belt running. tho tee
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Belt drive with air conditioner compressor

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14 Rep. Gr.13 - Crankshaft group

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