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Service

Workshop Manual
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4-cylinder diesel engine (1.9 l engine)


AVQ BJB BKC BLS BRU BXE Edition 08.2010

Engine ID

BXF

BXJ

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Service Department. Technical Information

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Service
List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups
AG. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or Repair Group eo th u ra a c ss 00 - Technical data

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10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling

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20 - Fuel supply system 21 - Turbocharging/supercharging 23 - Mixture preparation - injection 26 - Exhaust system 28 - Glow plug system

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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
All rights reserved. No reproduction without prior agreement from publisher. Copyright 2010 Volkswagen AG, Wolfsburg D3E801CBF41

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1.1 1.2 1 1.1 1.2 1.3 1.4 1.5 1.6 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 4 4.1 4.2 4.3 4.4 4.5 1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.4 2.5 1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing engine (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing engine (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing engine (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .en AG..Vo.lk.swage.n.A.G. . . . . . . . . . . . . . . . . . . . . . ... . ... do ag k. Assembly overview - crankshaft . . . . .V. l. sw. . . . . . . . . . . . . . . . . . es.n. t.g. . . . . . . . . . . . . . . . . o o ua by d Pistons and conrods . . . . . . . . . r.se . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.ante . . . . . . . . . . . .. i . o eo h ut Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.ac. . . . . . . . . a ss Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1 1 1

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

3
3 3 9 14 20 21 22 24 24 28 29 32 33 33 34 36 38 40 46 48 48 54 54 55 56 57 57

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60


Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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Contents

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.......................... ............................ Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter bracket, oil pressure, engine oil cooler and oil supply line . . . . . . . . . . . . . . . . . . Assembly overview - oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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103 103 103 104 104 105 109 109 110 111 112 114 115 117 117 119 120 122 123 126 127 128 130 132 134 136 136 137 137 138 138 142 148 150 151 152 156 158 160 161 162 165 167 168 169 170 171 176 176 183 185

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1 1.1 2 2.1 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 5 5.1 5.2 5.3 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of cooling system, body side (radiator with two radiator fans) . . . . . . . . . . . . . . . . . . Assembly overview - parts of cooling system, body side (radiator with one radiator fan) . . Removing and installing fan support with fans (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . Removing and installing fan support with fans (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing radiator (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing radiator (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . Parts of fuel supply system (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel tank, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of fuel supply system (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of fuel supply system (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emptying fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 5.4 5.5 6 6.1 7 7.1 7.2 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3 3.1 3.2 1 1.1 1.2 1.3 1.4 1.5 1.6 2 2.1 2.2 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
s no olk Diesel direct s g. y V injection system . . . . . . . .t . ua. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . db e precautions . . . . . . . . . . . . . . . . . . .ran. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . te ris eo tho Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . r.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . au c s s Removing and installing pre-wired wiring harness for unit injectors and glow plugs . . . . . . Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting non-contact gap of unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the intake manifold flap support, Engine code BLS and BXJ . . . . . . . . . . . . . . . . Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading and clearing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine control unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing anti-theft engine control unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine control unit (Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing anti-theft engine control unit (Golf Plus) . . . . . . . . . . . . . . . . . . . . Removing and installing engine control unit (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing anti-theft engine control unit (Touran) . . . . . . . . . . . . . . . . . . . . . . Engine control unit (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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189 191 193 193 195 195 198 201 201 201 202 203 216 218 221 223 225 225 226 226 229 230 232 233 235 237 238 239 239 240 240 241 243 244 246 247 250 250 251 255 255 256 258 261 262 262 264 264 268

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

23 - Mixture preparation eninjection ge. AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 - AG. Volkswa n . .


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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255


Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . . . Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . Assembly overview - silencer with mountings (vehicles with front wheel drive) . . . . . . . . . . Assembly overview - silencers (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - silencer with mountings (vehicles with four-wheel drive) . . . . . . . . . . Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - parts of exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking mechanical exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents

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iii

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269


1 1.1 1.2 1.3 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing, installing and checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Characteristics of ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing, installing and checking ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 269 270 271

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Contents

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

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Technical data
Technical data
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Engine number page 1 Engine data page 1


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Engine number

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

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1.2

Engine data
AVQ

Edition 07.2010 Version 5.0

BJB

BKC 10.03 12.04

BRU

BLS

BXE

BXF

BXJ 11.07
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05.05 03.06 10.03 10.04 02.06 03.06 EU4 EU4 EU4 EU4 standard stan stan stan dard dard dard Capacity l 1.9 1.9 1.9 1.9 1.9 1.9 Output kW at rpm 74/4000 77/ 77/ 66/ 77/ 77/ 4000 4000 4000 4000 4000 Torque Nm at 250/1900 250/ 250/ 210/ 250/ 250/ rpm 1900 1900 1800 ...2 1900 1900 500 Bore mm 79.5 79.5 79.5 79.5 79.5 79.5 Stroke mm 95.5 95.5 95.5 95.5 95.5 95.5 Valves per cylinder 2 2 2 2 2 2 Compression ratio 19.0 19.0 19.0 19.0 18.5 18.5 Fuel according DIN EN DIN EN DIN EN DIN EN DIN EN DIN to 590 590 590 590 590 EN 590 Firing or 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4der 2 Catalytic yes yes yes yes yes yes converter Exhaust yes yes yes yes yes yes gas recir culation
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Golf/Golf Plus produc 10.03 tion Passat production Touran 02.03 production Emissions fulfil EU4 stan EU3 dard standard

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04.04 02.06 03.06 03.06

03.06 10.06 EU4 stan dard 1.9 66/ 4000 210/ 1800 EU4 stan dard

1.9 66/ 4000 210/ 1800 ...25 00 79.5 79.5 95.5 95.5 2 2 19.0 19.0 DIN EN DIN EN 590 590 1-3-4-2 yes yes 1-3-4-2 yes yes

1. Technical data

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 AVQ Tur bocharg ing/super charging Charge air cooler Particulate filter yes BJB yes BKC yes BRU yes BLS yes BXE yes BXF yes BXJ yes

yes no

yes no

yes no

yes no

yes yes

yes no

yes no

yes yes

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Rep. gr.00 - Technical data

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Removing and installing engine


Removing and installing engine
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Removing engine (Golf, Golf Plus) page 3 Removing engine (Touran) wagen A9 . Volkswagen AG does page G
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Securing engineauth assembly stand page 20 . to Assembly mountings page 22


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Removing engine (Golf, Golf Plus)

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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 hoist -V.A.G 1202 A Drip tray -V.A.G 1306ht rig py Co t.

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1. Removing and installing engine

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 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

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Note

Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted and obtain anti-theft coding if necessary. The engine is removed downwards together with the gearbox. All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 WARNING

When doing any repair work, especially in the engine com partment, pay attention to the following due to the cramped conditions: Route all the various lines (e.g. for fuel, hydraulics, acti vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po sitions. Ensure that there is sufficient clearance to all moving or hot components.
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 upwards at -arrows-, then pull inner engine cover abruptly up wards at -arrows-. . Volkswagen AG gen AG d Remove plenum chamber bulkhead. General d by Vo repairs, body ise exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead . or
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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.

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1. Removing and installing engine

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 WARNING

The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! Wear eye and hand protection when performing any type of repair work on the fuel system!
Remove noise insulation General body repairs, exterior; Rep. gr. 50 ; Assembly overview - Body - front . Bring lock carrier into service position General body repairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po sition . Drain coolant page 123 . Vehicles with air conditioner
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Note

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To facilitate removing and installing engine without opening re frigerant circuit: Remove poly V-belt page 25 . Remove air conditioner compressor Heating, air condition ing; Rep. gr. 87 ; Removing and installing compressor brack et . Secure air conditioner compressor to lock carrier so that re frigerant lines/hoses are free of stress. Remove alternator Electrical system; Rep. gr. 27 ; Remov ing 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 in stalling drive shaft . Release connector from engine control unit, disconnect con nector.
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Rep. gr.10 - Removing and installing engine

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Remove front exhaust pipe page 255 .


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Open all cable guide fasteners

Pull off or disconnect all other electrical connections from en gine and gearbox as necessary and lay to side. Separate all connecting, coolant, vacuum and intake hoses from engine. Vehicles with manual gearbox Remove slave cylinder for hydraulic clutch. 6-speed manual gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism; As sembly overview - hydraulics . Unbolt selector mechanism from gearbox 6-speed manual gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism . Vehicles with four-wheel drive: Remove selector mechanism from gearbox 6-speed man ual gearbox 02Q, four-wheel drive; Rep. gr. 34 ; Repairing selector mechanism .
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Remove wiring harness from cable guide on longitudinal mem ber and lay to side on engine.

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Separate pressure line for hydraulic clutch control. Remove front propshaft Final drive 02D, 0AV; Rep. gr. 39 ; Assembly overview - repairing propshaft . Continuation for all vehicles: Unbolt pendulum support -arrows-. 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
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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- .

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1. Removing and installing engine

Note

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To remove securing bolts, use stepladder -VAS 5085- .

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

Rep. gr.10 - Removing and installing engine

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Engine with gearbox must be guided carefully when lowered to prevent damage to bodywork.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.2

Removing engine (Touran)

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 hoist -V.A.G 1202 A Drip tray -V.A.G 1306-

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1. Removing and installing engine

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 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
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Note

The engine is removed downwards together with the gearbox.

All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.

10

Rep. gr.10 - Removing and installing engine

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Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 WARNING

When doing any repair work, especially in the engine com partment, pay attention to the following due to the cramped conditions: Route all the various lines (e.g. for fuel, hydraulics, acti vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electricalen AG. Volkswagen AG doe po wiring in their original wag s no olks sitions. t gu yV Ensure that therethisissufficient clearance to all moving or or hot components. au s
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Remove engine cover. To do this, pull engine cover upwards abruptly at front -arrows A- and then pull forwards out of rear fastening -arrow B-.

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

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1. Removing and installing engine

11

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 WARNING

The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! Wear eye and hand protection when performing any type of repair work on the fuel system!
Remove noise insulation. General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . Bring lock carrier into service position. General body re pairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier service position . Drain coolant page 123 Vehicles with air conditioner Note

To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
To facilitate removing and installing engine without opening re frigerant circuit: Remove poly V-belt page 25 . Remove air conditioner compressor. Heating, air condition ing; Rep. gr. 87 ; Removing and installing compressor brack et .
a Secure air conditioner compressor to lock carrier so lthat gen ksw re Vo frigerant lines/hoses are free of stress. by d
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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 in stalling drive shaft . Remove front exhaust pipe.

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Continuation for all vehicles

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Remove alternator. Electrical system; Rep. gr. 27 ; Re tho au moving and installing alternator with poly V-belt . ss

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Remove securing nuts -arrows- for engine control unit. Release connector from engine control unit, disconnect con nector.

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Rep. gr.10 - Removing and installing engine

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Open all cable guide fasteners -arrows-. Remove wiring harness from cable guide on longitudinal mem ber and lay to side on engine. Pull off or disconnect all other electrical connections from en gine and gearbox as necessary and lay to side. Separate all connecting, coolant, vacuum and intake hoses from engine. Remove slave cylinder for hydraulic clutch. 6-speed manual gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism; As sembly overview - hydraulics . Unbolt selector mechanism from gearbox 6-speed manual gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism . Unbolt pendulum support -arrows-. 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 agen AG. Volkswagen AG do vehicles:
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Note

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


Fit engine bracket -T10012- to cylinder block with M10 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- .

Unbolt assembly mounting on engine side from engine bracket -arrows-. Note

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To remove securing bolts, use stepladder -VAS 5085- .


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1. Removing and installing engine

13

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Unbolt assembly mounting on gearbox side from gearbox bracket -arrows-. Carefully lower engine with gearbox. Note

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

1.3

Removing engine (Passat)

Special tools and workshop equipment required Lifting tackle -2024 A Engine bracket -T10012 Support clamp -VW 313 Engine and gearbox sup port -VW 540- or engine and gearbox support -VAS 6095 Workshop hoist -V.A.G 1202 A- or workshop crane -VAS 6100 Drip tray -V.A.G 1306- or drip tray -VAS 6208n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss

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Rep. gr.10 - Removing and installing engine

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Torque wrench (5... 50 Nm) -V.A.G 1331 Torque wrench (40... 200 Nm) -V.A.G 1332 Engine and gearbox jack V.A.G 1383 A Spring-type clip pliers -VAS 5024 Stepladder -VAS 5085-

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Not illustrated:

Container for removed parts -V.A.G 1698 Engine bung set -VAS 6122 Grease -G 000 100 Cable ties

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1. Removing and installing engine

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15

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Procedure
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strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.

The engine is removed downwards together with the gearbox.

Leave ignition key in ignition lock to prevent steering lock from engaging.

It is advisable to remove the front wheels before beginning engine removal. The vehicle can then be lowered on hoist until the brake disc splash plates are just above the floor. This pro vides the most ergonomic working position regarding acces sibility of engine compartment components. All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed. To prevent damage to removed components, place them in the container for removed parts -V.A.G 1698- . Some components cannot be removed, or removed only with difficulty, with the engine installed. Therefore, you should de termine all defective components before removing engine and renew them while engine is removed.
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WARNING

When doing any repair work, especially in the engine com partment, pay attention to the following due to the cramped conditions: Route all the various lines (e.g. for fuel, hydraulics, acti vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po sitions. Ensure that there is sufficient clearance to all moving or hot components.
Read fault memories of all control units before removal Di agnosis tester VAS 5051; Guided fault finding; Vehicle system test or VAS 5052; Vehicle self-diagnosis . 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-.

16

Rep. gr.10 - Removing and installing engine

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Two-piece engine cover
. Volkswagen AG gen AG does swa no olkcover, first pull outer engine tcover abruptly For two-piece engine V gu by ara upwards at -arrows-, then pull inner engine cover abruptly up ed nte ris o eo wards at -arrows-. th ra au c s s

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Remove bolt -arrow A- and pull air filter housing upwards out of mounting. Remove air filter housing together with air mass meter and connecting pipe.
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Remove battery and battery tray.


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Remove wiper arms Electrical system; Rep. gr. 92 ; Wind screen wiper system; Removing and installing wiper arms . Remove plenum chamber cover General body repairs, ex terior; Rep. gr. 64 ; Removing and installing plenum chamber cover. Vehicles without anti-theft alarm system Release and disconnect connector from engine control unit page 251 , Removing and installing engine control unit. Vehicles with anti-theft alarm system Release and disconnect connector from engine control unit page 240 , Removing and installing engine control unit with theft protection. Continuation for all vehicles Remove feed-through for engine control unit wiring harness -arrow-.
AG.

1. Removing and installing engine

17

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Open all cable guide fasteners -arrows-. Remove wiring harness from cable guide on longitudinal mem ber and lay to side on engine.

Pull off fuel hose -3-.

The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! Wear eye and hand protection when performing any type of repair work on the fuel system!

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WARNING

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Remove wire from central electrics -arrow-.

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Unscrew earth cable from longitudinal member. Pull off or disconnect all other electrical connections from en gine and gearbox as necessary and lay to side. Separate all connecting, vacuum and intake hoses from en gine. Remove selector mechanism from gearbox 5-speed man ual gearbox 0A4; Rep. gr. 34 ; Repairing selector mechanism . Remove hydraulic clutch slave cylinder 5-speed manual gearbox 0A4; Rep. gr. 30 . Remove noise insulation General body repairs, exterior; Rep. gr. 50 ; Assembly overview - Body - front . Bring lock carrier into service position General body repairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po sition . Pull connector off oil level and oil temperature sender -G266- .

18

Rep. gr.10 - Removing and installing engine

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Drain coolant page 123 .


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Completely remove exhaust pipes from auxiliary heater Heating, air conditioning; Rep. gr. 82 . Pull off coolant hoses on coolant pipes to supplementary heater. Separate all other coolant hoses from engine. Unbolt left and right drive shafts from gearbox Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts . Unbolt pendulum support -arrows-.
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Pull retainer for oil level and oil temperature sender -G266connector off subframe.
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To facilitate removing and installing engine without opening re frigerant circuit: Remove poly V-belt page 25 . Remove air conditioner compressor from ancillary bracket Heating, air conditioning; Rep. gr. 87 ; Removing and in stalling compressor bracket . Secure air conditioner compressor to lock carrier so that re frigerant lines/hoses are free of stress. Note
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To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
On vehicles with particulate filter remove subframe Running gear, axles, steering; Rep. gr. 40 Remove front exhaust pipe page 255 . Unscrew rear coolant pipe page 120 . Tighten engine bracket -T10012- on cylinder block with se curing nut and M10 25/ 8.8 bolt to approx. 40 Nm. Insert engine bracket -T10012- in engine and gearbox jack V.A.G 1383 A- . Raise engine and gearbox slightly using engine and gearbox jack -V.A.G 1383 A- .

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1. Removing and installing engine

19

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Unbolt assembly mounting on engine side from engine bracket -arrows-. Note

To remove securing bolts, use stepladder -VAS 5085- .

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

To remove securing bolts, use stepladder -VAS 5085- .


Carefully lower engine with gearbox. Note

Engine with gearbox must be guided carefully when lowering to prevent damage to bodywork.
n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or When working on the engine, secure it to support clamp -VW 540ac au ss of the assembly stand using engine and gearbox support -VW

1.4

Securing engine to assembly stand

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313- .

Procedure

Disconnect gearbox.

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Attach lifting tackle -2024 A- as shown and raise engine out of engine and gearbox jack -V.A.G 1202 A- using workshop crane -V.A.G 1383 A- . Belt pulley end: 2nd hole in hook rail at position 1 Flywheel end: 4th hole in hook rail at position 8 WARNING

The hooks and locating pins must be secured with locking pins.

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Note

Secure engine on support clamp -VW 540- using engine and gearbox jack -VW 313- .

20

Rep. gr.10 - Removing and installing engine

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The holes in the hook rails are counted up from the hook.
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The holes marked with 1 4 of the support bar point to the belt pulley.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.5

Notes on installing

Installation is carried out in the reverse order. When installing, note the following: Check clutch release bearing for wear and renew if necessary. Lubricate splines of input shaft lightly with G 000 100. Check whether dowel sleeves for centring engine and gearbox are in cylinder block and install if necessary. When installing engine, ensure correct position of assembly mounting: 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 checkedVwith agen AG d rod of n AG. olksw a metal o es n wage suitable size, or similar. ot g olks V
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Ensure that the edges of the support arm on the gearbox as ss sembly mounting -2- and gearbox support -1- are parallel with one another. Dimension -x- must be identical at top and bot tom. Note

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Specified torques for assembly mountings page 22 Electrical connections and routing. Electrical system; Rep. gr. 97 Procedure

Install pendulum support. Install drive shafts Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts . Install front exhaust pipe page 255 . Vehicles with manual gearbox
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Install slave cylinder for hydraulic clutch 6-speed manual gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism; As sembly overview - hydraulics .
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Remove selector mechanism from gearbox 6-speed man ual gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism . Vehicles with four-wheel drive: Install selector mechanism on gearbox 6-speed manual gearbox 02Q, four-wheel drive; Rep. gr. 34 ; Repairing selec tor mechanism . Install pressure line for hydraulic clutch mechanism. Install front propshaft Final drive 02D, 0AV; Rep. gr. 39 ; Assembly overview - repairing propshaft .
AG.

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1. Removing and installing engine

21

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Continuation for all vehicles:
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Install alternator Electrical system; Rep. gr. 27 ; Removing and installing alternator and poly V- belt . Install air conditioner compressor Heating, air conditioning; Rep. gr. 87 ; Removing and installing compressor bracket. Install poly V-belt page 26 . Install noise insulation General body repairs, exterior; Rep. gr. 50 ; Assembly overview - Body - front . Install engine control unit page 239 . Install plenum chamber bulkhead General body repairs, exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulk head . Fill coolant system with coolant page 123 . Carry out road test and then read fault memory page 239 . Specified torques Threaded connection Bolts, nuts Specified torque

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1.6

Assembly mountings

Engine assembly mountings A = 20 Nm + 90 further 1) B = 40 Nm + 90 further 1) C = 60 Nm + 90 further 1)


1)

Renew.

Gearbox assembly mounting A = 40 Nm + 90 further 1) B = 60 Nm + 90 further 1)


1)

Renew.

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Rep. gr.10 - Removing and installing engine

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M6 M8 M10 M12

10 Nm 20 Nm 45 Nm 60 Nm

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Pendulum support Always note the size and strength rating of bolt. Different specified torques are valid. Caution
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For these and all other gearboxes bolts with strength rating 10.9 must be used. If Heli Coil inserts are not fitted in manual gearboxes 02Q, use bolts with strength rating 8.8 and the specified torques.
Bolt -A-

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From model year 08, in manual gearboxes serts are installed in the threaded connections to pendulum support. Difference Rep. gr. 34

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M10 x 35 strength rating 8.8: turn 40 Nm + 90 further M10 x 35 strength rating 10.9: turn 50 Nm + 90 further Always renew after removing Bolt -B-

M10 x 75 strength rating 8.8: turn 40 Nm + 90 further M10 x 75 strength rating 10.9: turn 50 Nm + 90 further Always renew after removing Bolt -CM14 x 1.5 x 70 100 Nm + 90 turn Always renew after removing
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Do not tighten until pendulum support is bolted on gearbox

1. Removing and installing engine

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23

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

13
1

Crankshaft group
Dismantling and assembling engine

Assembly overview - poly V-belt drive page 24 . Removing and installing poly V-belt page 25 . Assembly overview - toothed belt drive page 28 . Assembly overview - crankcase page 32 Note
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If large quantities of swarf or metal particles (caused, for example, by partial seizure of the crankshaft or conrod bearings) are found in the engine oil when performing repairs, clean the oil passages thoroughly and renew the engine oil cooler in order to prevent subsequent damage.
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1.1

Assembly overview - poly V-belt drive

1 - Belt pulley and vibration damper Can only be installed in one position, holes are offset. 2 - 25 Nm 3 - Alternator 4 - Bracket For alternator and air conditioner compressor. 5 - Poly V-belt tensioning ele ment Swing with ring spanner to slacken poly V-belt. 6 - 25 Nm 7 - Air conditioner compressor 8 - 25 Nm 9 - Dowel sleeves 10 - Poly V-belt Mark direction of rota tion before removing. Check for wear. Do not kink. Removing and installing page 25

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Rep. gr.13 - Crankshaft group

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1.1.1

Removing poly V-belt

Locking pin -T10060 A-

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Special tools and workshop equipment required

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16 mm open-end spanner -T 10241-

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Remove noise insulation. General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . Remove lower part of front right wheel housing liner Gen eral body repairs, exterior; Rep. gr. 66 ; Removing and in stalling wheel housing liner . WARNING

The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! Wear eye and hand protection when performing any type of repair work on the fuel system!
Golf, Golf Plus, Touran: Pull fuel filter out of bracket and place it with hoses to one side.

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1. Dismantling and assembling engine

25

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Only Passat: Separate push-fit couplings of fuel lines -arrows-. Note

Do this by lifting catch of push-on connectors.


All other vehicles continued
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Swing tensioning element in direction of arrow to remove ten sion from poly V-belt.
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Lock tensioning element using locking pin -T10060 A- . Remove poly V-belt.
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1.1.2

Installing poly V-belt

Install in reverse order. Note Ensure, before installing poly V-belt, 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. Only Passat: Install fuel filter. Specified torque: 10 Nm. After completing repairs always:

26

Rep. gr.13 - Crankshaft group

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 (1.9 l engine) - Edition 08.2010

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Belt drive with air conditioner compressor

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1. Dismantling and assembling engine

27

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.2

Assembly overview - toothed belt drive

1 - Toothed belt guard upper part 2 - 100 Nm 3 - 25 Nm 4 - Camshaft pulley 5 - Hub With sender wheel AG. Volkswagen AG d Use counterhold tool agen oes not lksw T10051- to loosen andVo gu by ara d tighten. nte ise or eo thpuller To remove, use u ra a c T10052- . ss Removing and installing page 97 , remov ing and installing camshaft.
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6 - 10 Nm Renew. 7 - Stud 15 Nm 9 - 25 Nm

8 - Rear toothed belt guard 10 - Sealing grommet Renew if damaged. 11 - 20 Nm + turn (45) 12 - Tensioning roller Remove engine support in order to remove and install page 29 .
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15 - Coolant pump Removing and installing page 128 16 - Crankshaft toothed belt pulley

17 - 120 Nm + turn (90) 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 + turn (90) Renew.

28

Rep. gr.13 - Crankshaft group

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14 - Idler roller

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13 - 20 Nm

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 22 - Cover 23 - Toothed belt Mark direction of rotation before removing. Check for wear. Do not kink. Removing, installing and tensioning page 66 . 24 - 40 Nm + turn (180) Renew. 25 - Toothed belt guard centre part 26 - Engine bracket

1.3

Removing and installing engine support

Special tools and workshop equipment required Support bracket -10 - 222 A
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To do this, pull engine cover upwards abruptly at front and right -arrows A- and then pull forwards out of rear fastening -arrow B-.

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

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1. Dismantling and assembling engine

29

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 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 tur bocharger. Carefully cover or seal open ends. Golf, Golf Plus and Touran: Fit engine support bracket -10-222A- with adapters -10-222A/ 13- and take up weight of engine in installation position.

Remove securing bolts from assembly mounting/engine sup port -arrows- and remove complete assembly mounting. Note

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The assembly mounting may only be removed if the engine is supported with support bracket 10-222A! The engine support must only be loosened when the assembly mounting has been removed. WARNING

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When raising and lowering engine using support bracket -10-222A- , ensure that no components or hoses are damaged, strained or torn off.
Remove noise insulation General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula tion . Remove front right wheel housing liner.
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Rep. gr.13 - Crankshaft group

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Raise engine with support bracket -10-222A- until both upper bolts of engine support can be loosened and removed. Lower engine with support bracket -10-222A- until lower bolt can be loosened and removed. Remove engine support upwards. Installing Insert new bolts and
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Caution

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The tightening sequence and specified torques for the engine support securing bolts must always be followed. Otherwise the engine support can be stressed and it can break.

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Tighten bolts for engine support in the sequence shown -13- to 40 Nm + (180) turn further. To do this, raise or lower engine using support bracket -10 - 222 A- . I : Engine support with less clearance to engine II: Engine support with greater clearance to engine Note

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Before installing assembly mounting, tighten all engine support bolts to prescribed torque.
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Install assembly mounting between engine and body, renew securing bolts page 22 .
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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 + turn 90 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. General body repairs, exterior; Rep. gr. 50 ; Body - front, assembly overview - noise insulation .

AG.

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1. Dismantling and assembling engine

31

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.4

Assembly overview - crankcase

1 - Cylinder block Removing and installing sealing flange and fly wheel page 33 . Removing and installing crankshaft page 48 . Dismantling and assem bling pistons and con rods page 48 2 - Seal Renew. 3 - Oil filter bracket Dismantling and assem bling page 109 . 4 - 15 Nm + turn (90) Renew. First fit upper left and lower right bolts and then tighten all 4 bolts in diagonal sequence. 5 - Bracket 6 - 20 Nm 7 - Connection For thermostat. 8 - 15 Nm 9 - O-ring Renew.

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10 - Thermostat Removing and installing page 130 Observe installation position page 130 , removing and installing thermostat. Checking: heat thermostat in water. Opening begins at approx. 85 C. Ends at approx. 105 C Opening lift at least 7 mm.

11 - Hexagon bolt Tightening sequence and torque specifications Heating, air conditioning; Rep. gr. 87 ; Removing and installing compressor bracket .
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12 - Bracket For alternator, if air conditioner compressor is fitted 14 - 25 Nm 15 - Oil sump Clean sealing surface before fitting. Install with silicone sealant -D 176 404 A2- . 16 - 15 Nm
AG.

13 - Poly V-belt tensioning element

32

Rep. gr.13 - Crankshaft group

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

Removing and installing sealing flange and flywheel

Assembly overview - sealing flange and flywheel page 33 Removing and installing engine speed sender page 46 Renewing crankshaft oil seal - belt pulley end page 36 . Removing and installing sealing flange - pulley end page 36 . Removing and installing dual-mass flywheel page 34 . Renewing crankshaft sealing flange - flywheel end page 40 .

2.1
Note

Assembly overview - sealing flanges and flywheel


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Repairing clutch 6-speed manual gearbox 02S; Rep. gr. 30 ; Repairing clutch .
1 - Seal Do not additionally oil or grease the oil seal seal ing lip. Before installing, re move deposits from crankshaft journal using a clean cloth. Renewing crankshaft oil seal - belt pulley end page 36 . 2 - Sealing flange Must seat on dowel sleeves. Removing and installing page 38 Install with silicone sealant -D 176 404 A2 page 38 .

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3 - Cylinder block Removing and installing crankshaft page 48 . Dismantling and assem bling pistons and con rods page 48 4 - 60 Nm + turn (90) Renew. 5 - Flywheel To remove and install flywheel, counterhold with 3067. Removing and installing dual-mass flywheel

2. Removing and installing sealing flange and flywheel

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33

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 page 34 . 6 - Intermediate plate Must sit on dowel sleeves Do not damage or bend when assembling. 7 - 15 Nm Renew. 8 - Sealing flange with oil seal Renew complete with oil seal and sender wheel only. Removing and installing page 40 9 - Removing and installing engine speed sender -G28- page 46 . Loosen and tighten using commercially available ball-ended hexagon key socket Specified torque: 5 Nm.

2.2

Removing and installing dual-mass fly wheel

Special tools and workshop equipment required Counterhold -3067-

Removing

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Remove moving and installing gearbox . Caution

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To prevent damage to the dual-mass flywheel when removing, the bolts -B- must not be removed with an impact wrench or similar. The bolts may only be removed by hand.
Mark position of dual-mass flywheel in relation to engine. Rotate the dual-mass flywheel -A- so that the bolts -B- align centrally with the holes -arrows-. When unscrewing bolts -B-, ensure that none of the bolt heads come into contact with the dual-mass flywheel -arrows-. The flywheel will otherwise be damaged when the bolts are un screwed further.

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Rep. gr.13 - Crankshaft group

AG.

34

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Insert counterhold -3067- in hole on cylinder block -B-. Unscrew dual-mass flywheel. Installing Installation is carried out in the note the following: Use new bolts for securing.
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Specified torque Item 4 (page 33) .

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Insert counterhold -3067- in hole on cylinder block -A-.

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2. Removing and installing sealing flange and flywheel

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

2.3

Renewing crankshaft oil seal - belt pulley end

Special tools and workshop equipment required


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Oil seal extractor -3203 Assembly tool -T10053+3 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332-

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Counterhold tool -3099-

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2.3.1

Removing

Remove toothed belt. page 66 Remove crankshaft toothed belt pulley. To do this, lock toothed belt pulley using counterhold -3099- . Note

When bolting on counterhold, place two washers between toothed belt pulley and counterhold.
To guide oil seal extractor -3203- , screw central bolt by hand into crankshaft to stop. Unscrew inner part of oil seal extractor two turns (approx. 3 mm) out of outer part and lock with knurled screw. Oil threaded head of oil seal extractor.

36

Rep. gr.13 - Crankshaft group

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

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2.3.2

Installing

Note

The oil seal sealing lip must not be additionally oiled or greased.
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Remove oil residue from crankshaft journal using clean cloth. Place guide sleeve -T10053/1- onto crankshaft journal.
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Slide oil seal over guide sleeve onto crankshaft journal.


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Press oil seal in to stop using assembly tool -T10053- and centre bolt. Install and tighten toothed belt page 66 .

2. Removing and installing sealing flange and flywheel

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

2.4

Removing and installing sealing flange - pulley end

Special tools and workshop equipment required Counterhold tool -3099 Assembly tool -T10053 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Hand drill with plastic brush attachment Silicone sealant -D 176 404 A Flat scraper
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Remove toothed belt. page 66

Note

When bolting on counterhold, place two washers between toothed belt pulley and counterhold.
Drain engine oil. Remove sump page 105 . Pull off front sealing flange. Remove sealing flange; if necessary, loosen by applying light blows with a rubber-headed hammer. Remove sealant residue from cylinder block with a flat scraper.

38

Rep. gr.13 - Crankshaft group

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Remove crankshaft toothed belt pulley. To do this, lock toothed belt pulley using counterhold -3099- .
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2.4.1

Removing
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 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.

2.4.2
Note

Installing
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Cut off tube nozzle at forward marking ( of nozzle approx. 3 mm). Note

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The sealing flange must be installed within 5 minutes of ap plying the silicone sealant.

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The sealant bead must not be thicker than 2 3 mm, other wise excess sealant can enter sump and block the strainer in oil pump suction pipe, as well as drip onto the sealing surface of crankshaft oil seal. Before applying sealant bead, cover sealing surface of oil seal with a clean cloth. Apply silicone sealant bead as shown to the clean sealing sur face of sealing flange.
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Install sealing flange immediately and tighten all bolts lightly. Note
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When fitting sealing flange with oil seal installed use guide sleeve -T10053/1- .
Tighten securing bolts for sealing flange to 15 Nm using alter nate and diagonal sequence. Install sump page 105 . Note
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Sealing compound must dry for approx. 30 minutes after instal lation. Only then fill with engine oil.
Installing toothed belt and adjusting valve timing. page 66

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2. Removing and installing sealing flange and flywheel

39

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

2.5

Renewing crankshaft sealing flange flywheel end

Special tools and workshop equipment required Assembly tool -T10134-

Torque wrench -V.A.G 1331 Socket -V.A.G 1332/11 Vernier gauge Three hexagon bolts M 6 x 35 mm Two hexagon bolts M 7 x 35 mm

2.5.1

Pressing out sealing flange with sender wheel

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Set engine to TDC No. 1 cylinder page 66 , Removing and installing toothed belt. Remove sump page 105 . Remove engine speed sender -G28- -arrow- using a commer cially available ball-ended hex key socket page 46 . Unscrew sealing flange securing bolts. Note

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Sealing flange and sender wheel are pressed off the crankshaft together using three M 6 x 35 mm bolts.

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Rep. gr.13 - Crankshaft group

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Screw three M 6 x 35 mm bolts into threaded holes -arrowsof sealing flange. Screw bolts alternately (max. 1/2 turn 180 for each bolt) into sealing flange and press sealing flange together with sender wheel off crankshaft.

2.5.2

Pressing in sealing flange with sender wheel

Note The sealing flange with a PTFE seal is equipped with a sealing lip support ring. This support ring serves as a fitting sleeve and must not be removed prior to installation. Sealing flange and sender wheel must not be separated or turned after removal from packaging. The sender wheel is held in its installation position on the as sembly device -T10134- by a locating pin. Sealing flange and oil seal form one unit and must only be renewed together with the sender wheel. The assembly device -T10134- is held in its position .relativeg Volkswa to the crankshaft by a guide pin inserted intowagen AG the en AG does a hole in not olks V crankshaft. gu by a Assembly tool -T10134B - Hexagon nut D - Locating pin
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A - Clamping surface

C - Assembly housing

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E - Hexagon socket head bolt

F - Guide pin for diesel engines (black knob) G - Guide pin for petrol engines (red knob)

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2. Removing and installing sealing flange and flywheel

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

2.5.3

A - Assembling seal with sender wheel on assembly tool -T10134-

Screw in hexagon nut -B- to just before clamping surface -Aof threaded spindle.

Clamp assembly device -T10134- in a vice on clamping sur face -A- of threaded spindle. Press assembly housing -C- downwards until it lies on hexagon nut -B- -arrow-. Note

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

Remove securing clip -arrow- from new sealing flange. Note

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Locating hole -A- on sender wheel -C- must align with marking -B- on sealing flange.

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Place sealing flange with front side downwards on a clean flat surface.

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42

Rep. gr.13 - Crankshaft group

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Push sealing lip support ring -A- downwards in direction of ar row until it lies on flat surface.

Upper edge of sender wheel and front edge of sealing flange must align -arrows-.

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Place sealing flange with front side on assembly tool -T10134so that locating pin -B- can be inserted in sender wheel hole -A-.
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Push sealing flange and support ring for sealing lip -B- against surface of assembly tool -T10134- whilst tightening the three knurled screws -A- so that locating pin cannot slide out of sender wheel hole. Note

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

2.5.4

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

Crankshaft flange must be free of oil and grease. Engine positioned at TDC No. 1 cylinder.

2. Removing and installing sealing flange and flywheel

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Ensure sealing flange lies flat on assembly tool.


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Note

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43

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Screw hexagon nut -B- to end of threaded spindle. Press threaded spindle of assembly tool -T10134- in swagen AG. direction k Vol of arrow, until hexagon nut -B- lies against assembly housing by ed -A-. ris
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au Align flat side of assembly housing on sump side of crankcase ss sealing surface.

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Secure assembly tool -T10134- to crankshaft flange using hexagon socket head bolts -A-. Note

Screw hexagon socket head bolts -A- into crankshaft flange (ap prox. 5 full turns).

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2.5.5

C - Bolting assembly tool -T10134- onto crankshaft flange

Push assembly housing -C- by hand in direction of arrow until sealing lip support ring -B- contacts crankshaft flange -A-. Push guide pin for diesel engines (black knob) -D- into hole in crankshaft. This ensures that the sender wheel reaches its fi nal installation position. Note

The guide pin for petrol engines (red knob) -F- must not be in serted in threaded hole of crankshaft.
Hand-tighten both hexagon socket head bolts of assembly tool. Screw hexagon nut -E- onto threaded spindle by hand until it lies on assembly housing -C-.

44

Rep. gr.13 - Crankshaft group

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To guide sealing flange, screw two M 7 35 mm bolts -A- into cylinder block.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

2.5.6

Tighten hexagon nut of assembly tool -T10134- to 35 Nm us ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G 1332/11- . Note

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D - Pressing sender wheel onto crankshaft flange using assembly tool T10134-

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After hexagon nut is tightened to 35 Nm, a small air gap must still be present between cylinder block and sealing flange.

2.5.7

E - Checking sender wheel installation position on crankshaft

Screw hexagon nut -E- to end of threaded spindle. Remove the two bolts -A- from cylinder block. Remove assembly tool -T10134- . Remove sealing lip support ring.
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Screw the three knurled screws -B- out of sealing flange.


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The sender wheel is in the correct installation position on the crankshaft if a gap -a- = 0.5 mm exists between crankshaft flange -A- and sender wheel -B-.

Set vernier gauge on crankshaft flange. Measure distance -a- between crankshaft flange and sender wheel. If measurement -a- is too small: Press sender wheel further. page 46 If dimension -a- is attained: Tighten new securing bolts for sealing flange to 15 Nm using alternate and diagonal sequence.

2. Removing and installing sealing flange and flywheel

AG.

45

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Install engine speed sender -G28- -arrow- and tighten secur ing bolt to 5 Nm. Install sump page 105 . Install intermediate plate. Install flywheel using new bolts. Tighten securing bolts to 60 Nm + turn 90 further.

2.5.8

F - Re-pressing sender wheel

Secure assembly tool -T10134- to crankshaft flange using hexagon socket head bolts -A-. Hand tighten both hexagon socket head bolts. gen AG. Volkswagen AG do a Push assembly tool -T10134- by hand by Vsealing flange. to ed
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Screw hexagon nut -E- onto threaded spindle by hand until it lies on assembly housing -C-.

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If dimension -a- is too small again:

Tighten hexagon nut for assembly tool -T10134- to 45 Nm. Check installation position of sender wheel on crankshaft again. page 45

2.6

Removing and installing engine speed sender -G28-

Special tools and workshop equipment required

46

Rep. gr.13 - Crankshaft group

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Check installation position of sender wheel on crankshaft again. page 45

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Tighten hexagon nut of assembly tool -T10134- to 40 Nm us ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G 1332/11- .
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Hexagon key extension, 4 mm -T10370-

Or commercially available ball-ended hexagon key socket, 5 mm . Volkswag Note


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Remove noise insulation General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula tion . Clamp off coolant hoses at engine oil cooler using hose clip and pull off hoses. Remove oil filter bracket. Remove securing bolt -arrow- and pull out engine speed sender -G28- . Installation is performed in the reverse order, observing the fol lowing: specified torque for engine speed sender -G28- securing bolt: 5 Nm.

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2. Removing and installing sealing flange and flywheel

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

Crankshaft

Assembly overview - crankshaft page 48 . Renewing needle bearing in crankshaft - vehicles with dual clutch gearbox page 49 Crankshaft dimensions page 48 .

3.1

Assembly overview - crankshaft

1 - Bearing shells 1, 2, 4 and 5 For bearing cap without oil groove. For cylinder block with oil groove. Do not interchange used bearing shells (mark). 2 - 65 Nm + turn (90) Renew. To measure radial clear ance, tighten to 65 Nm but not further. 3 - Bearing cap Bearing cap 1: pulley end. Bearing cap 3 with re cesses for thrust wash ers. Bearing shell retaining lugs in cylinder block and bearing caps must align.

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4 - Bearing shell 3 For bearing cap without oil groove. For cylinder block with oil groove. 5 - Thrust washer For bearing cap 3. Note fixing arrange ment.

6 - Crankshaft Axial clearance new: 0.07 0.17 mm wear limit: 0.37 mm Check radial clearance with Plastigage new: 0.030.08 mm, wear limit: 0.17 mm Do not rotate crankshaft when checking radial clearance. Crankshaft dimensions page 48 . 7 - Thrust washer For cylinder block, bearing 3
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3.1.1

Crankshaft dimensions

(Dimensions in mm)

48

Rep. gr.13 - Crankshaft group

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Honing dimen sion Main journal -0.022 -0.042 47.80 Conrod journal -0.022 -0.042

Basic dimension 54.00

3.1.2

Renewing needle bearing in crankshaft - vehicles with dual clutch gearbox

6-speed dual clutch gearbox: If the engine or gearbox has to be removed during repairs, check needle bearing in crankshaft. If it is damaged or tarnished blue, it must be renewed. If it is not damaged, lightly grease with high-temperature grease -G052133A2- .

7-speed dual clutch gearbox: Always renew needle bearing when removing engine or gearbox. 6-speed dual clutch gearbox

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Special tools, testers, measuring instruments and auxiliary items required

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- This gearbox can be identified by the gearbox oil cooler.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 1 - -1- Kukko 21/2 2 - Centring mandrel -31763 - Drift -VW 207 C-

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Gearbox is separated from engine

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Procedure Pulling needle bearing out:

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Puller -T10055- with adapter -T10055/3-

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Pull out needle roller bearing using Kukko 21/2, adapter T10055/3- and puller -T10055- .

7-speed dual clutch gearbox

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 1 - -1- Kukko 21/2 and -4Kukko 22/1 2 - Centring mandrel -31763 - Drift -VW 207 C-

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Gearbox is separated from engine

Pulling needle bearing out: Pull out using commercially available puller -A-, e.g. Kukko 21/2 and Kukko 22/1. Installing

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Procedure

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Drive needle bearing in with drift -VW 207 C- or with centring mandrel -3176- . Carefully drive needle bearing in. Always measure the driving depth when driving in. Renew bearing, if driving depth is too deep.

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

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3. Crankshaft

53

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

Checking piston projection at TDC page 56 . Piston and cylinder dimensions page 57 . Piston rings, cylinder bore and piston installation position page 57

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4.1

Assembly overview - pistons and conrods

1 - Piston rings Offset gaps by 120. Use piston ring pliers to remove and install. TOP faces towards piston crown. Checking ring gap page 57 . Checking ring-to-groove clearance page 58 . 2 - Piston With combustion cham ber. Mark installation posi tion and cylinder num ber. Installation position and allocation of piston to cylinder page 58 . Arrow on piston crown points to belt pulley end. Install using piston ring clamp. If piston skirt is cracked, renew piston. Checking piston projec tion at TDC page 56 . 3 - Piston pin If difficult to remove, heat piston to 60 C. Remove and install us ing drift -VW 222- . 4 - Circlip 5 - Conrod Mark cylinder allocation -A- with coloured pen. Installation position: Marking -B- faces towards pulley end. With industrially cracked conrod cap. 6 - Bearing shell Note installation position.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi cation: Black line on bearing surface in area of joint. Do not interchange used bearing shells. Insert bearing shells centrally. Check for secure seating. Axial clearance, wear limit: 0.37 mm. Check radial clearance with Plastigage: Wear limit: 0.08 mm, do not rotate crankshaft when checking radial clearance 7 - Cylinder block Checking cylinder bores page 58 . Piston and cylinder dimensions page 57 . 8 - Conrod bearing cap n AG. Volkswagen AG do es n wage ot g olks Note installation position. yV ua db ran se the appropriate conrod due to the breaking procedure The caps only fit in one position and onlyoron i tee h or (cracking) separating the cap from theaut conrod. a
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9 - Oil spray jet For piston cooling. Note 10 - 25 Nm Insert without sealant.

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11 - Conrod bolt, 30 Nm + turn (90) Renew. Oil threads and contact surface. Use old bolt for measuring radial clearance.

4.2

Separating new conrod


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Note

Clamp conrod in below the marked line. Unscrew the two bolts -arrows- approx. 5 turns.

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To prevent damage to the conrod, only clamp conrod in lightly.

4. Pistons and conrods

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Using a plastic hammer, carefully knock against conrod bear ing cap -arrow- until it is loose.

4.3

Checking piston projection at TDC

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

End dimension plate -VW 385/17-

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Dial gauge Test procedure Note

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

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Rep. gr.13 - Crankshaft group

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Piston projection at TDC must be measured when installing new pistons or a short engine. Install the appropriate cylinder head gasket depending upon piston projection, according to following table: Note

Turn engine clockwise to measure piston projection at TDC.


Piston projection 0.91 mm 1.00 mm 1.01 mm 1.10 mm 1.11 mm 1.20 mm Cylinder head gasket identification Part No. = arrow 1 Production control code = arrow 2 (can be disregarded) Holes = arrow 3 Identification Holes/notches 1 2 3

4.4

Piston and cylinder dimensions


mm mm mm
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4.5

Piston rings, cylinder bore and piston in stallation position

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Checking piston ring gap

Feeler gauges

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57

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Push piston ring squarely from above down to approx. 15 mm from bottom end of cylinder. Piston ring dimensions in mm 1. compression ring 2. compression ring Oil scraper ring New 0.20 ... 0.40 0.20 ... 0.40 0.25 ... 0.50 Wear limit 1.0 1.0 1.0

Checking ring-to-groove clearance

Special tools and workshop equipment required Feeler gauges Clean ring groove before checking. Piston ring dimensions in mm 1. compression ring 2. compression ring Oil scraper ring New Wear limit

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Checking cylinder bores

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Special tools and workshop equipment required Inside caliper 50 100 mm Take measurements at 3 positions in both transverse -A- and longitudinal -B- directions, as illustrated. Difference between actual and nominal diameter max. 0.10 mm. Note

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Piston installation position and allocation of piston to cylinder Piston in cylinders 1 and 2: Larger inlet valve recess -arrows- towards flywheel. Piston in cylinders 3 and 4: Larger inlet valve recess -arrows- towards belt pulley end.

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Cylinder bores must not be measured when cylinder block is mounted on a repair stand with engine support bracket -VW 540- , as measurements may then be incorrect.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note New piston allocation to cylinders is shown by a coloured marking on piston crown. Piston for cylinders 1 and 2: marked 1/2 Piston for cylinders 3 and 4: marked 3/4

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59

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

15
1
Note

Cylinder head, valve gear


Cylinder head

The plastic packing pieces for protecting the open valves must not be removed until immediately before fitting cylinder head. If the cylinder head is replaced, all the coolant in the system must also be renewed.

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Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Assembly overview - cylinder head page 61 . Removing and installing cylinder head cover page 64 . Removing, installing and tensioning toothed belt page 66 . Removing and installing cylinder head page 83 . Checking compression page 89 .

1.1

Assembly overview - cylinder head

1 - Toothed belt guard upper part 2 - Toothed belt Mark direction of rota tion before removing. Check for wear. Do not kink. Removing, installing and tensioning page 66 . 3 - 10 Nm Renew. 4 - 25 Nm 5 - 100 Nm 6 - Camshaft pulley 7 - Hub With sender wheel Use counterhold tool T10051- to loosen and tighten. To remove, use puller T10052- . Removing and in stalling. 8 - Rear toothed belt guard 9 - Sealing grommet Renew if damaged.

10 - Hall sender -G40 For camshaft position To remove, unbutton sealing grommet Item 9 (page 61) from rear toothed belt guard. 11 - Stud 15 Nm

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12 - Cylinder head bolt Observe sequence when loosening and tightening page 83 . Before installing, place washers in cylinder head Item 4 (page 92) .

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 13 - Fuel return line 14 - Fuel supply line 15 - Coolant line 16 - Cylinder head cover Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth. 17 - Pressure regulating valve For crankcase ventilation. 18 - To turbocharger. 19 - Cap Renew seal if damaged. 20 - Seal Renew if damaged. 21 - 10 Nm Observe tightening sequence page 64 . 22 - Gasket for cylinder head cover Renew together with cylinder head cover only. Before fitting, seal transitions with AMV 174 004g01 G. Volkswagen AG d en A page 64 23 - 20 Nm 24 - Lifting eye
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26 - 10 Nm 27 - Central connector For unit injector 28 - From brake servo

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25 - Unit injector Removing and installing page 230

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29 - Tandem pump For fuel and vacuum supply Check page 195 . Removing and installing page 198 Must not be dismantled. 30 - Supply hose From fuel filter. White or with white marking. Check for secure seating. Secure with spring-type clips. 31 - Return hose To fuel filter Blue or with blue marking. Check for secure seating. Secure with spring-type clips. 32 - Seal Renew.

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Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 33 - Bracket 34 - 20 Nm 35 - Cylinder head Removing and installing page 83 After renewing, renew entire coolant. 36 - Cylinder head gasket Renew. Note marking page 63 . After renewing, renew entire coolant. 37 - Glow plug olkswagen AG en AG. V does 15 Nm olkswag not gu yV ara Check b page 269 . ed n is
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39 - 20 Nm + turn (45) Checking cylinder head for distortion

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Special tools and workshop equipment required Straight edge Max. permissible distortion: 0.1 mm. Note
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Feeler gauges

Reworking diesel cylinder heads is not permissible.


Cylinder head gasket identification Part No. = arrow 1 Production control code = arrow 2 (can be disregarded) Holes = arrow 3

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ag Golf 2004 , Golf Plus 2005 , Passat 2006 l, sTouran 2003 k w Vo by08.2010 d 4-cylinder diesel engine (1.9 l engine) - Edition se

Different thicknesses of cylinder head gasket are fitted de pending on the piston projection. When renewing gasket, install new gasket with same identification. Piston projection at TDC must be determined when installing new pistons or a short engine. page 56

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1.2

Removing and installing cylinder head cover

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Sealant -AMV 174 004 01 page 5 Removing Remove engine cover. To do this, pull engine cover upwards abruptly at front -arrows A- and then pull forwards out of rear fastening -arrow B-.

64

Rep. gr.15 - Cylinder head, valve gear

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Torque wrench -V.A.G 1331-

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Special tools and workshop equipment required

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Two-piece engine cover For two-piece engine cover, first pull outer engine cover abruptly upwards at -arrows-, then pull inner engine cover abruptly up wards at -arrows-. Remove upper toothed belt guard. Disconnect crankcase breather hose at union on rear of charge air pipe. Unbolt bracket from exhaust gas recirculation valve.

Engine codes BLS, BXJ: to remove cylinder head cover, addi tionally remove: -1- upper toothed belt guard -2- intake hose -3- intake manifold flap Renew seal. -4- bolt, 8 Nm Continuation for all vehicles Remove cylinder head cover. Cylinder head cover, engine codes: AVQ, BJB, BKC, BRU, BXE, BXF n AG. Volkswagen AG do e wage
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Cylinder head cover, engine codes: BLS, BXJ Installing for all engine codes

Install in reverse order. In the process, note the following: Note

Renew cylinder head cover gasket and seal for bolts if dam aged. Renew seal for intake manifold flap. Engine codes BLS, BXJ
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Place a drop of sealant -AMV 174 004 01- ( approx. 5 mm) -arrows- on edges of both sealing surfaces of bearing cap and cylinder head at front of engine.
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Cylinder head cover, engine codes: BJB, BKC, BRU, BXE, BXF Screw on cylinder head cover by hand in sequence -1 13-. Tighten bolts in sequence -1 13- to 10 Nm.

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Cylinder head cover, engine codes: BLS, BXJ Tighten bolts in sequence -1 13- to 10 Nm.
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1.3

Removing, installing and tensioning toothed belts


Note

A revised engine support has been introduced gradually and it is no longer necessary to remove the engine support and to support the engine for the procedure removing, installing and tensioning toothed belt. To change the tensioning roller, for both versions the engine support must be removed. Determine which type of engine support is installed in the ve hicle. -1-: Engine support bolted close to engine (removal necessary) page 67 .

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Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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1.3.1

Removing and installing toothed belt (vehicles with engine support bolted close to engine)
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Pin wrench -T10020- or hexagon wrench

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Special tools and workshop equipment required

1. Cylinder head

67

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Support bracket -10-222Awith adapters -10-222A/1 Counterhold tool -T10172with pins -T10172/4 Crankshaft stop -T10100(on vehicles with oval crankshaft belt pulley)
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Note

From model year 2004, a new toothed belt tensioner is installed. The tensioner has an additional hexagon hole -arrow-. To tension and release toothed belt, use Allen key instead of pin wrench T10020- . This does not alter the procedure.
Removing Note

Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature.
Remove engine cover. page 5 Remove coolant expansion tank, coolant hoses remain con nected. Remove poly V-belt page 25 . Remove tensioning element for poly V-belt.

68

Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove front right wheel housing liner. Remove charge air pipe between charge air cooler and tur bocharger. page 218 Carefully cover or seal open ends. Remove belt pulley with vibration damper. Remove lower and centre parts of toothed belt guard. Golf, Golf Plus, Touran Set up support bracket -10-222A- with adapters -10-222A/22and support engine AGinstallationA in . Volkswagen position. n
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If toothed belt is to be removed in order to remove cylinder head, set up support bracket -10-222A- with higher adapters -10-222A/ 13- . This will provide the space necessary for removing the cylin der head.
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Passat:

Set up support bracket -10-222A- with adapters -10-222A/1and support engine in installation position. Passat: If the toothed belt has to be taken off for removal of the cylinder head.

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Note

Both lifting eyes for the support are located on the cylinder head, so an additional spindle -A- with bracket to support the engine must be secured on the cylinder block.
Set up support bracket -10-222A- with adapters -10-222A/1and support engine in installation position with spindles -Band -C-. Note Spindle -A- hangs loose. Unscrew filler neck for window wash system. Unbolt coolant expansion tank and lay to side (hoses remain connected). Pull fuel filter out of bracket. Unscrew filler neck for window wash system.
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1. Cylinder head

69

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Unbolt fuel filter bracket from engine mounting -arrows-. Unbolt coolant expansion tank and lay to side (hoses remain connected). Continuation for all vehicles

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

Raise engine with support bracket -10-222A- until both upper bolts of engine bracket can be loosened. Lower engine with support bracket -10-222A- until both lower bolts of engine bracket can be loosened. Remove refrigerant line securing clamp from longitudinal member. Remove engine support. Turn crankshaft to TDC No. 1 cylinder. Note

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Gradual introduction of oval crankshaft toothed belt pulleys. When installing this toothed belt pulley, the crankshaft stop T10100- must be installed to determine the TDC position instead of crankshaft stop -T10050- . Observe identification characteris tics -arrows-.
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Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Characteristics of crankshaft toothed belt pulley A = round belt pulley, lock using crankshaft stop -T10050- , TDC marking at 12 o'clock B = oval belt pulley, lock using crankshaft stop -T10100- . TDC marking at 1 o'clock Vehicles with round crankshaft pulley Turn crankshaft to TDC No. 1 cylinder.

Note

Turn crankshaft until marking on crankshaft pulley and tooth seg ment of camshaft pulley is on top. The marking on the rear toothed belt guard must align with the marking on the camshaft sender wheel -arrow-.
Lock hub using locking pin -3359- . To do this, slide locking pin through the free elongated hole on left into hole in cylinder head. Lock crankshaft toothed belt pulley with crankshaft stop T10050 - . To do this, push crankshaft stop into teeth of belt pulley from face side.
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crankshaft stop must engage in the drilling of sealing flange.


Vehicles with oval crankshaft pulley Turn crankshaft to TDC No. 1 cylinder.

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1. Cylinder head

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note

Turn crankshaft until marking on crankshaft pulley and tooth seg ment of camshaft pulley is on top. The marking on the rear toothed belt guard must align with the marking on the camshaft sender wheel -arrow-.
Lock hub using locking pin -3359- . To do this, slide locking pin through the free elongated hole on left into hole in cylinder head. Lock crankshaft toothed belt pulley with crankshaft stop T10100- . To do this, push crankshaft stop into teeth of belt pulley from face side. Note

The marks on the crankshaft toothed belt pulley and the crankshaft stop must align. When doing this, the pin of the crankshaft stop must engage in the drilling of sealing flange.
Continuation for all vehicles
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Loosen tensioning roller securing nut.

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

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


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Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Now turn pin wrench -T10020- clockwise to stop and tighten securing nut -1- hand tight. Remove toothed belt first from coolant pump and then from remaining pulleys. Installing
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Tensioning roller locked with locking pin -T10115- and se cured to right stop. Note

Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature.

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Turn camshaft pulley in its elongated holes to centre position -arrows-.

Fit toothed belt onto crankshaft toothed belt pulley, tensioning roller, camshaft toothed belt pulley and idler roller. Then fit toothed belt on coolant pump toothed belt pulley.

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Note

Ensure that tensioning roller seats correctly in rear toothed belt guard -arrow-.
Loosen tensioning roller securing nut and pull out locking pin -T10115- .

Now carefully turn tensioning roller clockwise using pin wrench -T10020- until indicator is in middle of gap in the base plate -arrow-. Ensure that securing nut does not turn as well. Hold tensioning roller in this position and tighten tensioning roller securing nut as follows: 20 Nm and 45 (1/8 turn) further.

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Remove locking pin -3359- and crankshaft stop -T10050- . Turn crankshaft two rotations in engine direction of rotation until crankshaft is just before TDC No. 1 cylinder. Vehicles with round crankshaft pulley

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

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 AG. Volkswagen A

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Lock hub with locking pin -3359- whilst turning engine in di rection of rotation. Check whether crankshaft can be locked with crankshaft stop -T10050- . If crankshaft cannot be locked:

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

Turn crankshaft slightly against engine direction of rotation until the pin of the crankshaft stop is positioned just before the hole in the sealing flange -arrow-. Now turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange whilst turning. Vehicles with oval crankshaft pulley

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Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Lock hub with locking pin -3359- whilst turning engine in di rection of rotation. Check whether crankshaft can be locked with crankshaft stop -T10100- . If crankshaft cannot be locked:

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

Now turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange whilst turning.
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Continuation for all vehicles

Fit counterhold -T10172- with pins -T10172/4- as shown. Press counterhold -T10172- in direction of arrow, keeping camshaft toothed belt pulley under tension. In this position, tighten camshaft toothed belt pulley securing bolts -1- to 25 Nm. Remove locking pin -3359- and crankshaft stop -T10050- . Turn crankshaft two rotations in engine direction of rotation until crankshaft is just before TDC No. 1 cylinder. Repeat check.

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Turn crankshaft slightly against engine direction of rotation until the pin of the crankshaft stop is positioned just before the hole in the sealing flange -arrow-.
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1. Cylinder head

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Set engine bracket against cylinder block and tighten securing bolts -A- to 40 Nm + (180) turn further. Note

Before installing assembly mounting, tighten all engine bracket bolts to specified torque.
Install assembly mounting between engine and body (renew securing bolts). Tightening torque of M 8 bolts: 20 Nm + (90) turn further Tightening torque of M 10 bolts: 40 Nm + (90) turn further Bolt engine assembly mounting to engine bracket by bringing contact surfaces together using support bracket -10-222A- . Specified torque: 60 Nm + turn (90) further Install centre and lower parts of toothed belt guard. Install belt pulley vibration damper (renew securing bolts). Tightening torque: 10 Nm + (90) turn further Install poly V-belt page 26 . Install upper toothed belt guard. Install front right wheel housing liner. Install coolant expansion tank.
n AG. Volkswagen AG do es n wage ot g olks yV ua Bolt fuel filter bracket to engine mounting to 8 Nm torque db ran se tee ri -arrows-. ho t or ac au Engage fuel filter in bracket. ss
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Bolt on filler neck for window wash system. Fit engine cover.
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76

Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.3.2

Removing and installing toothed belt (vehicles with engine support bolted further away from engine)

Note A revised engine support has been introduced gradually and it is no longer necessary to remove the engine support and to support the engine for the procedure removing, installing and tensioning toothed belt. To change the tensioning roller, for both versions the engine support must be removed. Special tools and workshop equipment required Diesel injection pump lock ing pin -3359 Locking pin -T10060 A Crankshaft stop -T10100 Counterhold tool -T10172 Special wrench, long reach -T10264 Locking tool -T10265- n AG. Volkswagen AG doe wage
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Removing

Remove engine cover. page 5 To do this, pull engine cover upwards abruptly at front -arrows A- and then pull forwards out of rear fastening -arrow B-.
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1. Cylinder head

77

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove two-piece engine cover panel page 5 . WARNING

In extreme cases the fuel lines and the fuel can reach a temperature of 100 C on vehicles with unit injector en gine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. Wear protective gloves. Wear eye protection.

Pull fuel supply hose -1- and fuel return hose -2- off fuel lines. Pull off coolant line -3-. Remove bolt -1-.

Remove connecting pipe between charge air cooler and intake connecting pipe, to do this, lightly lift retaining clips -arrows-.

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Disconnect fuel supply line -3- and return line -2- by pulling release tabs. Remove fuel filter screwed filter and lay it with hoses to side -arrow-.

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Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Pull fuel filter inserted filter out of bracket -arrow-. Unscrew bolt at filler neck -2- for windscreen washer system reservoir. Unscrew bracket -3- for fuel filter.

Disconnect electrical connector on coolant expansion tank -1-. Remove coolant expansion tank, coolant hoses remain con nected. Place it on engine. Remove poly V-belt page 25 . Remove tensioning element for poly V-belt.

Remove upper toothed belt guard, to do this, loosen retaining clips -arrows-. Remove front right wheel housing liner.
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Note

Turn crankshaft until marking on crankshaft pulley and tooth seg ment of camshaft pulley is on top. The marking on the rear toothed belt guard must align with the marking on the camshaft sender wheel -arrow-.
Lock hub using locking pin -3359- . To do this, slide locking pin through the free elongated hole on left into hole in cylinder head. Lock crankshaft toothed belt pulley with crankshaft stop T10100- . To do this, push crankshaft stop into teeth of belt pulley from face side. Note
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The marks on the crankshaft toothed belt pulley and the crankshaft stop must align. When doing this, the pin of the crankshaft stop must engage in the drilling of sealing flange.

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1. Cylinder head

79

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Mark direction of rotation of toothed belt. Loosen securing bolts -1- of camshaft pulley until the camshaft pulley can be moved within the elongated holes.
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Loosen tensioning roller securing nut -1-. Turn eccentric of tensioning roller anti-clockwise -arrow- using socket -T10264- , until the tensioning roller can be locked with locking tool -T10265- .

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Camshaft locked with locking pin -3359- .

Crankshaft locked with crankshaft stop -T10100- . Tensioning roller locked with locking pin -T10265- and se cured to right stop with securing nut. Note

Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature.
Turn camshaft pulley in its elongated holes to centre position -arrows-. Guide toothed belt through gap between engine support and engine. Fit toothed belt onto crankshaft toothed belt pulley, tensioning roller, camshaft toothed belt pulley and idler roller. Then fit toothed belt on coolant pump toothed belt pulley.

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Rep. gr.15 - Cylinder head, valve gear

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Remove toothed belt first from coolant pump and then from remaining toothed belt pulleys.

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Now turn tensioning roller eccentric clockwise -arrow- onto stop and tighten securing nut -1- hand-tight.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note

Ensure that tensioning roller seats correctly in rear toothed belt guard -arrow-.
Remove locking pin -T10265- from tensioning roller. Loosen tensioning roller securing nut -1-.

Turn eccentric of tensioning roller clockwise -arrow- using special wrench, long reach -T10264- until indicator -2- is in middle of gap in base plate. Note

Ensure that securing nut does not turn as well.


Hold tensioning roller in this position and tighten tensioning roller nut to 20 Nm + turn 45 further.
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Tighten bolts -1- of camshaft toothed belt pulley to 25 Nm. Remove locking pin -3359- and crankshaft stop -T10100- . Turn crankshaft two rotations in engine direction of rotation until the crankshaft is just before TDC again.

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Lock hub of camshaft with locking pin -3359- whilst turning engine in direction of rotation.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Check whether crankshaft can be locked with crankshaft stop -T10100- . If crankshaft cannot be locked:

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

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Now turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange whilst turning.
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Turn crankshaft slightly against engine direction of rotation until the pin of the crankshaft stop is positioned just before the hole in the sealing flange -arrow-.

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Fit counterhold -T10172- with pins -T10172/4- as shown. Press counterhold -T10172- in direction of arrow, keeping camshaft toothed belt pulley under tension. In this position, tighten camshaft toothed belt pulley securing bolts -1- to 25 Nm. Remove locking pin -3359- and crankshaft stop -T10100- . Turn crankshaft two rotations in engine direction of rotation until crankshaft is just before TDC No. 1 cylinder. Repeat check and adjustment if necessary. Install centre and lower parts of toothed belt guard. Install belt pulley vibration damper (renew securing bolts).

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Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Tightening torque: 10 Nm + (90) turn further Install poly V-belt page 26 . Install upper toothed belt guard. Install connecting pipe between charge air cooler and intake connecting pipe. Install front right wheel housing liner. Install coolant expansion tank. Bolt fuel filter -arrows-.
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Engage fuel filter in bracket. Fit engine cover.


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Bolt on filler neck for window wash system.

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1.4

Removing and installing cylinder head

Note

From 05.05 a modified engine support has been introduced, it is no longer necessary to support the engine for the procedure removing and installing the cylinder head.
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-1-: Engine support 05.05 (support necessary)

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1. Cylinder head

83

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Special tools and workshop equipment required Drip tray -V.A.G 1306- or drip tray -VAS 6208 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Hand vacuum pump with accessories -V.A.G 1390 Water drainage container V.A.G 1390/1 Retainer -T10014- (only ve hicles 05.05)

Special tools and workshop equipment required

Support bracket -10-222A- with adapters -10-222A/13- (only vehicles 05.05)

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Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note From 05.05 a modified engine support has been introduced, it is no longer necessary to support the engine for the procedure removing and installing the cylinder head. -1-: Engine support 05.05 (support necessary)
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cylinder head is installed.


WARNING

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When doing any repair work, especially in the engine com partment, pay attention to the following due to the cramped conditions: Route all the various lines (e.g. for fuel, hydraulics, acti vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po sitions. Ensure that there is sufficient clearance to all moving or hot components.

1.4.1
Note

Removing

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Remove engine cover panel page 5 . Golf, Golf Plus, Touran Remove plenum chamber bulkhead. General body repairs, exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead . All other vehicles continued Remove air filter housing with air mass meter and connecting pipe. Remove bolt -arrow A- and pull air filter housing upwards out of mounting. Remove noise insulation. General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . Drain coolant page 123 Disconnect fuel supply and return lines as well as coolant line on cylinder head. Before removing cylinder head, extract fuel from tandem pump using hand-operated vacuum pump with accessories -V.A.G 1390- and water drainage container -V.A.G 1390/1- page 195 . Pull fuel filter module upwards out of bracket and lay it with hoses to side.
1. Cylinder head

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Before removing cylinder head, extract fuel using hand-operated vacuum pump with accessories -V.A.G 1390- and water drainage container -V.A.G 1390/1- .

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85

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove front exhaust pipe page 255 . Remove turbocharger support and oil return from turbocharg er. Remove oil supply line and lay it to side page 112 . Note

From 05.05 a modified engine support has been introduced, it is no longer necessary to remove the engine support and supporting the engine for the procedure removing, installing and tensioning toothed belt page 66
Remove toothed belt. page 66 Remove toothed belt tensioning roller. Install hub for camshaft pulley page 97 , Removing installing camshaft.
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Remove rear toothed belt guard securing bolts -2- and -4-. Unscrew Hall sender -G40- -3-. Remove exhaust gas recirculation connecting pipe.

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Pull off or disconnect all other electrical connections as nec essary from cylinder head and lay to one side. Separate all connection, coolant, vacuum and intake hoses from cylinder head. Golf, Golf Plus Touran: Vehicles 05.05 Note

Both lifting eyes for the support are located on the cylinder head, so an additional bracket for supporting the engine must be se cured on the cylinder block.
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Screw retainer -T10014- into threaded hole above coolant pump and tighten to 20 Nm. Unhook spindle -B- and push it to side. Passat: Vehicles 05.05 Note

Both lifting eyes for the support bracket are located on the cylinder head. Therefore, an additional spindle with bracket must be se cured on the cylinder block to support the engine.

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Rep. gr.15 - Cylinder head, valve gear

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Lift engine slightly using spindle -A- until spindle -B- is relieved.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Screw retainer -T10014- into threaded hole above coolant pump and tighten to 20 Nm. Lift up engine slightly via spindle -A-.

Once spindles -B- and -C- are no longer under tension, unhook them and slide them to one side. For vehicles 06.05 Remove tensioning roller securing nut for toothed belt Continuation for all vehicles Remove cylinder head cover. page 64

Maintain

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Lift cylinder head slightly and remove from engine laterally past toothed belt guard. Note
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The cylinder head must be guided carefully to prevent damage.

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1. Cylinder head

87

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.4.2
Note

Installing

Always renew cylinder head bolts. In cases of repair carefully remove gasket remains from cylin der head and cylinder block. Ensure that no long scores or scratches are made on the surfaces. When using abrasive paper do not use a grade less than 100. Carefully remove remains of emery and abrasives. Do not remove new cylinder head gasket from packaging until it is ready to be fitted. Handle gasket very carefully. Damage to the silicone coating or the indented area will lead to leaks. Turn crankshaft to TDC marking before fitting cylinder head. Turn crankshaft opposite engine direction of rotation until all pistons are approximately equally placed below TDC. Fit cylinder head gasket. Note

Note identification on cylinder head gasket page 63 .


Fit cylinder head and tighten all cylinder head bolts hand-tight. Tighten cylinder head in four stages in sequence as shown as follows: Volkswa 1Stage I = 35 Nm 2Tighten initially with torque wrench: Volksw y
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Stage III = + (90) turn further Stage IV = + (90) turn further Note

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Turn further with rigid spanner:

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After repair work it is not necessary to retighten the cylinder head bolts.
Further installation is carried out in the reverse order. In the pro cess, note the following:

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88

Rep. gr.15 - Cylinder head, valve gear

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After tightening cylinder head, turn camshaft so that cams for No. 1 cylinder point equally upwards. Before fitting toothed belt, turn crankshaft in engine direction of rotation page 66 , removing, installing and tightening toothed belt. Install hub for camshaft toothed belt pulley page 97 , Removing and installing camshaft. Install toothed belt page 66 . Install poly V-belt page 26 . Install oil supply line page 112 . Install noise insulation General body repairs, exterior; Rep. gr. 50 ; Assembly overview - Body - front . Install plenum chamber bulkhead General body repairs, exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulk head . Fill coolant system with coolant page 123 . Carry out road test and then read fault memory page 239 .
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1.5
Note

Checking compression

If ceramic glow plugs are fitted, before removing check idling speed smooth running control using vehicle diagnosis, testing and information system -VAS 5051B- . The compression test is only justified if one or more cylinders are conspicuous.

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1. Cylinder head

89

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Special tools and workshop equipment required Jointed spanner -3220 Torque wrench V.A.G 1331 Adapter -V.A.G 1381/12 Compression tester V.A.G 1763-

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Test prerequisite Test procedure

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Engine oil temperature min. 30 C.

Pull off central connector for unit injectors. Note

If ceramic glow plugs are fitted, always observe notes on remov ing and installing ceramic glow plugs page 269 .
Remove all glow plugs or ceramic glow plugs using jointed extension and socket -3220- .

90

Rep. gr.15 - Cylinder head, valve gear

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

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

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Using the compression tester Operating instructions.


Operate starter until tester shows no further pressure in crease. Compression pressures: New: 25 31 bar, wear limit: 19 bar

Maximum permissible difference between all cylinders: 5 bar Note

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Specified torque: 15 Nm.

Read fault memory of engine control unit page 239 . Note

Disconnecting the central connector for unit injectors causes faults to be stored. Therefore, read fault memory and clear if nec essary.

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Remove glow plugs or ceramic glow plugs using jointed ex tension and socket -3220- .
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If ceramic glow plugs are fitted, always observe notes on remov ing and installing ceramic glow plugs page 269 .
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1. Cylinder head

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

2
Note

Valve gear

Assembly overview - valve gear page 92 .


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Checking valve guides page 94 . Renewing valve stem seals page 95 . Removing and installing camshaft page 97 . Removing and installing camshaft seal page 101 .

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2.1

Assembly overview - valve gear

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1 - 20 Nm + turn (90) Renew. Note sequence when loosening and tighten ing page 97 , Re moving and installing camshaft.
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2 - Rocker arm shaft Do not interchange.

4 - Washer For cylinder head bolts. Insert in cylinder head before installing bearing caps 5 - Bucket tappet Do not interchange. With hydraulic valve clearance compensa tion. Store with cam contact surface downwards. Before installing, check camshaft axial clear ance page 93 . Oil contact surfaces. Before removing, remove camshaft bearing caps

92

Rep. gr.15 - Cylinder head, valve gear

AG.

3 - Cylinder head bolt Renew. Note sequence when loosening and tighten ing page 83 , Remov ing and installing cylin der head. Before installing, insert washers Item 4 (page 92) in cylinder head.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 6 - Valve cotter 7 - Valve
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9 - Inner valve spring Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder head installed page 95 , Renewing valve stem seals.
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10 - Valve stem seal Renewing page 95 . 11 - Valve guide Check page 94 . 12 - Unit injector Removing and installing page 230 13 - Cylinder head See note page 92 .

14 - Seal Do not additionally oil or grease the oil seal sealing lip. Before installing, remove residual oil from camshaft journal using a clean cloth. To install, tape over groove in taper of camshaft (e.g. using Sellotape). Removing and installing page 101
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8 - Outer Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder head installed page 95 , Renewing valve stem seals.
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16 - Bearing shell Do not interchange used bearing shells (mark). Ensure that retaining lugs are correctly seated in bearing caps and cylinder head 17 - Camshaft Checking axial clearance page 93 . Removing and installing page 97 Check radial clearance with Plastigage, wear limit: 0.11 mm. Runout: max. 0.01 mm. 18 - Bearing cap Installation sequence page 97 , removing and installing camshaft To install, seal parting surfaces of bearing caps 1 and 5 with sealant -AMV 174 004 01- page 94 19 - 8 Nm + turn (90) Renew. Checking camshaft axial clearance

AG.

15 - Valves Valve dimensions page 94 .

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2. Valve gear

93

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Special tools and workshop equipment required Universal dial gauge bracket -VW 387 Dial gauge Check with bucket tappets removed and with first, third and last n AG. Volkswagen AG do bearing caps fitted. es wage Wear limit: max. 0.15 mm Seal parting surfaces of bearing caps 1 174 004 01olks yV db e ris tho and 5 uwith sealant a ss

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Apply sealant -AMV 174 004 01- thinly and evenly on the sur faces -1-. Note

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Be careful that no sealant gets into grooves -arrows-.

Valve dimensions Note

Valves must not be reworked. Only lapping-in is permitted.


Dimension a b c mm mm mm Inlet valve 35.95 6.980 89.95 45 Exhaust valve 31.45 6.956 89.95 45

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2.2

Checking valve guides

Special tools and workshop equipment required Universal dial gauge bracket -VW 387-

Dial gauge

94

Rep. gr.15 - Cylinder head, valve gear

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Insert new valve into guide. The end of the valve stem must be flush with the guide. On account of differing stem diame ters, only use inlet valve in inlet guide and exhaust valve in exhaust guide. Determine rock. Wear limit: max. 1.3 mm Cylinder head must be renewed if rock exceeds wear limit.

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Test procedure

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2.3

Renewing valve stem seals


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Special tools and workshop equipment required Assembly tool -2036 Puller -3047 A Fitting tool -3129 Valve lever -VW 541/1A Thrust piece -VW 541/5-

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2.3.1

Removing

(With cylinder head installed) Remove camshaft. page 97

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2. Valve gear

95

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove bucket tappets and place them with the contact sur face downwards. When doing this, ensure that the tappets are not interchanged. Set piston of respective cylinder to top dead centre (TDC). Insert valve assembly device -2036- and adjust mounting to height of studs. Remove valve springs using valve lever -VW 541/1A- and press tool -VW 541/5- . Note
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The valves are supported by the piston

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Pull off valve stem seals using puller -3047 A- .

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2.3.2

Installing

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Insert new valve stem seal in fitting tool -3129- .

96

Rep. gr.15 - Cylinder head, valve gear

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Lubricate sealing lip of valve stem seal and carefully push on valve guide.
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Place the plastic sleeve -A- supplied on the respective valve stem. This will prevent the new valve stem seal -B- being damaged.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

2.4

Removing and installing camshaft

Special tools and workshop equipment required Counterhold tool -T10051 Puller -T10052 Torque wrench (5... 50 Nm) -V.A.G 1331 Torque wrench (40... 200 Nm) -V.A.G 1332 Sealant -AMV 174 004 01-

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2.4.1

Removing

Remove toothed belt. page 66 Remove securing bolts for camshaft toothed belt pulley -1-. Pull camshaft toothed belt pulley off hub.

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2. Valve gear

97

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Loosen hub securing bolt -1-. To do this, use counterhold -T10051- . Loosen hub securing bolt about 2 turns.

Apply

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Apply arates from taper of camshaft. Note

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When doing this, hold puller with 30 mm spanner.


Remove hub from taper of camshaft. Remove cylinder head cover. Mark rocker arm shafts using a permanent felt tip marker to prevent interchanging. This will prevent having to perform ba sic settings of unit injectors -arrows-. Remove rocker arm shafts. Note

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First loosen both outer and then inner securing bolts respectively.
Remove tandem pump page 195 .
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First remove bearing caps 5, 1 and 3. Then loosen bearing caps 2 and 4 alternately and diagonally. Remove camshaft.
AG.

98

Rep. gr.15 - Cylinder head, valve gear

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

2.4.2
Note

Installing

When camshaft is installed, No. 1 cylinder cams must point upwards. Do not interchange used bearing shells (mark). When installing the camshaft, ensure proper seating of retain ing lugs in bearing caps and cylinder head. Before installing bearing caps, ensure that cylinder head bolt washers are inserted in the cylinder head. Oil bearing shell running surfaces. Install bearing caps 2 and 4 using new bolts. Tighten bearing caps 2 and 4 in diagonal sequence alternately to 8 Nm + (90) turn further. Install bearing caps 5, 1 and 3 using new bolts. Note
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Bearing cap 5 must be flush with outer edge of cylinder head, otherwise leaks can occur at the tandem pump. Tighten bearing caps 5, 1 and 3 likewise to 8 Nm + (90) turn further. Install camshaft oil seal. page 101 Install injector rocker arm shafts with new securing bolts and tighten, first the inner -2- and then the outer -1-, evenly and in diagonal sequence to 20 Nm + (90) turn further. Fit hub onto camshaft.

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Seal parting surfaces of bearing caps 1 and 5 with sealant AMV 174 004 01- page 94 .

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To do this, use counterhold -T10051- .

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Tighten hub securing bolt -1- to 100 Nm.

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2. Valve gear

99

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Push camshaft toothed belt pulley onto hub. Note

The toothed segment -arrow- of the camshaft belt pulley must be on top.
Align camshaft toothed belt pulley at centre of elongated holes. Hand tighten securing bolts -1- to camshaft toothed belt pulley so that there is no play. Lock hub using locking pin -3359- . Install and tighten toothed belt page 66 . Screw new adjustment screws into rocker arms hand-tight and fit lock nut. Fit dial gauge onto adjustment screw of unit injector as shown. Turn crankshaft in direction of engine rotation until roller of rocker arm is located at tip of drive cam. Roller side -arrow A- positioned at highest point, dial gauge -arrow B- po sitioned at lowest point. Remove dial gauge. Now turn the adjuster screw into rocker arm until significant AG. Volkswagen AG d agen resistance can be felt (unit injector is at limit stop). oes n lksw
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Hold adjuster screw in this position and tighten lock nut to 30 Nm. Install tandem pump page 195 . Install cylinder head cover. Note

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Turn adjustment screw 180 back off stop.

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When new bucket tappets have been installed the engine must not be started for about 30 minutes. The hydraulic compensation elements must settle (otherwise valves will strike pistons).

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100

Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

2.5

Removing and installing camshaft oil seal

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

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2.5.1

Removing

Remove toothed belt. page 66

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

AG.

Lubricate threaded head of oil seal extractor -3240- , place it in position and exerting firm pressure, screw it as far as pos sible into oil seal.

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Unscrew inner part of oil seal extractor -3240- two turns (ap prox. 3 mm) out of outer part and lock with knurled screw.

2. Valve gear

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Remove camshaft toothed belt pulley and hub page 97 , Removing and installing camshaft.

101

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

2.5.2
Note

Installing

The oil seal sealing lip must not be additionally oiled or greased.
Remove oil residue from camshaft journal using a clean cloth. Tape over groove in taper of camshaft (e.g. with Sellotape). Fit oil seal carefully on camshaft. Press in oil seal with press piece of fitting tool -10-203- and bolt M12 -5 x 65 onto stop. Install and tighten toothed belt page 66 .

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102

Rep. gr.15 - Cylinder head, valve gear

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

17
1
Note

Lubrication
Engine oil

The oil level must not be above the max. mark - danger of damage to catalytic converter! Markings.
Engine oil specification Maintenance ; Booklet 38 Oil capacities page 103 Checking engine oil level
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1.1

Oil capacities
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Engine codes AVQ BJB, BKC, BRU, BXE and BXF With oil filter change: 3.8 l Without oil filter change: 3.3 l Engine codes BLS and BXJ With oil filter change: 4.3 l Without oil filter change: 3.8 l

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1.2

Checking engine oil level

Check which dipstick is installed. 1 - Max. mark 2 - Min. mark

a - Area above hatched field up to max. mark: Do not top up with engine oil!
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b - Oil level within hatched field: Can be topped up with engine oil.
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c - Area from min. mark up to hatched field: Must be topped up, max. 0.5 l of engine oil!
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1.3

Checking engine oil level

1 - Min. mark 2 - Max. mark a - Area of min. mark: top-up with max. 0.5 l of engine oil! b - Oil level in middle range: can be topped-up with engine oil. c - Area of max. mark: do not add engine oil!

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1. Engine oil

103

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

Parts of lubrication system


Caution

Finding metal shavings or a large quantity of small metal par ticles during engine repair could indicate that the crankshaft bearings or conrod bearings are damaged. To prevent this from causing further damage, perform the following repairs: en AG. Volkswagen AG Thoroughly clean oil channels. Renew engine oil cooler
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Assembly overview - oil pump, sump page 104 Removing and installing sump page 105 .

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Renew oil filter element

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2.1
1 - 15 Nm

Assembly overview - oil pump, sump

3 - Chain tensioner with ten sioning rail, 15 Nm When installing, preten sion spring and fit. 4 - Oil dipstick The oil level must not be above the max. mark! Markings page 103 . 5 - Piston fitting tool 6 - Guide tube 7 - Dowel sleeves 8 - O-ring Renew.

104

Rep. gr.17 - Lubrication

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2 - Sealing flange With seal. Must sit on dowel sleeves Removing and installing page 38 Install with silicone sealant -D 176 404 A2 page 38 . 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 - belt pulley end page 36 .

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14 - Oil sump Clean sealing surface before fitting. Install with silicone sealant -D176404A2- . Removing and installing page 105 15 - Oil drain plug, 30 Nm Renew. 16 - 10 Nm 17 - Oil level and oil temperature sender -G266 Black 3-pin connector 18 - Seal Renew.
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19 - Oil pump With 12 bar pressure relief valve. Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted. Renew if running surfaces and gears are scored.
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21 - Bracket For oil level/temperature sender wiring harness. 22 - 20 Nm + turn (90) Renew. 23 - Chain 24 - 25 Nm Insert without sealant. 25 - Oil spray jet For piston cooling. Note
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2.2

Removing and installing oil sump

Special tools and workshop equipment required

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20 - Chain sprocket for oil pump


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2. Parts of lubrication system

105

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Torque wrench -V.A.G 1331-

Hexagon key extension, 5 mm -3249-

Hand drill with plastic brush attachment Silicone sealant -D176404A2 Hand drill with plastic brush attachment Eye protection Flat scraper
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2.2.1

Removing

Remove noise insulation. General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . Drain engine oil. Note

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Observe environmental regulations for disposal.

Pull 3-pin connector off oil level and oil temperature sender G266- . Remove sump. Loosen sump with light blows of a rubber headed hammer if necessary. Remove sealant residue from cylinder block with a flat scraper.
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106

Rep. gr.17 - Lubrication

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Clean sealing surfaces. They must be free of oil and grease.

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2.2.2
Note

Installing

Observe expiry date of sealing compound. The sump must be installed within 5 minutes of applying sili cone sealing compound. Cut off tube nozzle at forward marking ( of nozzle approx. 3 mm).
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Apply silicone sealing compound, as shown, to clean sealing surface on sump. Sealant bead must be: Run bead along inner side of bolt holes -arrows-. Note
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2 ... 23 mm thick.

The sealant bead must not be thicker, otherwise excess sealing compound will enter the oil sump and may block the oil suction line strainer.
Apply silicone sealing compound bead as shown to the clean sealing surface of the sump. (The figure shows the position of the sealant bead on the cylinder block.) Install sump immediately and tighten all sump bolts lightly. Ensure that sump is flush against intermediate plate and gear box flange. Note

When installing sump with engine removed, ensure that sump is flush with cylinder block at flywheel end.
Tighten sump bolts diagonally to 15 Nm. Tighten bolts securing sump to gearbox to 45 Nm. Note

Let sealing compound dry for approx. 30 minutes after installing oil sump. Only then fill with engine oil.

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107

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Further assembly is basically the reverse of the dismantling se quence.

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Rep. gr.17 - Lubrication

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

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

Assembly overview - oil filter bracket and oil cooler page 109 Checking oil pressure and oil pressure switch page 110 . Assembly overview -oil supply line to turbocharger page 111 Removing and installing oil supply line to turbocharger page 112

3.1

Assembly overview - oil filter bracket and engine oil cooler

1 - Oil filter bracket 2 - 15 Nm + turn (90) Renew. First fit upper left and lower right bolts and then tighten all four bolts diagonally. 3 - Seal Renew. 4 - Seal Renew. 5 - Union, 35 Nm 6 - Oil supply line, 22 Nm To turbocharger. Removing and installing page 112 7 - Cap, 25 Nm 8 - Seal Renew. 9 - Oil filter element Ensure "Top" is upper most when fitting 10 - Plug, 10 Nm If seal is leaking, nip open and renew. 11 - Oil pressure switch -F1 0.7 bar switch: brown. Tighten to 20 Nm. If seal is leaking, nip open and renew. Check page 110 . 12 - Plug, 25 Nm 13 - Seal Renew. 14 - Engine oil cooler Ensure clearance to adjacent components.
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109

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 See note page 104 . Checking engine oil cooler for leaks page 134 15 - Seal Renew. 16 - Bracket 17 - 10 Nm

3.2

Checking oil pressure and oil pressure switch

Special tools and workshop equipment required Oil pressure tester V.A.G 1342 Voltage tester V.A.G 1527 B Auxiliary measuring set V.A.G 1594 A-

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Note

Test procedure

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Rep. gr.17 - Lubrication

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Functional check and repair of optical and acoustic oil pressure warning: Current flow diagrams, Electrical fault finding and Fit ting locations Guided fault finding with VAS 5051.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove oil pressure switch -F1- and screw into tester. Screw tester into oil filter bracket in place of oil pressure switch. Connect brown wire of tester to earth (-). Connect voltage tester -V.A.G 1527 B- to battery positive (+) and oil pressure switch using cable from auxiliary measuring set -V.A.G 1594 A- . LED must not light up. Start engine and increase speed slowly. At 0.55 0.85 bar, the LED must light up; otherwise renew oil pressure switch. Increase engine speed further. At 2000 rpm and an oil tem perature of 80 C the oil pressure should be at least 2.0 bar. At higher engine speeds, oil pressure must not exceed 7.0 bar. If necessary renew oil filter bracket.

3.3

Assembly overview - oil supply line to turbocharger

1 - Retaining clamp 2 - 25 Nm 3 - Oil supply line To turbocharger. 4 - 10 Nm 5 - Bracket 6 - Union nut, 22 Nm 7 - 10 Nm 8 - Union nut, 22 Nm
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111

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

3.4

Removing and installing oil supply line to turbocharger

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

3.4.1

Removing

Remove engine cover. page 5 Remove air filter housing with air mass meter and connecting pipe. Remove bolt -arrow A- and pull air filter housing upwards out of mounting. Remove noise insulation. General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . Loosen securing bolts for retaining clips.
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Installing

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Note

The procedure must be adhered to, this will ensure that the oil supply line is installed tension-free.

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112

Rep. gr.17 - Lubrication

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

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

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

19
1

Cooling
Parts of cooling system
WARNING

When doing any repair work, especially in the engine com partment, pay attention to the following due to the cramped conditions: Route all the various lines (e.g. for fuel, hydraulics, acti vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po sitions. olkswagen AG en AG. V
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When the engine is warm, the cooling system is under pres sure. If necessary, release pressure before beginning repair work. Hoses are secured with spring-type clips. In case of repair, only use spring-type clips. Spring-type clip pliers -VAS 5024- or hose clip pliers V.A.G 1921- are recommended for fitting spring-type clips. When installing coolant hoses, route stress-free so that they do not come into contact with other components (observe markings on coolant connection and hose).

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Rep. gr.19 - Cooling

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Perform leakage test of cooling system using cooling system tester -V.A.G 1274- and adapters adapter -V.A.G 1274/8- and adapter -V.A.G 1274/9- . Parts of cooling system, body side (radiator with two radiator fans) page 115 . Parts of cooling system, body side (radiator with one radiator fan) page 117 Removing and installing fan support with fans (Golf, Golf Plus, Touran) page 117 Removing and installing fan support with fans (Passat) page 119 Parts of cooling system - engine side page 120 . Coolant hose schematic diagram page 122 . Draining and filling with coolant page 123 . Removing and installing radiator (Golf, Golf Plus, Touran) page 126 Removing and installing radiator (Passat) page 127 Removing and installing coolant pump page 128 . Removing and installing thermostat page 130 . Checking cooling system for leaks page 132 . Checking pressure relief valve in filler cap page 133 . Checking engine oil cooler for leaks page 134 gen AG a ksw
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1.1

Parts of cooling system, body side (radiator with two radiator fans)
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115

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 diagram page 122 . 2 - O-ring Renew if damaged. 3 - Cooler Removing and installing page 126 After renewing, renew entire coolant. 4 - Cap Check using cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/9- . Test pressure 1.4 1.6 bar 5 - Connector 6 - 5 Nm 7 - Expansion tank Check using cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/8- . 8 - 5 Nm 9 - 10 Nm 10 - Fan support 11 - Additional fan Vehicles with optional equipment only. 12 - Radiator fan 13 - Connector
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14 - Lower coolant hose Coolant hose schematic diagram page 122 . 15 - Retaining clip Check for secure seating.
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16 - Radiator outlet coolant temperature sender -G83-

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116

Rep. gr.19 - Cooling

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.2

Assembly overview - parts of cooling system, body side (radiator with one radiator fan)

1 - Upper coolant hose Coolant hose schematic diagram page 122 . 2 - O-ring Renew if damaged. 3 - Radiator Removing and installing page 126 After renewing, renew entire coolant. 5 - Cap Check using cooling system tester V.A.G 1274- and adapter V.A.G 1274/9- . 6 - Connector 7 - 5 Nm
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8 - Expansion tank Check using cooling system tester V.A.G 1274- and adapter V.A.G 1274/8- . 9 - Radiator mounting 10 - 5 Nm 11 - Mounting 12 - Radiator fan 13 - Fan support 14 - 5 Nm 15 - 5 Nm 16 - Connector

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17 - Lower coolant hose Coolant hose schematic diagram page 122 . 18 - Retaining clip Check for secure seating. 19 - Radiator outlet coolant temperature sender -G83-

1.3

Removing and installing fan support with fans (Golf, Golf Plus, Touran)

Special tools and workshop equipment required

1. Parts of cooling system

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117

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Torque wrench (5... 50 Nm) -V.A.G 1331-

Removing The procedure for the single fan is identical. Remove noise insulation General body repairs, exterior; lksw o agen AG Rep. gr. 50 ; Assembly overview - Body - front swagen AG. V . does Remove air intake duct from air filter. sition.
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Separate connector -1- and remove fan support securing bolts -arrows-. Remove fan support with fans upwards.

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Separate connection -2- and free wiring. Unclip connector -1- from fan support and free wiring. Remove securing nuts -arrows- and remove fans.
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Installing

The procedure for the single fan is identical.

Specified torques: Item 15 (page 117)

Component Radiator fan to fan support (single fan) Radiator fan to fan support (double fan) Fan support to radiator

118

Rep. gr.19 - Cooling

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Installation is carried out in the reverse order. When installing, note the following:
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.4

Removing and installing fan support with fans (Passat)

Special tools and workshop equipment required Torque wrench (5... 50 Nm) -V.A.G 1331-

Removing The procedure for the single fan is identical. Remove noise insulation General body repairs, exterior; Rep. gr. 50 ; Assembly overview - Body - front . Remove air intake duct from air filter. Separate connector -1- and remove fan support securing bolts -arrows-. G. Volkswagen Remove fan support with fans upwards.
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Separate connection -2- and free wiring. Unclip connector -1- from fan support and free wiring. Remove securing nuts -arrows- and remove fans. Installing The procedure for the single fan is identical. Installation is carried out in the reverse order. When installing, note the following: Specified torques: Item 15 (page 117)

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Radiator fan to fan support (double fan) Fan support to radiator

1. Parts of cooling system

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Component Radiator fan to fan support (single fan)

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119

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.5

Parts of cooling system, engine side

1 - To top of expansion tank Coolant hose schematic diagram page 122 . 2 - Upper coolant pipe Bolted to cylinder head cover 3 - To bypass flap Coolant hose schematic diagram page 122 .
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4 - O-ring Renew.

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5 - Retaining clip Check for secure seat ing. 6 - Coolant temperature sender -G62 With coolant tempera ture display sender -G27 - To exhaust gas recircula tion cooler. Coolant hose schematic diagram page 122 . 8 - Connection 9 - 10 Nm

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11 - 40 Nm 12 - T-piece

14 - T-piece 15 - To top of radiator Coolant hose schematic diagram page 122 . 16 - 15 Nm 17 - To bottom of expansion tank Coolant hose schematic diagram page 122 . 18 - Coolant pipe 19 - To bottom of radiator Coolant hose schematic diagram page 122 . 20 - Connection For thermostat. 21 - Thermostat Removing and installing page 130 Observe installation position page 130 , removing and installing thermostat.

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Rep. gr.19 - Cooling

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13 - To bypass flap Coolant hose schematic diagram page 122 .

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10 - To heat exchanger Coolant hose schematic diagram page 122 .

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Checking: heat thermostat in water. Opening begins at approx. 85 C. Ends at approx. 105 C. Opening lift at least 7 mm.

22 - To heat exchanger Coolant hose schematic diagram page 122 23 - Rear coolant pipe 24 - 10 Nm 25 - To auxiliary heater Coolant hose schematic diagram page 122 26 - Coolant pipe 27 - To exhaust gas recirculation cooler. Coolant hose schematic diagram page 122 28 - Engine oil cooler Removing and installing page 109 29 - Coolant pump Check for ease of movement. Note installation position. Removing and installing page 128
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1.6

Coolant hose schematic diagram

1 - Expansion tank 2 - Rear coolant pipe 3 - Bypass flap 4 - Exhaust gas recirculation cooler 5 - Cylinder head/cylinder block 6 - Heat exchanger for heater unit 7 - Connection 8 - Front coolant pipe 9 - Gearbox oil cooler if fitted Only on vehicles with automatic gearbox. 11 - Radiator
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10 - Upper coolant hose

12 - Lower coolant hose 13 - Engine oil cooler 14 - Coolant pump and ther mostat 15 - Upper coolant pipe 16 - Circulation pump -V55 if fitted 17 - Auxiliary heater Vehicles with optional equipment only.

Note

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

122

Rep. gr.19 - Cooling

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.7

Draining and filling coolant

Special tools and workshop equipment required Refractometer -T10007 Drip tray -V.A.G 1306 Spring-type clip pliers VAS 5024 A Cooling system charge unit -VAS 6096 Adapter -V.A.G 1274/8-

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1.7.1

Draining
WARNING

Open cap on coolant expansion tank.


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Open cap on coolant expansion tank.

Remove noise insulation. General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . If drain plug is fitted:

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Hot steam may escape when expansion tank is opened. Place cloth over cap and open with caution.
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1. Parts of cooling system

123

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 To drain coolant from radiator, open drain plug -arrow-. If drain plug is not fitted:

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To drain coolant from engine, also remove coolant hose from engine oil cooler -arrow-. Note

Observe environmental regulations for disposal.


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Rep. gr.19 - Cooling

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.7.2
Note

Filling

In vehicles as of model year 2008, only G 12 plus-plus ac cording to TL VW 774 G may be used as coolant additive. For vehicles up to and including model year 2007 coolant ad ditive G 12 plus according to TL VW 774 F and G 12 plus-plus according to TL VW 774 G can be used. The coolant additive G 12 plus-plus can be mixed with the previous coolant additive G 12 plus. Identification: both are coloured purple. Coolant additives marked according to TL VW 774 G or ac cording to TL VW 774 F prevent n AG. Volkswagen AG does wage frost and corrosion damage, not olks scaling and also raise boiling point of coolant. Therefore,gthe yV ua d b filled all year round with coolant ada r n cooling system must e be tee ris ho ditive and corrosion protection additive. or ut
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Frost protection is required down to about -25 C (in countries with arctic climates: down to about -35 C). The coolant concentration must not be reduced by adding wa ter even in warmer seasons and in warmer countries. The coolant additive concentration must be at least 40 %. If for climatic reasons greater frost protection is required, the amount of coolant additive can be increased, but only up to 60 % (frost protection to about -40 C). Otherwise frost protection and cooling effectiveness are reduced again. The refractometer -T10007- is recommended for determining the current anti-freeze concentration. If radiator, heat exchanger, cylinder head or cylinder head gasket is renewed, do not reuse old coolant. Recommended mixture ratios:
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The quantity of coolant can vary depending upon the vehicle equipment. Close coolant drain plug. Connect coolant hoses to engine oil cooler. Install noise insulation. General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . Screw adapter -V.A.G 1274/8- onto expansion tank. Fill coolant circuit using cooling system charge unit VAS 6096Operating instructions for cooling system charge unit -VAS 6096are enclosed with unit.

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1. Parts of cooling system

125

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Fill coolant expansion tank of -VAS 6096- with at least 8 litres of pre-mixed coolant in correct mixture ratio. Note

Exhaust air takes a slight quantity of coolant along with it; this should be collected -2-.

1.8

Removing and installing radiator (Golf, Golf Plus, Touran)

Special tools and workshop equipment required Refractometer -T10007 Drip tray -V.A.G 1306 Torque wrench V.A.G 1331 Spring-type clip pliers VAS 5024 A Cooling system charge unit -VAS 6096un le

Adapter -V.A.G 1274/8-

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Rep. gr.19 - Cooling

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.8.1

Removing (Golf, Golf Plus, Touran)

Bring lock carrier into service position. General body re pairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier service position . Drain coolant page 123 Pull coolant hoses off radiator.
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Remove radiator downwards.

1.8.2

Installing (Golf, Golf Plus, Touran)

Installation is carried out in the reverse order. When installing, note the following: Fill with coolant. page 123

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1.9

Removing and installing radiator (Passat)

Special tools and workshop equipment required Refractometer -T10007 Torque wrench -V.A.G 1331/-

Hose clip pliers -VAS 6340-

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1. Parts of cooling system

127

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Removing Drain coolant page 123 . Pull coolant hoses off radiator. Pull off connector for radiator fan. Remove cowling together with fans page 119 . Remove bolts -arrow up- -arrow down- and lift radiator up and out. Installing Installation is carried out in the reverse order. When installing, note the following: Replenish coolant page 123 .

1.10

Removing and installing coolant pump

Special tools and workshop equipment required Refractometer -T10007 Drip tray -V.A.G 1306 Torque wrench V.A.G 1331 Spring-type clip pliers VAS 5024 A Adapter -V.A.G 1274/8 Cooling system charge unit -VAS 6096un le

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128

Rep. gr.19 - Cooling

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.10.1
Note

Removing

Always renew seals and gaskets.


Drain coolant page 123 . Remove poly V-belt page 25 . Remove toothed belt page 66 . Remove securing bolts -1- for coolant pump -2- and carefully remove coolant pump.

1.10.2

Installing
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Installation is carried out in the reverse order. When installing, note the following: Moisten new O-ring -3- with coolant. agen lksw Insert coolant pump bolts -1- to 15 Nm. Note
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The coolant pump plug faces downwards.


Install toothed belt page 66 . Install poly V-belt page 26 . Fill coolant system with coolant page 123 .

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1. Parts of cooling system

129

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.11

Removing and installing thermostat

Special tools and workshop equipment required Refractometer -T10007 Drip tray -V.A.G 1306 Torque wrench V.A.G 1331 Spring-type clip pliers VAS 5024 A Adapter -V.A.G 1274/8 Cooling system charge unit -VAS 6096-

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1.11.1

Removing

Note

Drain coolant page 123


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

130

Rep. gr.19 - Cooling

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove securing bolts -1- of connection -2- and remove con nection -2- with thermostat -4-. Turn thermostat -4- 1/4 turn (90) anticlockwise and remove it from connection -2-.

1.11.2

Installing

Installation is carried out in the reverse order. When installing, note the following: Moisten new O-ring -3- with coolant.
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The brace on the thermostat must be almost vertical.

Insert connection -2- with thermostat -4- in cylinder block. Tighten securing bolts -1- to 15 Nm. Replenish coolant. page 123

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1. Parts of cooling system

131

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.12

Checking cooling system for leaks


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Special tools and workshop equipment required


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Cooling system tester V.A.G 1274 Adapter for cooling system tester -V.A.G 1274/8 Adapter for cooling system tester -V.A.G 1274/9-

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Test prerequisite Engine at operating temperature. Test sequence: WARNING

Hot steam may escape when expansion tank is opened. Place cloth over cap and open with caution.
Open cap on coolant expansion tank.

132

Rep. gr.19 - Cooling

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Attach cooling system tester -V.A.G 1274- with cooling system tester adapter -V.A.G 1274/8- to expansion tank. Use hand pump on tester to create a pressure of about 1.0 bar. If pressure drops: Find leaks and rectify.
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Checking pressure relief valve in filler cap

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Attach cooling system tester -V.A.G 1274- with cooling system tester adapter -V.A.G 1274/9- to cap. Use hand pump on cooling system tester to create a pressure of max. 1.6 bar. The pressure relief valve must not open. If the pressure relief valve opens prematurely: Renew sealing cap. Increase pressure to over 1.6 bar. The pressure relief valve must open.
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Renew sealing cap.

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If the pressure relief valve does not open:

1. Parts of cooling system

133

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1.13

Checking engine oil cooler for leaks

Special tools and workshop equipment required Refractometer -T10007 Hose clamps up to 25 mm -3094 Cooling system tester V.A.G 1274 Adapter for cooling system tester -V.A.G 1274/8 Spring-type clip pliers -VAS 5024A Drip tray -VAS 6208-

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

134

Rep. gr.19 - Cooling

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Torque wrench -V.A.G 1331-

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Special tools and workshop equipment required

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Cap -1J0 121 324 Coolant hose -251 265 056 Screw clamp Test prerequisite: Engine cold Test procedure Remove noise insulation General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula tion . Clamp supply line and return line off engine oil cooler using hose clips to 25 mm -3094- . Loosen spring-type clips -arrows- using spring-type clip pliers -VAS 5024A- . Note
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Pull coolant hoses off engine oil cooler. Push sealing cap -5- to rear connection of engine oil cooler -4-. Secure sealing plug -2- to breather connection of expansion tank -1-. Secure coolant hose -3- to oil cooler and expansion tank. Fill expansion tank up to Max marking. Attach cooling system tester -V.A.G 1274- with cooling system tester adapter -V.A.G 1274/8- to expansion tank. Use hand pump on tester to create a pressure of about 1.6 bar. Watch pressure drop on pressure gauge. A pressure drop within 10 minutes is not permitted. If pressure drops: Renew engine oil cooler. Assembly is carried out in the reverse order, note the following:
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Check coolant level, if necessary replenish coolant.


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1. Parts of cooling system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

20
1
1.1

Fuel supply system


Safety precautions
Safety precautions when working on fu el supply system
WARNING

When doing any repair work, especially in the engine com partment, pay attention to the following due to the cramped conditions: Route all the various lines (e.g. for fuel, hydraulics, acti vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po sitions. Ensure that there is sufficient clearance to all moving or hot components. The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! Wear eye and hand protection when of repair work on the fuel system!

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

Even before work commences, the extraction hose of an ac tivated fume extraction system has to be placed in the vicinity of the assembly opening of the fuel tank to extract any escap ing fumes. If no exhaust extraction system is available, a radial fan with a displacement greater than 15 m3/h can be used providing that motor is not in air flow. Prevent skin contact with fuel! Wear fuel-resistant gloves!

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136

Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

2
2.1

Rules for cleanliness


Rules for cleanliness when working on fuel supply system
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When working on the fuel supply and injection system, pay careful attention to the following 6 rules for cleanliness:
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Carefully cover opened components or seal if repairs cannot be carried out immediately.

Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.).

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When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely nec essary. Also ensure that no diesel fuel comes into contact with the coolant hoses. Should this occur, the hoses must be cleaned immediately. Damaged hoses must be renewed.

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2. Rules for cleanliness

137

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

Fuel tank, vehicles with front-wheel drive page 138 . Fuel tank, vehicles with four-wheel drive page 142 . Emptying fuel tank page 148 . Removing and installing fuel delivery unit page 150 . Removing and installing fuel gauge sender page 151 . Checking fuel pump page 152 . Assembly overview - fuel filter page 156 . Removing and installing fuel cooler page 158 .

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Rules for cleanliness page 137 .

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3.1

Fuel tank, vehicles with front-wheel drive


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Note

Always renew clamp-type clips with spring-type clips.

Spring-type clip pliers -VAS 5024/- or hose clip pliers -V.A.G 1921/- are recommended for installation of spring-type clips.

138

Rep. gr.20 - Fuel supply system

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Hose connections are secured with either spring-type or clamp-type clips.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

3.1.1
1 - Cap 2 - 1.5 Nm

Assembly overview - fuel tank

3 - Earth connection Check for secure seat ing. 4 - 10 Nm 5 - Cable guide 6 - Fuel tank When removing, sup port using engine and gearbox jack -V.A.G 1383/A- . Removing and installing page 140
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7 - 25 Nm Renew.

8 - Clamping washer

9 - Securing strap Note installation posi tion. 10 - Heat shield For fuel tank.

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

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13 - Locking ring Remove and install using wrench -T10202- . Specified torque: 110 Nm 14 - Supply line To fuel filter Clipped onto fuel tank. Check for secure seating. Black To pull off flange, press release button on connecting piece. 15 - Return line From fuel cooler Blue or with blue marking.

3. Parts of fuel supply system (Golf, Golf Plus)

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12 - Fuel delivery unit With fuel gauge sender (G). Note installation posi tion of flange on fuel tank page 162 . Removing and installing page 150 Checking fuel pump page 152 . Removing and installing fuel gauge sender page 170 .
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139

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Clipped onto fuel tank. Check for secure seating. To pull off flange, press release button on connecting piece. 16 - Tank flap unit Removing and installing General body repairs, exterior; Rep. gr. 55 ; Tank flap unit .

3.1.2

Removing and installing fuel tank

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

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

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Note safety precautions before beginning work page 136 . Observe rules for cleanliness page 137 . Note
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Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary. When lowering fuel tank, guide it carefully to prevent damage. Disconnect earth strap from battery with ignition switched off Electrical system; Rep. gr. 27 ; Disconnecting and recon necting battery . Remove rear seat bench (Golf Plus: rear right seat) General body repairs, interior; Rep. gr. 72 ; Rear seats; Removing and installing seat bench .

140

Rep. gr.20 - Fuel supply system

AG.

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove cover from fuel delivery unit. Pull connector off flange. Remove fuel flap unit. General body repairs, exterior; Rep. gr. 55 ; Fuel flap unit Emptying fuel tank page 148 . Remove rear right wheel housing liner: General body re pairs, exterior; Rep. gr. 66 ; Removing and installing wheel housing liner .

Remove bolts from filler neck -arrows-.

Disconnect fuel lines at front right of fuel tank. Note

Press buttons on hose couplings to do this.


If vehicle has supplementary heating, separate connector to wagen AG. Volkswagen AG doe s no o metering pump and unclip wire. Supplementary heating; lks t gu yV ara Rep. gr. 82 ; Removing and installing metering pumped b -V54 n is Remove bolts -A- and remove heat shield for fueluttank. sa
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Support fuel tank using engine and gearbox jack -V.A.G 1383/ A- . Remove securing bolts -arrows- for the fuel tank. Slowly lower fuel tank and pull it forwards. Tilt fuel tank to get it past rear axle. Installing

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Install in reverse order. In the process, note the following: Install breather and fuel hoses free of kinks. Ensure that fuel hose connections are tight.

Do not interchange supply line and return line (return line blue or with blue marking, supply line black). Clip supply and return lines onto fuel tank.

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3. Parts of fuel supply system (Golf, Golf Plus)

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141

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3.2 3.2.1

Fuel tank, vehicles with four-wheel drive Assembly overview - fuel tank

1 - Supply line Black Check for secure seat ing. 2 - Return line blue Check for secure seat ing. 3 - Seal Renew. When installing, fit dry in fuel tank opening. Moisten with fuel only when installing flange. 4 - Fuel delivery unit Removing and installing page 150 Checking fuel pump Note installation posi tion on fuel tank page 143 . With fuel gauge sender -G- . Removing and installing fuel gauge sender page 170 . 5 - Locking ring, 110 Nm Check for secure seat ing. Remove and install us ing wrench -T10202- .

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6 - Tank flap unit With rubber cup. Removing and installing General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and installing fuel tank flap unit . 7 - Cap Renew if damaged. 8 - Securing bolt Tighten to 1.5 Nm. 9 - Earth connection Check for secure seating. 10 - 10 Nm 11 - Suction-jet pump Clipped onto fuel gauge sender 2 -G169 Removing and installing page 147

142

Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 12 - Fuel gauge sender 2 -G16913 - Fuel tank When removing, support using engine and gearbox jack -V.A.G 1383 A- . Removing and installing page 143 14 - Securing strap Note installation position. 15 - 25 Nm Renew. 16 - Heat shield Riveted to exhaust pipe mounting Installation position of flange for fuel delivery unit and fuel gauge sender 2 -G169The marking on the flange must align with the marking on the fuel tank -arrow-. Note

The marking on the fuel tank is not clearly visible.

Special tools and workshop equipment required Torque wrench (5... 50 Nm) -V.A.G 1331-

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3.2.2

Removing and installing fuel tank

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

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Note safety precautions before beginning work page 136 .

3. Parts of fuel supply system (Golf, Golf Plus)

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143

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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Disconnect earth strap from battery with ignition switched off Electrical system; Rep. gr. 27 ; Disconnecting and recon necting battery . If necessary, drain fuel tank using fuel extractor -VAS 5190- . page 148 Remove rear right wheel. Remove rear right wheel housing liner. General body re pairs, exterior; Rep. gr. 66 ; Removing and installing wheel housing liner; Rear wheel housing liner . Unscrew securing bolts and remove tank flap unit. General body repairs, exterior; Rep. gr. 55 ; Fuel flap unit
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First check whether a coded radio is fitted. If so, obtain antitheft coding.

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Unscrew filler neck from body -arrows- and unclip electrical wire from filler neck. Remove bench seat General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing seat bench .
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Remove covers and separate electrical connectors -arrows-. Remove centre and rear silencers.

Secure exhaust system to underbody using wire. Remove rear propshaft Manual gearbox; Rep. gr. 39 ; Final drive, differential, differential lock WARNING

Fuel supply line is pressurised. Wear eye protection and pro tective clothing to avoid possible injury and skin contact. Be fore loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

144

Rep. gr.20 - Fuel supply system

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

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

Raise fuel tank slowly up to installation position and secure it in place.

3. Parts of fuel supply system (Golf, Golf Plus)

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145

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Fit adapter cable on four-wheel drive control unit -J492- . The remaining installation steps are carried out in the reverse se quence. In the process, note the following: Install breather and fuel lines free of kinks. Do not interchange supply line and return line (return line blue or with blue marking, supply line black). Ensure that fuel line connections are tight. Check earth connection on fuel tank and body to filler neck.

3.2.3

Removing and installing fuel gauge sender 2 -G169-

The fuel tank should be no more than half full Note

Ensure that the fuel gauge sender is not bent. If necessary, drain fuel tank using fuel extractor -VAS 5190- . page 148 Note safety precautions before beginning work page 136 . Observe rules for cleanliness page 137 . Removing: First check whether a coded radio is fitted. If so, obtain antitheft coding. Disconnect earth strap from battery with ignition switched off Electrical system; Rep. gr. 27 ; Disconnecting and recon necting battery . G. Volkswagen
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Disconnect electrical connectors. Open locking ring using wrench -T10202- .

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Remove left cover (asau seen facing direction of normal travel) ss from fuel gauge sender 2 -G169- .

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Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Pull fuel gauge sender 2 -G 169- upwards slightly and unclip . Volkswagen AG it from the suction-jet pump. gen AG d Installing:
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When installing do not bend fuel gauge sender 2 -G169- float arm.
Place fuel gauge sender 2 -G 169- in fuel tank. Fit suction-jet pump on sender on inside of fuel tank. Locating lugs must engage. Place a new flange seal dry into aperture in fuel tank and moisten only inside (contact to flange) with fuel. Note installation position of fuel gauge sender 2 -G169- page 143 Check correct position of seal.

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Tighten locking ring using wrench -T10202- . Specified torque: 110 Nm. Install cover.
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Fit connectors.

Install bench seat. General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing seat bench .

3.2.4

Removing and installing suction-jet pump

Note On vehicles with four-wheel drive, fuel must be pumped from the area of fuel gauge sender 2 -G169- , to the fuel pump with a suction-jet pump due to the shape of the fuel tank. Checking is only necessary when the engine stops due to lack of fuel, even though the fuel gauge shows that the tank is still 1/4 full. Procedure Remove fuel delivery unit page 150 .

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3. Parts of fuel supply system (Golf, Golf Plus)

147

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Pull return hose of suction-jet pump out of fuel delivery unit -arrow-. Separate quick-release coupling of supply line from suctionjet pump on Y-piece of fuel delivery unit. Remove fuel gauge sender 2 -G 169- page 146 . Now the suction-jet pump can be pulled out from the side of the fuel gauge sender 2 -G169- (left side of vehicle). Check that the fuel lines on suction-jet pump are fitted securely and are not damaged. Additionally check suction-jet pump for possible soiling.

3.3

Emptying fuel tank

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

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Fuel tank sender unit tool -T10202-

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

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Emptying fuel tank if it is more than 3/4 full page 148 . Emptying fuel tank if it is less than 3/4 full page 149 .

3.3.1

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


Caution

Secure earth wire of fuel extractor -VAS 5190- to a bare metal part of the body.

148

Rep. gr.20 - Fuel supply system

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Note safety precautions before beginning work page 136 .

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Remove filler cap from fuel tank filler neck. Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel filler neck. Push extraction hose into fuel tank until marking on hose -arrow- coincides with shaft end.

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A ball valve -2- is located at the bottom of the filler neck in the fuel tank -1-; it must not be damaged by the extraction hose -3-. Therefore push hose into filler neck only as far as marking -arrow-.
Empty fuel tank as far as possible. Carefully pull out extraction hose. Note When no more fuel is extracted, the tank is emptied just enough for the sender flange to be opened without danger. If the fuel tank has to be drained fully, proceed as follows: page 149

3.3.2

Emptying fuel tank if it is less than 3/4 full

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

Fuel supply line is pressurised. Wear eye protection and pro tective clothing to avoid possible injury and skin contact. Be fore loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

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Note

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3. Parts of fuel supply system (Golf, Golf Plus)

149

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Pull connector and fuel lines off flange. Note

Press buttons on hose couplings to do this.


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

3.4

Removing and installing fuel delivery unit

Special tools and workshop equipment required Wrench -T10202-

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Torque wrench -V.A.G 1332-

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Removing

Observe safety precautions page 136 .

Observe rules for cleanliness page 137 .


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First check whether a coded radio is fitted. If so, obtain antitheft coding.
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150

Rep. gr.20 - Fuel supply system

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Disconnect earth strap from battery with ignition switched off Electrical system; Rep. gr. 27 ; Disconnecting and recon necting battery .

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove rear seat bench (Golf Plus: rear right seat) General body repairs, interior; Rep. gr. 72 ; Rear seats; Removing and installing seat bench . Remove cover from fuel delivery unit. Pull 5-pin connector and fuel lines off flange. Note

Press buttons on hose couplings to do this.


WARNING

The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! Wear eye and hand protection when performing any type of repair work on the fuel system!

Remove union nut with wrench -T10202- . Pull fuel delivery unit and seal out of the opening in fuel tank. Note

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Installing the fuel delivery unit is carried out in reverse order of removal. Note
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Do not bend fuel gauge sender when installing. Insert seal for flange or fuel delivery unit dry into opening of fuel tank. Moisten seal with fuel only when installing flange or fuel de livery unit. Ensure that fuel hose connections are tight. After installing fuel delivery unit, check that the supply, return and breather lines are still clipped onto the fuel tank.
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Note installation position of fuel delivery unit flange: mark on flange must align with mark on fuel tank -arrows-.

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Removing Remove fuel delivery unit page 150 .

3. Parts of fuel supply system (Golf, Golf Plus)

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3.5

Removing and installing fuel gauge sender

151

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Release connector lugs on lines -3- and -4- and pull off. Lift retaining tabs -1- and -2- using a screwdriver and pull fuel gauge sender off downwards -arrows-. Installing Insert fuel sender into guides on fuel delivery unit and press upwards until it engages.

3.6
Note

Checking fuel pump

3.6.1

Checking delivery pressure of fuel pump

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Check fuel filter connections for correct arrangement, before starting to check the fuel pump page 156

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Special tools and workshop equipment required Pressure gauge -VAS 6550 Vehicle diagnosis tester Test prerequisite: Fuses must be OK. Battery voltage at least 12 V

All electrical consumers, e.g. lights and rear window heating, must be switched off.

Separate quick-release coupling -A- (completely black or with black marking) of fuel supply line. Connect pressure tester -VAS 6550- with cables -VAS 6550/1and -VAS 6550/2- to open ends of fuel supply line.
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Switch on pressure tester -VAS 6550- by pressing On/Off button.


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Open shut-off taps A and B of pressure tester and close shut-off tap C. Start engine and run at idling speed.

Read pressure on pressure tester -VAS 6550- . Specification: min. 0.5 bar. Place pressure tester -VAS 6550- onto windscreen so that it can be read from inside vehicle. Increase idling speed to 2500 rpm and read the pressure on pressure tester -VAS 6550- , specification min 0.25 bar. If the delivery pressure temporarily drops, renew fuel delivery unit page 180 . If the specifications are attained, check tandem pump to en sure the fuel filter is not blocked page 195 . If the tandem pump values are OK, check fuel pump delivery rate page 153 .

152

Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

3.6.2

Checking fuel pump delivery rate

Special tools and workshop equipment required Pressure gauge -VAS 6550 Container > 3 litre with measuring scale Vehicle diagnosis tester Test prerequisite: Fuses must be OK. Battery voltage at least 12 V All electrical consumers, e.g. lights and rear must be switched off.
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Note

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The delivered fuel may be cloudy. This is normal and can be ig nored.
Separate quick-release coupling -A- (completely black or with black marking) of fuel supply line. Connect -VAS 6550/1- pressure tester line to fuel supply -A-. Guide open end of line into measuring container. Connect vehicle diagnosis tester and perform guided function checking electric fuel pump(s). Note

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The fuel pump is now activated for 30 seconds.

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If the specification is not attained:

If necessary, renew defective line and repeat test.

If it is not kinked, crushed or damaged, remove rear seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats . Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor Remove cover from fuel delivery unit. Note

Press in securing ring to release fuel line.

3. Parts of fuel supply system (Golf, Golf Plus)

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After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s.

153

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Connect -VAS 6550/1- pressure tester line to fuel supply -A-. Guide open end of line into measuring container. Connect diagnosis tester and perform the guided function Checking electric fuel pump(s). Note

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The fuel pump is now activated for 30 seconds.


After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s. If the specification is not attained: Check voltage supply page 154 and current draw page 155 of fuel pump.

3.6.3

Checking voltage supply of fuel pump


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Hand-held multimeter -V.A.G 1526D Pickup clamp -V.A.G 1526B/2-

Test prerequisites Fuses must be OK. The battery voltage must be at least 12 V, if necessary connect a battery charger. All electrical consumers, e.g. lights and rear window heating, must be switched off.

Remove seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats . Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor Remove cover from fuel delivery unit. Switch on ignition. The fuel pump must be heard to run for about 2 seconds. Switch off ignition. If the fuel pump does not start: Pull connector off fuel delivery unit flange.

154

Rep. gr.20 - Fuel supply system

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Test instrument adapter/DSO (5-pin) -VAS 5565-

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Special tools and workshop equipment required

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Connect test instrument adapter/DSO (5-pin) -VAS 5565- be tween connector and flange. Connect hand-held multimeter -V.A.G 1526D- to contacts -1and -5- of adapter. Connect vehicle diagnosis tester and perform guided function checking electric fuel pump(s). Note

The fuel pump is now activated for 30 seconds.


Read voltage value on hand-held multimeter -V.A.G 1526D- : Specification = battery voltage. If no voltage is present: Check activation of fuel pump relay and wiring for an open or short circuit Vehicle diagnostic, testing and information sys tem VAS 5051. Voltage supply OK: Remove fuel delivery unit page 180 . Check that electrical wiring between flange and fuel pump is connected and has continuity. If no open circuit can be found: Renew fuel delivery unit.

3.6.4

Checking current draw of fuel pump

Special tools and workshop equipment required

Vehicle diagnosis tester Note

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The battery voltage and the diesel fuel temperature have a great influence on the current draw of the fuel pump. For this reason ensure that the battery voltage is at least 12 V whilst checking and the diesel fuel temperature does not fall to the freezing point.
Test prerequisites Battery voltage at least 12 V

Diesel fuel temperature above (10 ) C

Remove seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats . Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor
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3. Parts of fuel supply system (Golf, Golf Plus)

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Remove cover from fuel delivery unit.

155

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Pull connector -C- off flange.

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Connect test instrument adapter/DSO (5-pin) -VAS 5565- to connector and fuel delivery unit. Connect pick-up clamp -A- to red terminal with lettering pickup clamp for test instrument adapter/DSO (5-pin) -VAS 5565- . Note

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Switch on ignition.

Connect vehicle diagnosis tester and perform guided function checking electric fuel pump(s). Note

The fuel pump is now activated for 30 seconds.


Read current draw on hand-held multimeter -V.A.G 1526D- . Specification: max. 7.5 amps. If the measured value is not within specifications: Renew fuel delivery unit page 180 .

3.7
Note

Assembly overview - fuel filter

Note that there are different versions of fuel filter upper part page 158 .

156

Rep. gr.20 - Fuel supply system

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Pickup clamp of hand-held multimeter -V.A.G 1715- can also be connected to red terminal with lettering pickup clamp of test in strument adapter/DSO (5-pin) -VAS 5565- .
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 1 - Supply line From fuel tank. White or with white marking. Check for secure seat ing. 2 - 5 Nm 3 - Return line To fuel cooler Check for secure seat ing. Blue or with blue mark ing.
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4 - Plug for water extraction Remove and extract about 100 cm3 liquid us ing hand-operated vac uum pump with acces sories -V.A.G 1390- and water drainage contain er -V.A.G 1390/1- . 5 - Seal Renew.

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6 - Supply line To tandem pump

10 - Seal Renew. 11 - Filter insert 12 - Seal Renew. 13 - Lower part of fuel filter 14 - 8 Nm 15 - Bracket 16 - Seal Renew. 17 - Retaining clip 18 - Connection 19 - From tandem pump.

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9 - Fuel temperature sender -G81-

3. Parts of fuel supply system (Golf, Golf Plus)

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8 - Upper part of fuel filter

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7 - Return line From tandem pump Blue or with blue mark ing. Check for secure seat ing.

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157

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

3.7.1

Upper part of fuel filter

Type A page 158 Type B page 158 Upper part of fuel filter, type A 1 - 8 Nm 2 - Plug for water extraction (remove and extract about 100 cm3 liquid using hand-operated vacuum pump with accessories V.A.G 1390- and water drainage container -V.A.G 1390/1- , renew seal) 3 - Fuel supply line from fuel tank, white or white marking. Check for secure seating. 4 - Fuel return line to fuel tank, blue or blue marking. Check for secure seating. 5 - Fuel supply line to engine, white or white marking. Check for secure seating. 6 - Fuel return line from engine, blue or blue marking. Check for secure seating.
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secure seating.

3 - Fuel supply line from fuel tank, white or white marking. Check for secure seating. 4 - Fuel return line from engine, blue or blue marking. Check for secure seating. 5 - Fuel supply line to engine, white or white marking. Check for secure seating.

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3.8

Removing and installing fuel cooler

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

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Removing Note safety precautions before beginning work page 136 . Observe rules for cleanliness page 137 .

158

Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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Remove underbody panel. Separate fuel lines at fuel cooler. Remove securing nuts -arrows-. Installing Install in reverse order. In the process, note the following: Tighten fuel cooler securing nuts to 15 Nm.

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159

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Parts of fuel supply system (Touran)

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Note

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Hose connections are secured with either spring-type or clamp-type clips. Always renew clamp-type clips with spring-type clips. Spring-type clip pliers -VAS 5024/- or hose clip pliers -V.A.G 1921/- are recommended for installation of spring-type clips.

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Rep. gr.20 - Fuel supply system

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Assembly overview o-r fuel tank with attachments h ut Removing and installing fuel tank page 165 . Assembly overview - fuel filter page 167 . Removing and installing fuel cooler page 168 .
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s Emptying fuel tank page 162 .

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Removing and installing fuel delivery unit page 169 . Removing and installing fuel gauge sender page 170 . Checking fuel pump page 171 .

4.1

Assembly overview - fuel tank with attachments

1 - Cap

2 - 1.5 Nm

5 - 10 Nm 6 - Pressure retention valve with connecting hose 7 - Gravity/overflow valve 8 - Fuel tank When removing, sup port using engine and gearbox jack -V.A.G 1383/A- . Removing and installing page 165 . 9 - Heat shield For fuel tank. 10 - Securing strap 11 - 20 Nm + turn (90) 12 - Fuel delivery unit With fuel gauge sender (G). Note installation posi tion of flange on fuel tank page 162 . Removing and installing page 169 Checking fuel pump page 152 . Removing and installing fuel sender page 170 . Clean strainer if soiled.

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4 - Earth connection Check for secure seat ing.

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3 - Tank flap unit Removing and in stalling. General body repairs, exterior; Rep. gr. 55 ; Fuel flap unit
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4. Parts of fuel supply system (Touran)

161

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 13 - Seal Renew. Moisten with fuel when installing. 14 - Union nut, 80 Nm Remove and install using union nut tool -3217- . 15 - Supply line To fuel filter Clipped onto fuel tank. Check for secure seating. Black To pull off flange, press release button on connecting piece. 16 - Return line From fuel cooler Blue or with blue marking. Clipped onto fuel tank. Check for secure seating. To pull off flange, press release button on connecting piece. Installation position of fuel delivery unit Marking on flange must align with marking on fuel tank -arrows-. Black supply line -1- to connection marked -V-. Return line -2- (blue or with blue marking) to connection marked -R-. Note

After installing fuel delivery unit flange, check that supply, return n AG. Volkswagen A G do es n wage and breather lines are still clipped onto fuel tank. o olks

4.2

Emptying fuel tank


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

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Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Union nut tool -3217-

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

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Note safety precautions before beginning work page 136 . Emptying fuel tank if it is more than 3/4 full page 163 . Emptying fuel tank if it is less than 3/4 full page 164 .

4.2.1

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


Caution

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Secure earth wire of fuel extractor -VAS 5190- to a bare metal part of the body.
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Remove cotter -2- from shaft -1- of fuel extractor -VAS 5190- .
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At distance -a- = 1,200 mm from end, mark extraction hose with insulating tape -arrow-.
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4. Parts of fuel supply system (Touran)

163

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove filler cap from fuel tank filler neck. Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel filler neck. Push extraction hose into fuel tank until marking on hose -arrow- coincides with shaft end.

Note

A ball valve -2- is located at the bottom of the filler neck in the fuel tank -1-; it must not be damaged by the extraction hose -3-. Therefore push hose into filler neck only as far as marking -arrow-.
Drain fuel tank as much as possible through fuel filler neck. Carefully pull out extraction hose. Note
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When no more fuel is extracted, the tank is emptied just enough for the sender flange to be opened without danger. The tank may be removed while containing remaining fuel. If work must be performed on fuel pump or fuel tank sender, proceed as follows:

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4.2.2

Emptying fuel tank if it is less than 3/4 full

Fold rear seats forwards.

Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor Remove cover from fuel delivery unit. WARNING

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Pull connector and fuel lines off flange. Note

Press buttons on hose couplings to do this.

164

Rep. gr.20 - Fuel supply system

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Fuel supply line is pressurised. Wear eye protection and pro tective clothing to avoid possible injury and skin contact. Be fore loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Open locking ring using union nut tool -3217- . Raise fuel delivery unit. Insert extraction hose of fuel extractor -VAS 5190- as deeply as possible into fuel tank and extract fuel. If fuel tank needed only to be emptied, install fuel delivery unit again page 169 .

4.3

Removing and installing fuel tank


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

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

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Removing Note safety precautions before starting work page 136 . Observe rules for cleanliness page 137 . Note Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary. When lowering fuel tank, guide it carefully to prevent damage. Disconnect earth strap from battery with ignition switched off Electrical system; Rep. gr. 27 ; Disconnecting and recon necting battery . Fold rear seats forwards.
4. Parts of fuel supply system (Touran)

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165

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor Remove cover from fuel delivery unit. Pull connector off flange. Remove fuel flap unit. General body repairs, exterior; Rep. gr. 55 ; Fuel flap unit Draining fuel tank page 162 Remove rear right wheel housing liner: General body re lkswagen pairs, exterior; Rep. gr. 66 ; Removing and installing wheel Vo y db housing liner . ise or Remove bolts from filler neck -arrows-.
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Disconnect fuel lines at front right of fuel tank. Note

Press buttons on hose couplings to do this.

Remove securing bolts -B- and remove retaining strap. Slowly lower fuel tank and pull it forwards. Tilt fuel tank to get it past rear axle. Installing Install in reverse order. In the process, note the following: Install breather and fuel hoses free of kinks. Ensure that fuel hose connections are tight. Do not interchange supply line and return line (return line blue or with blue marking, supply line black). Clip supply and return lines onto fuel tank.

166

Rep. gr.20 - Fuel supply system

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Support fuel tank using engine and gearbox jack -V.A.G 1383/ A- .

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Remove bolts -A- and remove heat shield for fuel tank.

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If vehicle has supplementary heating, separate connector to metering pump and unclip wire. Supplementary heating; Rep. gr. 82 ; Removing and installing metering pump -V54
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

4.4

Assembly overview - fuel filter

1 - Upper part of fuel filter Observe various types page 167 2 - Fuel temperature sender G81 Installed in engine re turn line 3 - Seal Renew. 4 - Filter insert Observe change inter vals. 5 - Seal Renew. 6 - Fuel filter lower part 7 - 8 Nm 8 - Bracket 9 - Seal Renew. 10 - Retaining clip Check for secure seat AG. Volkswagen AG do agen es n ksw ing. ot g Vol
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12 - From tandem pump.


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4.4.1

Upper part of fuel filter

Type A page 167 Type B page 168 Upper part of fuel filter, type A 1 - 8 Nm

2 - Plug for water extraction (remove and extract about 100 cm3 liquid using hand-operated vacuum pump with accessories V.A.G 1390- and water drainage container -V.A.G 1390/1- , renew seal) 3 - Fuel supply line from fuel tank, white or white marking. Check for secure seating.
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4 - Fuel return line to fuel tank, blue or blue marking. Check for secure seating. 5 - Fuel supply line to engine, white or white marking. Check for secure seating.
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4. Parts of fuel supply system (Touran)

167

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 6 - Fuel return line from engine, blue or blue marking. Check for secure seating. Upper part of fuel filter, type B 1 - 5 Nm 2 - Fuel return line to fuel tank, blue or blue marking. Check for secure seating. 3 - Fuel supply line from fuel tank, white or white marking. Check for secure seating. 4 - Fuel return line from engine, blue or blue marking. Check for secure seating. 5 - Fuel supply line to engine, white or white marking. Check for secure seating.

4.5

Removing and installing fuel cooler

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

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Removing

Note safety precautions before starting work page 136 . Observe rules for cleanliness page 137 . Note

The fuel cooler is located in the return line to fuel tank. It is located on the vehicle underbody.
Remove underbody panel. Remove securing nuts -arrows-. Install in reverse order. In the process, note the following:
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Separate fuel lines at fuel cooler. Installing

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Tighten fuel cooler securing nuts to 15 Nm.


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168

Rep. gr.20 - Fuel supply system

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

4.6

Removing and installing fuel delivery unit

Special tools and workshop equipment required Union nut tool -3217n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss

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Torque wrench -V.A.G 1332-

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Removing

First check whether a coded radio is fitted. If so, obtain antitheft coding. Disconnect earth strap from battery with ignition switched off Electrical system; Rep. gr. 27 ; Disconnecting and recon necting battery . Fold rear seats forwards. Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor Remove cover from fuel delivery unit. Pull 5-pin connector and fuel lines off flange. Note

Press buttons on hose couplings to do this.

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Observe rules for cleanliness page 137 .

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Observe safety precautions page 136 .

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4. Parts of fuel supply system (Touran)

169

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 WARNING

The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! Wear eye and hand protection when performing any type of repair work on the fuel system!

Unscrew union nut with union nut tool -3217- wrench . Pull fuel delivery unit and seal out of the opening in fuel tank. Note

If delivery unit is to be renewed, drain old delivery unit before dis posal.
Installing Installing the fuel delivery unit is carried out in reverse order of removal. Note Do not bend fuel gauge sender when installing. Insert seal for flange or fuel delivery unit dry into opening of fuel tank. Moisten seal with fuel only when installing flange or fuel de n AG. Volkswagen AG do livery unit. e wage
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Note installation position of fuel delivery unit flange: mark on flange must align with mark on fuel tank -arrows-.

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h After installing fuel delivery unit, check that the supply, return ut sa s and breather lines are still clipped onto the fuel tank.

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4.7
Removing

Removing and installing fuel gauge sender

Remove fuel delivery unit page 169 .

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Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Release connector lugs on lines -3- and -4- and pull off. Lift retaining tabs -1- and -2- using a screwdriver and pull fuel gauge sender off downwards -arrows-. Installing Insert fuel sender into guides on fuel delivery unit and press upwards until it engages.

4.8
Note

Checking fuel pump

Check fuel filter connections for correct arrangement, before starting to check the fuel pump page 158

4.8.1

Checking delivery pressure of fuel pump

Special tools and workshop equipment required Pressure gauge -VAS 6550 Vehicle diagnosis tester Test prerequisite: Fuses must be OK. Battery voltage at least 12 V All electrical consumers, e.g. lights and rear window heating, must be switched off.
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Switch on pressure tester -VAS 6550- by pressing On/Off button.


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Open shut-off taps A and B of pressure tester and close shut-off tap C. Start engine and run at idling speed. Read pressure on pressure tester -VAS 6550- . Specification: min. 0.5 bar. Place pressure tester -VAS 6550- onto windscreen so that it can be read from inside vehicle. Increase idling speed to 2500 rpm and read the pressure on pressure tester -VAS 6550- , specification min 0.25 bar. If the delivery pressure temporarily drops, renew fuel delivery unit page 180 .
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If the specifications are attained, check tandem pump to en sure the fuel filter is not blocked page 195 . If the tandem pump values are OK, check fuel pump delivery rate page 172 .
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4. Parts of fuel supply system (Touran)

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171

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

4.8.2

Checking fuel pump delivery rate

Special tools and workshop equipment required Pressure gauge -VAS 6550 Container > 3 litre with measuring scale Vehicle diagnosis tester Test prerequisite: Fuses must be OK. Battery voltage at least 12 V All electrical consumers, e.g. lights and rear window heating, must be switched off. Note

The delivered fuel may be cloudy. nored.

Connect -VAS 6550/1- pressure tester line to fuel supply -A-. Guide open end of line into measuring container. Connect vehicle diagnosis tester and perform guided function checking electric fuel pump(s). Note

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Separate quick-release coupling -A- (completely black or with black marking) of fuel supply line.
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The fuel pump is now activated for 30 seconds.


After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s. If the specification is not attained: Check fuel supply line between fuel pump and engine com partment for kinks, crushes or damage.
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If necessary, renew defective line and repeat test. If it is not kinked, crushed or damaged, remove rear seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats .
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Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor Remove cover from fuel delivery unit. Note

Press in securing ring to release fuel line.

172

Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Pull fuel supply line (black or black marking) -A- off fuel deliv ery unit.
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The fuel pump is now activated for 30 seconds.

After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s. If the specification is not attained:

Check voltage supply page 173 and current draw page 174 of fuel pump.

4.8.3

Checking voltage supply of fuel pump

Special tools and workshop equipment required Hand-held multimeter -V.A.G 1526D Pickup clamp -V.A.G 1526B/2ht rig py Co t.

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Test prerequisites Fuses must be OK. The battery voltage must be at least 12 V, if necessary connect a battery charger. All electrical consumers, e.g. lights and rear window heating, must be switched off.

Remove seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats . Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor Remove cover from fuel delivery unit. Switch on ignition. The fuel pump must be heard to run for about 2 seconds. Switch off ignition. If the fuel pump does not start: Pull connector off fuel delivery unit flange.
4. Parts of fuel supply system (Touran)

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173

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Connect test instrument adapter/DSO (5-pin) -VAS 5565- be tween connector and flange. Connect hand-held multimeter -V.A.G 1526D- to contacts -1and -5- of adapter. Connect vehicle diagnosis tester and perform guided function checking electric fuel pump(s). Note
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The fuel pump is now activated for 30

If no voltage is present:

Check activation of fuel pump relay and wiring for an open or short circuit Vehicle diagnostic, testing and information sys tem VAS 5051. Voltage supply OK: Remove fuel delivery unit page 180 . Check that electrical wiring between flange and fuel pump is connected and has continuity. If no open circuit can be found: Renew fuel delivery unit.

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Read voltage value on hand-held multimeter -V.A.G 1526D- : Specification = battery voltage.

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4.8.4

Checking current draw of fuel pump

Special tools and workshop equipment required


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Hand-held multimeter -V.A.G 1526D- or pickup clamp -V.A.G 1526B/2 Vehicle diagnosis tester Note
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Test instrument adapter/DSO (5-pin) -VAS 5565-

The battery voltage and the diesel fuel temperature have a great influence on the current draw of the fuel pump. For this reason ensure that the battery voltage is at least 12 V whilst checking and the diesel fuel temperature does not fall to the freezing point.
Test prerequisites Battery voltage at least 12 V Diesel fuel temperature above (10 ) C

Remove seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats . Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor Remove cover from fuel delivery unit.

174

Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Pull connector -C- off flange.

Connect test instrument adapter/DSO (5-pin) -VAS 5565- to connector and fuel delivery unit. Connect pick-up clamp -A- to red terminal with lettering pickup clamp for test instrument adapter/DSO (5-pin) -VAS 5565- . Note

Pickup clamp of hand-held multimeter -V.A.G 1715- can also be connected to red terminal with lettering pickup clamp of test in strument adapter/DSO (5-pin) -VAS 5565- .
Switch on ignition. Connect vehicle diagnosis tester and perform guided function checking electric fuel pump(s). Note
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If the measured value is not within specifications: Renew fuel delivery unit page 180 .

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4. Parts of fuel supply system (Touran)

175

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

Parts of fuel supply system (Passat)

Safety precautions page 136 .

Checking fuel pump page 185 .

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Emptying fuel tank, vehicles with front-wheel drive page 183 Assembly overview - fuel filter page 189 .

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Rules for cleanliness page 137 .

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Removing and installing fuel cooler page 191 .

5.1

Fuel tank, vehicles with front-wheel drive Assembly overview - fuel tank

5.1.1
1 - Cap 2 - 1.5 Nm

5 - Elbow 6 - 10 Nm 7 - Fuel tank When removing, sup port using engine and gearbox jack -V.A.G 1383/A- . Removing and installing page 178 Emptying fuel tank page 183 . 8 - Securing strap Note installation posi tion. 9 - Heat shield For fuel tank. 10 - Lock washer, 2.5 Nm 11 - 25 Nm Renew.

176

Rep. gr.20 - Fuel supply system

AG.

4 - Earth connection Check for secure seat ing.

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3 - Tank flap unit With rubber cup. Removing and installing General body re pairs, exterior; Rep. gr. 55 ; Tank flap unit

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 12 - Metering pump -V54For supplementary heater Removing and installing Heating, air conditioning system; Rep. gr. 82 . 13 - Seal Renew. When installing, fit dry in fuel tank opening. Moisten with fuel only when installing flange. 14 - Fuel delivery unit With fuel gauge sender (G). Removing and installing page 180 Checking fuel pump page 185 . Removing and installing fuel gauge sender page 183 . 15 - Suction-jet pump Clean strainer if soiled. Not necessarily installed 16 - Flange For fuel delivery unit Note installation position of flange on fuel tank page 178 . 17 - Locking ring, 110 Nm n AG. Volkswagen AG do es n wage ot g olks V Check for secure seating. ua by ran ed is tee Remove and install using wrench -3087- . or h 18 - Supply line ss For auxiliary heater. To metering pump -V54- . Clipped onto fuel tank. Check for secure seating. To pull off flange, press release button on connecting piece.
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19 - Return line From fuel cooler. Blue or with blue marking. Clipped onto fuel tank. Check for secure seating. To pull off flange, press release button on connecting piece. 20 - Supply line To fuel filter Clipped onto fuel tank. Check for secure seating. Black To pull off flange, press release button on connecting piece.
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5. Parts of fuel supply system (Passat)

177

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Installation position of fuel delivery unit Marking -4- on flange points opposite direction of travel. Note

The fuel delivery unit flange can be installed only in this position.swage G. Volk
Connect black Return line -2-R-.
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Black supply line -3- to metering pump -V54- for auxiliary heater. Note

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After installing fuel delivery unit flange, check that fuel lines are still clipped onto fuel tank.

5.1.2

Removing and installing fuel tank

Special tools and workshop equipment required Torque wrench (5... 50 Nm) -V.A.G 1331-

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

Removing Note The rear axle must be lowered to remove the fuel tank. Before disconnecting battery, open fuel tank flap and if nec essary remove wheel bolt lock adapter from luggage compart ment.

178

Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note safety precautions before beginning work page 136 . Observe rules for cleanliness page 137 . Note Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary. When lowering fuel tank, guide it carefully to prevent damage. With the ignition switched off, disconnect battery earth strap. Remove rear bench seat General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing bench AG. Volkswagen seat . Remove cover from fuel delivery unit. Pull 5-pin connector -5- off fuel Open fuel tank filler flap.
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Unscrew securing bolt and remove tank flap unit with rubber cup General body repairs, exterior; Rep. gr. 55 ; Tank flap unit . Empty fuel tank page 183 . Remove right rear wheel.

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Remove rear right wheel housing liner General body re pairs, exterior; Rep. gr. 66 ; Removing and installing wheel housing liner . Remove bolts from filler neck -arrows-.

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Remove underbody panel. WARNING

The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! Wear eye and hand protection when performing any type of repair work on the fuel system!

AG.

Unclip ABS sensor wiring on fuel tank filler neck -arrows-.

5. Parts of fuel supply system (Passat)

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179

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Separate fuel line -3- for metering pump -V54- at connections. Note

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Press in securing ring to release fuel lines.

Pull connector -arrow- off metering pump -V54- . Support rear axle using engine and gearbox jack -V.A.G 1383 A- . Remove securing bolts -arrows- and lower rear axle. Then support fuel tank using engine and gearbox jack -V.A.G 1383 A- .

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Remove securing strap bolts. Slowly lower fuel tank. When doing this, pull fuel tank forwards, turn and guide filler neck between rear axle and body. Installing Install in reverse order. In the process, note the following: Tighten bolts of rear axle to body Running gear, axles, steering; Rep. gr. 42 . Fuel lines are to be installed free of kinks. Do not interchange supply line and return line (return line blue or with blue marking, supply line black). Ensure that line connections are tight. Connections for fuel lines must engage audibly when joined. Check earth connection between body and filler neck for prop er seating. Clip fuel lines onto fuel tank.

5.1.3

Removing and installing fuel delivery unit

Special tools and workshop equipment required

180

Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Fuel tank sender unit tool -T10202-

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

Removing

Note safety precautions before beginning work page 136 . Observe rules for cleanliness page 137 . First check whether a coded radio is fitted. If so, obtain antitheft coding. With the ignition switched off, disconnect battery earth strap. The fuel tank must not be more than 1/2 full when removing the suction-jet pump. Empty fuel tank if necessary page 183 . Remove rear bench seat General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing bench seat . Remove cover from fuel delivery unit. Pull supply line -1-, return line -2-, supply line -3- to metering pump -V54- and 5-pin connector -5- off fuel delivery unit flange.
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Press in securing ring to release fuel lines.

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5. Parts of fuel supply system (Passat)

181

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Open locking ring using fuel tank sender wrench -T10202- . Lift sender flange.

Pull fuel line -1- off suction-jet pump (if fitted). Note

Press in securing ring to release fuel line.


Press tab -2- of suction-jet pump in -direction of arrow- and unclip from fuel delivery unit Pull fuel delivery unit along with suction-jet pump out of open ing in fuel tank. Note
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Installing

Installing the fuel delivery unit is carried out in reverse order of removal. Note

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If delivery unit is to be posal.

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For fuel delivery units of the new generation the suction-jet pump is no longer available. If the fuel delivery unit is to be renewed, remove suction-jet pump. When inserting fuel delivery unit, ensure that fuel gauge sender is not bent. Insert seal for flange or fuel delivery unit dry into opening of fuel tank. Moisten seal with fuel only when installing flange or fuel de livery unit. Do not interchange supply line and return line (return line blue or with blue marking, supply line black). Connections for fuel lines must engage audibly when joined. After installing fuel delivery unit, check that fuel lines are still clipped onto fuel tank. Observe installation position of fuel delivery unit page 178 .
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Fuel lines are to be installed free of kinks.


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Ensure that fuel hose connections are tight.


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182

Rep. gr.20 - Fuel supply system

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

5.1.4
Removing

Removing and installing fuel gauge sender

Remove fuel delivery unit page 180 . Release connector tabs of wires -arrows- and pull them off. Lift up retaining tabs -1- using a screwdriver and pull off fuel gauge sender upwards in direction of -arrow-. Installing Insert fuel gauge sender into guides on fuel delivery unit and press downwards until it engages. Install fuel delivery unit page 180 .
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5.2
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Special tools and workshop equipment required Fuel tank sender unit tool -T10202-

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Emptying fuel tank, vehicles with frontwheel drive

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Fuel extractor -VAS 5190-

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

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5. Parts of fuel supply system (Passat)

183

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Emptying fuel tank if more than 3/4 full page 184 Emptying fuel tank if less than 3/4 full page 184

5.2.1
Procedure

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

Note safety precautions before beginning work page 136 . At distance -a- = 990 mm from end, mark extraction hose with insulating tape -arrow-. Open fuel tank filler flap. Push extraction hose of fuel extractor -VAS 5190- into fuel filler neck until the previously made marking aligns with filler neck. Note The shaft

A flap is located on the lower end of the fuel filler neck, this must not be damaged by the extraction hose. Therefore, push the extraction hose into the fuel filler neck only up to previously made marking. Empty fuel tank as far as possible. Then carefully remove extraction hose. Note

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When no more fuel is extracted, the tank is emptied just enough for the sender flange to be opened without danger. The tank may be removed while containing remaining fuel.

5.2.2

Emptying fuel tank if it is less than 3/4 full


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Note safety precautions before beginning work page 136 .


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Remove rear bench seat General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing bench seat .
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Remove cover from fuel delivery unit. WARNING

The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! Wear eye and hand protection when performing any type of repair work on the fuel system!

184

Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Pull supply line -1-, return line -2-, supply line -3- to metering pump -V54- and 5-pin connector -5- off fuel delivery unit flange.
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Note

Press

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Open locking ring using fuel tank sender wrench -T10202- . Lift sender flange. Insert extraction hose of fuel extractor -VAS 5190- as deeply as possible into fuel tank and extract fuel. If fuel tank needed only to be emptied, reinstall sender flange page 180 .

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5.3

Checking fuel pump


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Check fuel filter connections for correct arrangement, before starting to check the fuel pump page 158

5.3.1

Checking delivery pressure of fuel pump

Special tools and workshop equipment required Pressure gauge -VAS 6550 Vehicle diagnosis tester Test prerequisite: Fuses must be OK. Battery voltage at least 12 V All electrical consumers, e.g. lights and rear window heating, must be switched off.

Separate quick-release coupling -A- (completely black or with black marking) of fuel supply line. Connect pressure tester -VAS 6550- with cables -VAS 6550/1and -VAS 6550/2- to open ends of fuel supply line. Switch on pressure tester -VAS 6550- by pressing On/Off button. Open shut-off taps A and B of pressure tester and close shut-off tap C. Start engine and run at idling speed. Read pressure on pressure tester -VAS 6550- . Specification: min. 0.5 bar.

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5. Parts of fuel supply system (Passat)

185

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Place pressure tester -VAS 6550- onto windscreen so that it can be read from inside vehicle. Increase idling speed to 2500 rpm and read the pressure on pressure tester -VAS 6550- , specification min 0.25 bar. If the delivery pressure temporarily drops, renew fuel delivery unit page 180 . If the specifications are attained, check tandem pump to en sure the fuel filter is not blocked page 195 . If the tandem pump values are OK, check fuel pump delivery rate page 186 .

5.3.2

Checking fuel pump delivery rate


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Special tools and workshop equipment required Pressure gauge -VAS 6550 Container > 3 litre with measuring scale Vehicle diagnosis tester Fuses must be OK. Battery voltage at least 12 V
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All electrical consumers, e.g. lights and rear window heating, must be switched off. Note

The delivered fuel may be cloudy. This is normal and can be ig nored.
Separate quick-release coupling -A- (completely black or with black marking) of fuel supply line. Connect -VAS 6550/1- pressure tester line to fuel supply -A-. Guide open end of line into measuring container.
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Connect vehicle diagnosis tester and perform guided function checking electric fuel pump(s). Note
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After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s. If the specification is not attained: Check fuel supply line between fuel pump and engine com partment for kinks, crushes or damage. If necessary, renew defective line and repeat test. If it is not kinked, crushed or damaged, remove rear seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats . Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor

186

Rep. gr.20 - Fuel supply system

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The fuel pump is now activated for 30 seconds.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove cover from fuel delivery unit. Note

Press in securing ring to release fuel line.


Pull fuel supply line (black or black marking) -A- off fuel deliv ery unit.
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The fuel pump is now activated for 30 seconds.


After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s. If the specification is not attained: Check voltage supply page 187 . Measure current draw page 188 of fuel pump.

5.3.3

Checking voltage supply of fuel pump

Special tools and workshop equipment required Hand-held multimeter -V.A.G 1526D Pickup clamp -V.A.G 1526B/2ht rig py Co t.

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Test instrument adapter/DSO (5-pin) -VAS 5565agen lksw Vo by


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Test prerequisites Fuses must be OK. The battery voltage must be at least 12 V, if necessary connect a battery charger. All electrical consumers, e.g. lights and rear window heating, must be switched off.

Remove seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats . Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor

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5. Parts of fuel supply system (Passat)

187

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove cover from fuel delivery unit. Switch on ignition. The fuel pump must be heard to run for about 2 seconds. Switch off ignition. If the fuel pump does not start: Pull connector off fuel delivery unit flange. Connect test instrument adapter/DSO (5-pin) -VAS 5565- be tween connector and flange. Connect hand-held multimeter -V.A.G 1526D- to contacts -1and -5- of adapter. Connect vehicle diagnosis tester and perform guided function checking electric fuel pump(s). Note

The fuel pump is now activated for 30 seconds.


Read voltage value on hand-held multimeter -V.A.G 1526D- : Specification = battery voltage. If no voltage is present: Check activation of fuel pump relay and wiring for an open or short circuit Vehicle diagnostic, testing and information sys tem VAS 5051. Voltage supply OK: Remove fuel delivery unit page 180 . Check that electrical wiring between flange and fuel pump is connected and has continuity. If no open circuit can be found:
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Renew fuel delivery unit.

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5.3.4

Checking current draw of fuel pump


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Special tools and workshop equipment required

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Hand-held multimeter -V.A.G 1526D- or pickup clamp -V.A.G 1526B/2 Test instrument adapter/DSO (5-pin) -VAS 5565 Vehicle diagnosis tester Note

Test prerequisites Battery voltage at least 12 V Diesel fuel temperature above (10 ) C

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The battery voltage and the diesel fuel temperature have a great influence on the current draw of the fuel pump. For this reason ensure that the battery voltage is at least 12 V whilst checking and the diesel fuel temperature does not fall to the freezing point.

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188

Rep. gr.20 - Fuel supply system

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Remove seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats .

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 (1.9 l engine) - Edition 08.2010

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Remove cover from fuel delivery unit. Pull connector -C- off flange.

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Connect test instrument adapter/DSO (5-pin) -VAS 5565- to connector and fuel delivery unit. Connect pick-up clamp -A- to red terminal with lettering pickup clamp for test instrument adapter/DSO (5-pin) -VAS 5565- . Note
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Pickup clamp of hand-held multimeter -V.A.G 1715- can also be connected to red terminal with lettering pickup clamp of test in strument adapter/DSO (5-pin) -VAS 5565- .
Switch on ignition. Connect vehicle diagnosis tester and perform guided function checking electric fuel pump(s). Note
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The fuel pump is now activated for 30 seconds.


Read current draw on hand-held multimeter -V.A.G 1526D- . Specification: max. 7.5 amps. If the measured value is not within specifications: Renew fuel delivery unit page 180 .

5.4
Note

Assembly overview - fuel filter

Note that there are different versions of fuel filter upper part page 191 .

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5. Parts of fuel supply system (Passat)

189

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 1 - Return line To fuel cooler Check for secure seat ing. Blue or with blue mark ing. 2 - 6 Nm 3 - Washer 4 - Supply line From fuel tank. White or with white marking. Check for secure seat ing. 5 - Return line From tandem pump. Blue marking Check for secure seat ing. 6 - Supply line To tandem pump. White marking Check for secure seat ing. 7 - Upper part of fuel filter 8 - Fuel temperature sender G819 - Seal Renew. 10 - Filter insert Observe change intervals. 11 - Lower part of fuel filter 12 - 10 Nm 14 - Retaining clip Check for secure seating. 15 - O-ring Renew.

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190

Rep. gr.20 - Fuel supply system

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13 - Connection for fuel temperature sender -G81-

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

5.4.1

Upper part of fuel filter

Type A page 191 Type B page 191 Upper part of fuel filter, type A 1 - 8 Nm 2 - Plug for water extraction (remove and extract about 100 cm3 liquid using hand-operated vacuum pump with accessories V.A.G 1390- and water drainage container -V.A.G 1390/1- , renew seal) 3 - Fuel supply line from fuel tank, white or white marking. Check for secure seating. 4 - Fuel return line to fuel tank, blue or blue marking. Check for secure seating. . Volkswag
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Upper part of fuel filter, type B 1 - 5 Nm 2 - Fuel return line to fuel tank, blue or blue marking. Check for secure seating. 3 - Fuel supply line from fuel tank, white or white marking. Check for secure seating. 4 - Fuel return line from engine, blue or blue marking. Check for secure seating. 5 - Fuel supply line to engine, white or white marking. Check for secure seating.

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6 - Fuel return line from s aut engine, blue or blue marking. Check for s secure seating.

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5.5

Removing and installing fuel cooler

Special tools and workshop equipment required Torque wrench (5... 50 Nm) -V.A.G 1331ht rig py Co t.
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Removing Note safety precautions before beginning work page 136 . Observe rules for cleanliness page 137 .

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5. Parts of fuel supply system (Passat)

191

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note

The fuel cooler is located in the return line to fuel tank. It is located on the vehicle underbody.
Remove underbody panel. Pull fuel lines -1- and -2- off fuel cooler. Remove securing nuts -arrows-. Installing Install in reverse order. In the process, note the following: Tighten fuel cooler securing nuts to 15 Nm.

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192

Rep. gr.20 - Fuel supply system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

6
6.1
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Accelerator mechanism
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Assembly overview - accelerator mech anism

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Removing and installing accelerator mechanism page 193 . 1 - Connector Black, 6-pin. 2 - Accelerator position sender -G79 Not adjustable. The accelerator position sender passes the posi tion of the accelerator on to the engine control unit. -A- openings for release tool Remove footwell cover to remove sender. 4 - Cap
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3 - 10 Nm

6.1.1

Removing and installing accelerator module

Special tools and workshop equipment required Release tool -T 10269- (for right-hand drive vehicles T10297- ).

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6. Accelerator mechanism

193

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Removing

Lever off cap Item 4 (page 193) using a screwdriver. Remove securing bolt beneath it. Golf, Golf Plus and Passat:

Touran:

To remove accelerator module, push release tool -T 10269(for right-hand drive models -T10297- ) into openings provided to stop. Continuation for all vehicle types: Pull connector off accelerator module. Pull wiring guide off accelerator pedal module. Pull out accelerator pedal module vertically. Installing Installation is carried out in the reverse order. When installing, note the following: Attach connector and wiring guide to accelerator pedal mod ule. Press accelerator pedal module onto securing pins. Insert centring pin into hole in vehicle underbody. Secure accelerator module with securing bolt -3-. Specified torque: 9 Nm. Attach cap. Install steering column cover.

194

Rep. gr.20 - Fuel supply system

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To remove accelerator module, push release tool -T 10238(for right-hand drive models -T10240- ) into openings provided to stop.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

Tandem pump

Checking tandem pump page 195 . Removing and installing tandem pump page 198 .

7.1

Checking tandem pump


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Banjo bolt with seals -VAS 5187/1Aor ate riv p or gf n

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Torque wrench -V.A.G 1331-

Test prerequisites Coolant temperature must be at least 85 C. Unit injectors OK. Fuel filter and fuel lines must not be blocked.

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7. Tandem pump

195

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Procedure Remove air filter housing. Remove screw plug -arrow-.

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Connect tandem pump tester -VAS 5187- if necessary, with adapter -VAS 5187/7- or banjo bolt with seal -VAS 5187/1Aas shown. Install air filter housing again. Start engine and raise engine speed to 4000 rpm. Observe pressure indicated on pressure gauge. Specification: at least 7.5 bar, tandem pump OK. If the specification is not attained: Renew fuel filter. Repeat check. If the specifications are still not attained:

Using a hose clip, clamp-off return line between fuel filter and tandem pump. If specification is now obtained:
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Repeat check.

If the specification is not attained: Renew tandem pump page 198 . Note

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

7.1.2
Note

Checking for internal leaks

The tandem pump must be checked for internal leaks between fuel side and oil side after reinstalling a used tandem pump, e.g. after renewing or repairing a cylinder head and/or when installing a "short" engine. When leaking it is possible for the fuel to mix with the oil which may cause the engine to fail.
Special tools and workshop equipment required

196

Rep. gr.20 - Fuel supply system

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Tandem pump is OK. Renew unit injector O-rings.

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Tester -V.A.G 1687-

Procedure Pull fuel supply hose (white marking) and fuel return hose (blue marking) off tandem pump. Seal fuel return union on tandem pump with a plug. Secure sealing plug with a spring-type clip. Prepare test unit -V.A.G 1687- as follows: Unscrew pressure regulating valve -2- and close valves -3and -4-. Connect test connection -5- to fuel supply union of tandem pump using a commercially available compressed air connec swagen AG . Volk gen AG does tion and a section of fuel hose. Use a spring-type lclipato secure. ksw no o Note
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To turn the pressure regulating valve -2- the knob must be pulled upwards.

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Connect compressed air hose -1- (compressed air source) to charge air system tester -V.A.G 1687- . Note

If there is water in the sight glass, drain at water drain screw -6-.
Open valve -3-.

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

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Open valve -4- and wait until the test circuit is filled. If neces sary readjust pressure to 1.0 bar. Close valve -3- to retain pressure and observe the pressure drop over a period of 1 minute. If the pressure does not drop the tandem pump can be reused, if the pressure drops the tandem pump must be renewed.

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

197

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

7.2

Removing and installing tandem pump


DANGER!

The tandem pump may, under no circumstances, be disman tled as the vacuum part could otherwise malfunction. This would result in the failure of the brake servo.

Special tools and workshop equipment required Torque wrench -V.A.G 1331 Hand vacuum pump with accessories -V.A.G 1390 Water drainage container V.A.G 1390/1 Spring-type clip pliers -VAS 5024 A-

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Rep. gr.20 - Fuel supply system

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198

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

7.2.1

Removing

Pull supply hose -1- (white marking) and return hose -2- (blue marking) off fuel filter. Connect hand vacuum pump with accessories -V.A.G 1390and water drainage container -V.A.G 1390/1- to return hose AG. Volkswagen AG d -2-. agen oes ksw n
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Pull vacuum hose -arrow- off tandem leading to brake servo.

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Disconnect fuel supply hose -2- from tandem pump. Disconnect fuel return hose -1- (blue marking) from fuel pipe.
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Unscrew bolts -arrows-. Remove tandem pump from cylinder head.

7.2.2

Installing

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

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7. Tandem pump

199

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note Renew tandem pump gaskets. Ensure proper seating of tandem pump actuator in camshaft. Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic parts catalogue . Install tandem pump and tighten upper wagen AG. Vboltsato n AG does securing olksw ge not lks 20 Nm. Vo gu by Tighten lower securing boltshoris 10 Nm. t to
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Attach supply hose (white marking) to supply connection of tandem pump. Reconnect vacuum line to tandem pump leading from brake servo. Attach supply hose -1- (white marking) to fuel filter. Connect hand vacuum pump with accessories -V.A.G 1390and water drainage container -V.A.G 1390/1- to return hose -2- (blue marking) of fuel filter. Operate hand vacuum pump until fuel comes out of return hose. Be careful that no fuel is sucked into hand vacuum pump. Attach return hose (blue marking) to fuel filter. Carry out a leakage test page 196 .

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Rep. gr.20 - Fuel supply system

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21
1

Turbocharging/supercharging
Charge air system with turbocharger

Safety precautions page 201 . Rules for cleanliness page 201 . Installing hose connections with connector couplings page 202 Assembly overview - turbocharger page 203 . Removing and installing turbocharger page 216 . Assembly overview - parts of charge air cooling page 218 . Checking charge air system for leaks page 221

1.1

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When partment, pay attention to the following due to the cramped conditions: Route all the various lines (e.g. for fuel, hydraulics, acti vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po sitions. Ensure that there is sufficient clearance to all moving or hot components.
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Note the following if testers and measuring instruments have to be used during a road test: Test and measuring instruments must always be secured to rear seat and operated by a second person from this location. If test and measuring instruments are operated from front pas senger seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered.
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1.2

Rules for cleanliness


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When working on the turbocharger, pay careful attention to the following rules for cleanliness: Thoroughly clean all unions and adjacent areas before dis connecting.
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Place removed parts on a clean surface and cover. Use only lint-free cloths. Carefully cover opened components or seal if repairs cannot be carried out immediately. Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.). Existing transport and protective packaging and sealing caps must only be removed immediately prior to installation. When making repairs, remove oil from connection and hose ends.
1. Charge air system with turbocharger

201

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely nec essary.

1.3 1.3.1

Hose connections Installing hose connections with con nector couplings


Caution

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

Bring securing clip to locking position -2- and then push charge air hose again. Check if connector coupling seats correctly andeisAG. Volkswagen AG d n properly oes wag engaged by pulling hose. not olks V
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Rep. gr.21 - Turbocharging/supercharging

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.3.2
Note

Hose connections with spring band ring

There is a danger of a hose detaching whilst driving after re moving and reinstalling charge pressure lines with spring-type clips. For this reason, spring band rings are used which can be opened if a defect item requires the charge pressure line has to be disconnected. In cases of repair, the charge air pipe must be removed if necessary, the spring band ring must be destroyed using a suitable tool (e.g. angle grinder) and must be renewed by a replacement part according to ETKA (electronic parts cata logue) .

1.4
Note

Assembly overview - turbocharger

All hose connections are secured. Charge air system must be free of leaks. Renew self-locking nuts.
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Observe rules for cleanliness page 201 . Observe safety precautions page 201 .

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1. Charge air system with turbocharger

203

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Engine codes AVQ, BJB, BKC, BRU, BXE and BXF page 204 Engine codes BLS and BXJ page 206 Changing and adjusting vacuum unit on turbocharger - only ve hicles with engine code: BLS from model year 2008 page 208

1.4.1
1 - 10 Nm

Engine codes AVQ BJB, BKC, BRU, BXE and BXF

2 - Union nut, 22 Nm 3 - Oil supply line Before installing oil sup ply line, ensure that it is not blocked. Before installing, fill tur bocharger with engine oil through oil supply line connection. Removing and installing page 112 4 - Union nut, 22 Nm 5 - Seal Renew. Note installation posi tion. 6 - Washer 7 - 25 Nm Renew. 8 - Support Between turbocharger and cylinder block. 9 - 40 Nm First hand tighten all bolts 10 - Connecting pipe Air filter/turbocharger 11 - Connecting piece 12 - Seal Renew. 13 - Seal Renew. 14 - Union, 40 Nm 15 - Oil return line To cylinder block. Tighten union nut to 30 Nm. 16 - 17 Nm 17 - Vacuum hose To solenoid valve block

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204

Rep. gr.21 - Turbocharging/supercharging

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 18 - Turbocharger Can only be renewed with exhaust manifold. To remove turbocharger, remove right drive shaft Running gear, axles, steering; Rep. gr. 40 ; Re moving and installing drive shafts . 19 - 20 Nm First hand tighten all bolts 20 - 20 Nm Renew. 21 - Heat shield 22 - Seal Renew. Note installation position. 23 - Clamp, 7 Nm 24 - Front exhaust pipe 25 - Bracket For oil supply line Item 3 (page 204) . Before installing, secure oil supply line.
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26 - 22 Nm Renew. 27 - Connecting pipe To bypass flap

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28 - Union, 30 Nm Renew. Coat threads and bolt head seating surface with G 052 112 A3.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.4.2
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4 - Oil supply hose To oil supply line con nection on turbocharger Before installing oil sup ply line, ensure that it is not blocked. Before installing, fill tur bocharger via oil supply hose with engine oil 5 - Turbocharger Can only be renewed with exhaust manifold. Removing and installing page 216 6 - Vacuum hose 7 - Seal Renew. Note installation posi tion. 8 - To particulate filter

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9 - Clamp, 7 Nm For turbocharger/partic ulate filter

10 - Exhaust manifold Can only be renewed to gether with turbocharg er 11 - 25 Nm Renew. 12 - 25 Nm 13 - Seal Renew. 14 - Connecting pipe For exhaust gas recirculation. Assembly overview - parts of exhaust gas recirculation page 267 . 15 - 25 Nm Renew. 16 - 15 Nm 17 - O-ring Renew. 18 - Banjo bolt, 60 Nm Renew.

206

Rep. gr.21 - Turbocharging/supercharging

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 19 - Support For turbocharger With oil return line 20 - Exhaust gas temperature sender bank 1 -G235- , 45 Nm Lubricate thread of sender using high-temperature paste -G 052 112 A3 To remove and install, use wrench -T1039521 - Heat shield 22 - Connection For intake hose for air filter/turbocharger Assembly overview - air filter page 238 . 23 - 9 Nm 24 - 10 Nm Installation position of exhaust gas temperature sender with an gled cable guide Note
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1. Charge air system with turbocharger

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.4.3

Changing and adjusting vacuum unit on turbocharger - only vehicles with engine code: BLS from model year 2008

Special tools and workshop

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208

Rep. gr.21 - Turbocharging/supercharging

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 equipment required Hand vacuum pump -VAS 6213 Turbocharger tester -V.A.G 1397A Pressure regulating valve -VAS 6342 Ring spanner -T10423 Allen key, long reach -T10454-

Caution

The special tools indicated, in particular the socket inset, T10454- is designed solely for use according to the following work instructions and must not be used for other threaded con nections. There is a danger of deformation if high torques are applied.

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Remove engine cover.

Pull cover off air duct (release clips on sides) -arrows-.

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1. Charge air system with turbocharger

209

Golf 2004 4-cylinder

Unclip air duct at mountings -3-. Swing air duct downwards and slightly to rear for this. Detach air pipe -1- from lower air duct -arrow B-.

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Unclip lower air duct -2- by releasing retaining clips on left and right -arrow A-.

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Detach hose -2- from crankcase breather. Lay aside ventilation hose -4- and vacuum hoses -1- at air hose. Unscrew bolt -3-. Swing air duct hose to rear and pull off of turbocharger. Seal opening in turbocharger with the plug from the spareparts kit. Pull off vacuum hose on turbocharger. Golf Plus, Touran Remove plenum chamber bulkhead General body repairs, exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead . All other vehicles continued

210

Rep. gr.21 - Turbocharging/supercharging

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Remove bolt -4- and remove air filter housing.

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Pull off vent hose -3- and also air duct hose -2-.

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Disconnect electrical connector -1- from air mass meter G70- .


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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Depending on version, unscrew nut -arrow- where the oil sup ply line/vacuum line is connected to the cylinder head. Caution

When detaching the oil supply line, counterhold the connec tion. Risk of damage as a consequence!
Prepare a 14 mm open-ended wrench for counterholding.

14 mm tool for counterholding connection piece of oil supply line A = 110 mm B = 25 mm

a Counterhold connection piece and unscrew oil supply line ksw Vol by -arrow- from turbocharger. ed

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Seal oil supply opening in turbochargerauth the plug with ss spare-parts kit.

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Counterhold lock nut -B- with ring spanner -T10423- and un screw securing nut -A- from the control rod using socket inset -T10454- .

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211

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove bolt -1-, then bolt -2- and remove vacuum unit -A-. Installing

Colour mark vacuum unit and control rods -as shown-. Note

The colour marks show that the control rods are adjusted cor olksw V db rectly, after tightening. Adjustments should then be madeeasy ris necessary. tho
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Only use new bolts and nuts from the spare-parts kit!
If necessary, remove lower securing nut of the control rod from the new vacuum unit. Screw locknut by hand onto the control rod as far as possible in the direction of the vacuum unit. Push control rod through the adjusting lever on turbocharger, fit vacuum unit -A- and lock. Fit bolts -1- and -2- from repair kit. Tighten bolts -1- and -2- to 8 Nm.

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Switch on turbocharger tester -V.A.G 1397A- and set sliding switch to position I. Subtract 600 mbar from atmospheric pressure displayed and note value. (Value 1) Subtract 650 mbar from atmospheric pressure displayed and note value. (Value 2)

212

Rep. gr.21 - Turbocharging/supercharging

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Connect test and measuring instruments together as illustrat ed and connect to connection I -arrow- of turbocharger tester -V.A.G 1397A- and to turbocharger vacuum unit. Close lever -1- on pressure regulating valve -VAS 6342- .
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Move slide ring -1- on hand vacuum pump -VAS 6213- to po sition -A- for vacuum. Caution

Excessive pressure may damage the vacuum unit. The pressure must not fall below the read atmospheric pres sure minus 800 mbar.
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An accuracy of +/- 20 mbar is acceptable when setting value 2. Make sure that the turbocharger adjusting lever moves easily on the control rod. Operate hand vacuum pump -VAS 6213- several times until noted value 2 is attained on turbocharger tester -V.A.G 1397A- .
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1. Charge air system with turbocharger

213

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Open pressure regulating valve -1- until value 1 is set exactly.

Screw nut -A- up a couple of threads on control rod.


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Hold adjusting lever -1- on stop of adjustment screw -2- by hand.

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Note

Screw securing nut -A- back if this occurs.

214

Rep. gr.21 - Turbocharging/supercharging

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During next procedure, ensure adjusting lever -1- remains against stop screw -2- and is not already contacting the se curing nut -A-.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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Note

Ensure control rod does not move while tightening securing nut -A-.
Counterhold lock nut -B- with ring spanner -T10423- and tight en securing nut -A- using socket inset -T10454- . Check colour marks on control rod, the must align -as shown-.

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Note

There very little space between cylinder head and turbocharger. Ensure you are aware of where the feeler gauge (0.05 mm) is positioned.

The feeler gauge (0.05 mm) must be positioned between ad justing lever and adjustment screw, as shown Note

The feeler gauge (0.05 mm) has a part number and must be or dered from the Electronic parts catalogue .
Operate the hand vacuum pump -VAS 6213- until the feeler gauge (0.05 mm) is pinched between adjusting lever and ad justment screw. Now the noted value 1 +/- 20 mbar should appear on the tur bocharger tester -V.A.G 1397A- . Value OK.

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Release vacuum, move slide ring -1- on hand vacuum pump to position -B- for this, then move slide ring back to position -A- again.
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1. Charge air system with turbocharger

215

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Seal connection between control rod and securing nut with sealing paint from the spare-parts kit. Press locking plate by hand onto the control rod and turn 90 in the -direction of the arrow-. Value not OK. Repeat adjustment procedure again. Continuation

14 mm tool for counterholding connection piece of oil supply line A = 110 mm B = 25 mm

Counterhold connection piece and tighten oil supply line -arrow- on turbocharger.

Depending on version, reconnect oil supply line/vacuum line to the cylinder head and tighten nut -arrow-. Golf Plus, Touran Install plenum chamber bulkhead General body repairs, exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead . All other vehicles continued Complete the engine.

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Start motor and delete event memory Vehicle diagnostic, testing and information system VAS 5051.

1.5

Removing and installing turbocharger


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Torque wrench -V.A.G 1331-

216

Rep. gr.21 - Turbocharging/supercharging

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Lambda probe open ring spanner set -3337n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss

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Tool set -T10395-

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When a mechanical fault is found on the turbocharger, e.g. a destroyed compressor impeller, it is not only sufficient to renew the turbocharger. To prevent this from causing further damage, perform the following repairs: Check air filter housing, air filter element and intake hoses for soiling. Check complete charged air routing and charge air cooler for foreign objects. If foreign objects are found in the charge air system, the charged air routing must be cleaned and the charge air cooler must be renewed, if necessary.
Removing Remove noise insulation General body repairs, exterior; Rep. gr. 50 ; Body - front; Noise insulation . Vehicles with four-wheel drive: Remove front propshaft Final drive 02D, 0AV; Rep. gr. 39 ; Assembly overview - repairing propshaft . Remove right drive shaft Running gear, axles, steering; Rep. gr. 40 . Vehicles with particulate filter Pull electrical connector off exhaust gas pressure sensor 1 G450- in engine compartment and unscrew securing bolts. Separate electrical connectors to particulate filter. Remove subframe including steering and right drive shaft Running gear, axles, steering; Rep. gr. 40 .

1. Charge air system with turbocharger

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217

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove particulate filter. On vehicles with four-wheel drive remove the bevel box to reach the threaded connection for turbocharger support 6speed manual gearbox; Rep. gr. 34 ; Removing and installing bevel box . Continuation for all vehicles: Disconnect fasteners -arrows- of coolant pipes for auxiliary heater, if part of original equipment.

Unbolt pendulum support -arrows-. Remove support and oil return line or combi support Item 19 (page 206) for turbocharger. Remove connecting pipe to exhaust gas recirculation cooler. Separate charge pressure line from turbocharger. Pull vacuum hose off turbocharger. Separate oil supply line from turbocharger.
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Installing Install in reverse order. Note

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Torque setting of pendulum support page 22 .

1.6

Assembly overview - parts of charge air cooling


Note

Charge air system must be free of leaks. When making repairs, remove oil from connection and hose ends.
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All hose connections of charge air system are secured by spring-type clips or by connector couplings. Checking charge air system for leaks page 221

218

Rep. gr.21 - Turbocharging/supercharging

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Engine codes AVQ BJB, BKC, BRU, BXE and BXF page 219 Engine codes BLS and BXJ page 220 Installing hose connections with connector couplings page 202

1.6.1

Engine codes AVQ BJB, BKC, BRU, BXE and BXF

1 - 8 Nm Fitting location page 220 2 - Bracket Note installation posi tion. 3 - Charge air cooler 4 - Connecting hose 56n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee 8 Nm or th or ac au To turbocharger. ss
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8 - To intake connecting pipe. 9 - Vacuum reservoir 10 - 15 Nm 11 - 8 Nm

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7 - Connecting pipe

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12 - O-ring Renew if damaged. 13 - Charge air pressure sender -G31- with intake air temperature sender -G4214 - 3 Nm

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1. Charge air system with turbocharger

219

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.6.2
1 - 8 Nm

Engine codes BLS and BXJ

Fitting location page 220

2 - Bracket Note installation posi tion.

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3 - Charge air cooler To remove, bring lock carrier into service posi tion General body re pairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier - service position 4 - Sealing strip Pushed onto top and bottom of charge air cooler 5 - 3 Nm

6 - Charge air pressure sender -G31- with intake air tempera ture sender -G42ht rig py Co t.

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9 - 5 Nm 10 - Connecting hose 11 - Charge air pipe 12 - Connecting hose To intake manifold flap motor -V157 Assembly overview - in take manifold page 235 . 13 - 8 Nm 14 - Connecting hose To turbocharger. Securing bolts for charge air cooler

To loosen or tighten securing bolts -arrows- remove bumper cov er.

220

Rep. gr.21 - Turbocharging/supercharging

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8 - Bracket

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7 - O-ring Renew if damaged.

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.7

Checking charge air system for leaks

Special tools and workshop equipment required Charge air system tester -V.A.G 1687-

Adapter -V.A.G 1687/10 Remove intake hose -1- from air filter. Insert adapter -V.A.G 1687/10- in intake hose -1- and secure AG. Volkswagen AG d with clip. agen oe
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Turn pressure regulating valve -2- anti-clockwise onto stop. Close valves -3- and -4-. Note

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1. Charge air system with turbocharger

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To turn the pressure regulating valve -2- the knob must be pulled upwards.
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221

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Connect charge air system tester -V.A.G 1687- to adapter V.A.G 1687/10- as shown.

Connect compressed air hose -1- (compressed air source) to charge air system tester -V.A.G 1687- . Note

If there is water in the sight glass, drain at water drain screw -6-.
Open valve -3-. Adjust pressure to 0.5 bar with pressure regulating valve -2-.
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Caution

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Open valve -4- and wait until the test circuit is filled. If neces sary readjust pressure to 0.5 bar. Check the charge air system for leaks by hearing, touching, with leak detector spray or using ultrasonic tester -V.A.G 1842- . Note

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How to use the ultrasonic tester -V.A.G 1842- operating instructions If leaks occur, when doing any repair work observe notes for charge air system page 218 . Depressurise test circuit by detaching coupling from adapter V.A.G 1687/10- before removing adapter.

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222

Rep. gr.21 - Turbocharging/supercharging

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.8

Vacuum hose schematic diagram

Vehicles with particulate filter page 223 Vehicles without particulate filter page 224

1.8.1

Vehicles with particulate filter

1 - Turbocharger 2 - Connecting pipe air filter/ turbocharger 3 - Non-return valve Note installation posi tion. 4 - To brake servo 5 - Charge pressure control solenoid valve -N756 - Air filter 7 - Cylinder head/cylinder block 8 - Intake manifold 9 - Bypass flap For exhaust gas recircu lation cooler. 10 - Radiator For exhaust gas recircu lation. 11 - Exhaust gas recirculation valve -N1812 - Exhaust gas recirculation cooler changeover valve N34513 - Non-return valve Note installation posi tion. 14 - Vacuum unit Turbocharger
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223

Golf 2004 4-cylinder

1 - Solenoid valve block 2 - Non-return valve Note installation posi tion. 3 - To brake servo 4 - Connecting pipe air filter/ turbocharger 5 - Air filter 6 - Intake manifold 7 - Cylinder head/cylinder block 8 - Vacuum reservoir 9 - Bypass flap For exhaust gas recircu lation cooler. 10 - Radiator For exhaust gas recircu lation. 11 - Exhaust gas recirculation valve -N1812 - Turbocharger 13 - Non-return valve Note installation posi tion.

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1.8.2

Vehicles without particulate filter

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224

Rep. gr.21 - Turbocharging/supercharging

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

23
1

Mixture preparation - injection


Diesel direct injection system

The diesel direct injection system control unit is equipped with a fault memory. Read fault memory before and after making repairs or adjustments. Safety precautions page 225 . Rules for cleanliness page 226 . Removing and installing pre-wired wiring harness for unit injec tors and glow plugs page 226 Assembly overview - unit injector page 229 Removing and installing unit injector page 230 Adjusting non-contact gap of unit injectors page 232 Removing and installing O-rings for unit injector page 233 . Repairing intake manifold flap page 235 Assembly overview - air filter page 238 .

1.1

Safety precautions
WARNING

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conditions:

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Route all the various lines (e.g. for fuel, hydraulics, acti vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po sitions. Ensure that there is sufficient clearance to all moving or hot components.

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Note the following if testers and measuring instruments have to be used during a road test: Test and measuring instruments must always be secured to rear seat and operated by a second person from this location. If test and measuring instruments are operated from front pas senger seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered. To prevent injuries to persons and/or destruction of the injection and glow plug system, the following must be noted:
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The ignition must be switched off before connecting or dis connecting injection or glow plug system wiring or tester ca bles.
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If the engine is to be turned at starter speed, without starting, e.g. when checking compressions, disconnect unit injector connector on cylinder head. Before disconnecting battery, obtain radio code for radios with anti-theft coding.

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1. Diesel direct injection system

225

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t gu V by ara ed sand connecting the battery must only bendone tee r Disconnectingi ho t ra with the ignition switched off, as otherwise the control unit ofor au c ss diesel direction injection system could become damaged.

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1.2

Rules for cleanliness

When working on fuel supply and injection system, pay careful attention to the following rules for cleanliness: Thoroughly clean all unions and adjacent areas before dis connecting.

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Place removed parts on a clean surface and cover. Use only lint-free cloths. Carefully cover opened components or seal if repairs cannot be carried out immediately. Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.). When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely nec essary. Also ensure that no diesel fuel comes into contact with the coolant hoses. Should this occur, the hoses must be cleaned immediately. Damaged hoses must be renewed.
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1.3

Removing and installing pre-wired wiring harness for unit injectors and glow plugs

Special tools and workshop equipment required Puller -T10312-

Special wrench -T10310-

226

Rep. gr.23 - Mixture preparation - injection

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Removing

Removal and installation of the pre-wired wiring harness may only be undertaken by unscrewing the clips. Releasing the ca ble channel at the clips bends the clips which may break the cables due the excessive play. This also applies when chang ing the unit injectors and all work which does not require the central connector to be completely removed.

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Caution

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Note

Disconnecting connectors on piezo unit injectors may only be un dertaken using special tool puller -T10312- .
Remove engine cover. To do this, pull engine cover upwards abruptly at front and right -arrows A- and then pull forwards out of rear fastening -arrow B-. Disconnect central connector on cylinder head.
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Remove cylinder head cover page 64 .


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Fit special wrench -T10310- on adapter ring and release it by turning key through 90 (1/4 turn) in -direction of arrow-.

Pull the securing clip -1- upwards lightly with a screwdriver and press the central connector -2- through inwards.

1. Diesel direct injection system

227

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Vo by ed Slide the puller -T10312- ontoris unit injector connector from the tho the side and pull it off in -direction of arrow-. Use pointed pliers au ss for the older connector version.

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Pull connectors off glow plugs -1- Unscrew securing bolts -2of steel clips and remove complete pre-wired wiring harness. Installing Installation is carried out in the reverse order. When installing, note the following: Route pre-wired wiring harness and tighten securing bolts to 10 Nm.
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Guide central connector through opening in retaining frame, ensure securing clips -arrows- are seated correctly when do ing this.
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Fit adapter ring (colour marked longer stud -arrow- faces 12 o'clock)

228

Rep. gr.23 - Mixture preparation - injection

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When adapter ring is installed correctly the colour marked short er stud faces 12 o'clock.
Fit central connector to cylinder head and lock in position. Install cylinder head cover page 64 . Fit engine cover.

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1.4

Assembly overview - unit injector

Observe rules for cleanliness page 226 . Always renew seals and O-rings 1 - 20 Nm + turn (90) Renew. 2 - Rocker arm shaft With rocker arms Removing and installing page 230 3 - Lock nut, 30 Nm 4 - Adjuster screw Renew. 5 - Ball stud Renew. 6 - Unit injector Removing and installing page 230 7 - O-ring Renewing page 233 . 8 - O-ring Renewing page 233 . 9 - O-ring Renewing page 233 . 10 - Heat shield seal Renew. 11 - Circlip 12 - Cylinder head 13 - Tensioning block 14 - 12 Nm + turn (270) Renew.

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1. Diesel direct injection system

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229

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.5

Removing and installing unit injector

Special tools and workshop equipment required Universal dial gauge brack et -VW 387 Special wrench, long reach -3410 Special wrench, long reach -T10054 Puller -T10055 Torque wrench V.A.G 1331un le

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Remove toothed belt guard upper part. Remove cylinder head cover. page 64

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

230

Rep. gr.23 - Mixture preparation - injection

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1.5.1

Removing

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Insert puller -T10055- in place of the clamping block in the slot on the side of the unit injector. Pull unit injector out of cylinder head seat by gently tapping upwards.

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1.5.2

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Installing

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Note

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Each time work is performed which requires adjustment of the unit injector, the adjustment screw in the rocker arm and also the unit injector ball stud must be renewed. New unit injectors are supplied with O-rings and heat shield seal. Heat shield seal and O-rings must be renewed if old unit in jector is reused. page 233 Check that the 3 O-rings and the heat shield seal along with securing clip are seated correctly before installing unit injector. Note

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The seals must not be twisted.


Oil the seals and fit the unit injector into the seat in cylinder head with great care.
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Push the unit injector evenly into the cylinder head onto its limit stop. Insert tensioning block in slot on side of unit injector. Note

If the unit injector is not at right angles to the tensioning block the securing bolt may loosen and this can damage the unit injector or the cylinder head.
Therefore align the unit injector as follows. Screw new securing bolt into clamping block, but do not tighten (it must still be possible to turn the unit injector slightly). Now align unit injector at right angles to camshaft bearing seat.

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231

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Check dimension a from outer edge of cylinder head to rounded edge of unit injector with a vernier gauge (measuring range at least 400 mm). Cylinder 1 2 3 4 Dimension a 333.0 0.8 mm 245.0 0.8 mm 153.6 0.8 mm 65.6 0.8 mm

If necessary, adjust the unit injector and tighten the securing bolt as follows: n AG. Volkswagen A
Vol Tighten securing bolt to 12 Nm and turn 270 (3/4 turn)kfurther by (turning further can be done in several stages).sed ri
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First evenly tighten inner bolts -2- and then outer bolts -1hand-tight. Then using same sequence, tighten to 20 Nm and 90 (1/4 turn) further evenly. Adjust non-contact gap of unit injectors page 232 .

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ho ut sa s Fit rocker arm shaft and tighten new securing bolts as follows:

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1.6

Adjusting non-contact gap of unit injec tors

Fit dial gauge onto adjustment screw of unit injector as shown. Turn crankshaft in direction of engine rotation until roller of rocker arm is located at tip of drive cam. Roller side -arrow A- positioned at highest point, dial gauge -arrow B- po sitioned at lowest point. Remove dial gauge. Now turn the adjuster screw into rocker arm until significant resistance can be felt (unit injector is at limit stop).
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Turn adjustment screw 180 back off stop. Hold adjuster screw in this position and tighten lock nut to 30 Nm. Connect unit injector connector. Install cylinder head cover page 64 .

232

Rep. gr.23 - Mixture preparation - injection

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.7

Removing and installing O-rings for unit injector

Special tools and workshop equipment required Assembly sleeves -T10056-

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1.7.1

Removing

Lever old O-rings very carefully out of unit injector. Above all ensure that burrs are not caused on O-ring seating.

1.7.2
Note

Installing

Always use the assembly sleeves to fit the O-rings. There is a danger of damaging the O-rings if the sleeves are not used.
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Gradual introduction of O-rings without different coloured markings. Note the correct allocation of O-rings to grooves: the thickness of the rings reduces towards injector nozzle.
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Prevent O-rings from rolling when sliding them on. The O-rings must not be twisted in their seats in unit injector. Pull heat shield seal off together with securing clip. Clean seating surfaces for O-rings on unit injector very care fully.
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Place assembly sleeve -T10056/1- onto stop on unit injector. Push the upper, thicker O-ring carefully onto assembly sleeve and into seat on unit injector. Remove assembly sleeve.

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1. Diesel direct injection system

233

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Place assembly sleeve -T10056/2- onto stop on unit injector. Slide the middle, thinner O-ring carefully onto assembly sleeve and into seat on unit injector. Remove assembly sleeve.

Place assembly sleeve -T10056/3-

Remove assembly sleeve.

Fit new heat shield seal together with securing clip.

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Push the lower O-ring carefully onto the assembly sleeve and into the seat of the unit injector.

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Rep. gr.23 - Mixture preparation - injection

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.8

Assembly overview - intake manifold

Engine codes AVQ BKC, BRU, BXE and BXF page 235 Engine code BJB page 236 Engine codes BLS and BXJ page 237

1.8.1

Engine codes AVQ, BKC, BRU, BXE and BXF

1 - Intake manifold Tighten securing bolts to 22 Nm. 2 - O-ring Renew. 3 - Intake connecting pipe With exhaust gas recir culation valve 4 - 10 Nm 5 - Intake manifold flap motor V157 The intake manifold flap is closed for approx. 3 seconds when stopping engine and then opens again. This reduces the stop jolt. 6 - 10 Nm 7 - Connecting pipe To exhaust gas recircu lation cooler. 8 - 22 Nm 9 - Seal Renew.
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1. Diesel direct injection system

235

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.8.2

Engine code BJB

1 - Intake manifold Tighten securing bolts to 22 Nm. 2 - O-ring Renew. 3 - Intake connecting pipe With exhaust gas recir culation valve and in take manifold flap 4 - 10 Nm 5 - Seal Renew. 6 - Connecting pipe To exhaust gas recircu lation cooler. 7 - 10 Nm 8 - Bracket 9 - Vacuum actuator 11 - 22 Nm
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10 - To solenoid valve block

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Rep. gr.23 - Mixture preparation - injection

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.8.3

Engine codes BLS and BXJ

1 - Seal Renew. 2 - Intake manifold Tighten securing bolts to 22 Nm 3 - Seal Renew. 4 - Connection 5 - Intake manifold flap motor V157 The intake manifold flap is closed for approx. 3 seconds when stopping engine and then opens again. This reduces the stop jolt. 6 - From charge air cooler 7 - 10 Nm 8 - Exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer G212 Assembly overview - ex haust gas recirculation page 267 9 - Seal Renew. 10 - Connecting pipe For exhaust gas recircu lation cooler. Assembly overview parts of exhaust gas re circulation page 264 11 - 22 Nm 12 - Bracket 13 - 22 Nm
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1.9

Cleaning the intake manifold flap sup port, Engine code BLS and BXJ
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1. Diesel direct injection system

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Carbon deposits can occur in the throttle valve support through the combination of unfavourable factors. If these are found, e.g. when disassembling the exhaust gas recirculation valve -N18- or the intake manifold flap motor -V157,- , the support will have to be cleaned.
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237

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 WARNING

Acetone is highly inflammable. Please observe the accidental regulations and safety notes when handling with highly in flammable fluids. Wear eye protection and protective clothing to avoid possible injury and skin contact.
Remove intake manifold flap connection. Remove the exhaust gas recirculation valve -N18- and the in take manifold flap motor -V157- . Thoroughly clean intake manifold flap support, especially around exhaust gas return valve, using commercially available acetone according to DIN 53247 and cleaning brush. Wipe off intake manifold flap support using a lint-free cloth. Allow the acetone to evaporate fully, assemble the cleaned intake manifold flap support, replace the seals and insert it back in position.

1.10

Assembly overview - air filter


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1 - Intake hose To turbocharger. 2 - Air mass meter -G703 - O-ring Renew if damaged. 4 - 8 Nm 6 - 8 Nm 5 - Air filter upper part

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7 - Vacuum hose To solenoid valve block 8 - Filter element 9 - Air duct To lock carrier. 11 - 10 Nm

10 - Air filter lower part

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Rep. gr.23 - Mixture preparation - injection

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

Engine control unit


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2.1

Reading and clearing engine control unit fault memory


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Connect vehicle diagnostic, testing and information system VAS 5051- as follows: Push diagnosis cable connector onto diagnosis connector. Start engine and run at idling speed. Only when engine does not start: Switch on ignition. Select operating mode Press button on display for Vehicle self-diagnosis. Select vehicle system Press button 01 - Engine electronics on display. The control unit identification and engine control unit coding are indicated on display. Select diagnostic function Press button 02 - Read fault memory on display.

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2. Engine control unit

239

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 If no fault is stored in engine control unit 0 fault detected is displayed. If faults are stored in the engine control unit, these are shown one below the other on the display. Press the button. Press button 05 - Clear fault memory on display. Press function 06-End output.

2.2

Adapting functions and components

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

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Select guided fault finding in vehicle diagnostic, testing and in formation system -VAS 5051- . When all control units have been read: Press GoTo button. Select Drive train. Select Engine code. Select Function/component selection.

Select 01 Systems capable of self-diagnosis. Select Functions.


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2.3

Removing Switch off ignition. Remove wiper arms, plenum chamber cover and plenum chamber bulkhead: Electrical system; Rep. gr. 92 ; Wind screen wiper system; Removing and installing windscreen wiper system .

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Before removing engine control unit, read control unit identifi cation and, with it, coding of current control unit as well page 240 .

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Removing and installing engine control unit (Golf)


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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Bend catch open slightly -1-. Then push engine control unit out of retainer -arrow-. Release now connector from engine control unit, disconnect connector. Installing Fit connector to engine control unit and lock connector in po sition. Push engine control unit onto bracket.

Press catch -1- against engine control unit. Install plenum chamber bulkhead, plenum chamber cover and wiper arms Electrical system; Rep. gr. 92 ; Windscreen wiper system; Removing and installing windscreen wiper sys tem .

2.4

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Saw set -V.A.G 1561/14 Grip pliers

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note If the engine control unit is to be renewed, connect vehicle diagnostic, testing and information system -VAS 5051B- and perform Renewing engine control unit in guided functions. The shear-head bolt threads are coated with locking com pound. To simplify removing, the shear-head bolts can be heated using hot air blower -VAS 1978/14- . When doing this, ensure that no adjacent cables, connectors or components are damaged! Removing Switch off ignition. Remove wiper arms, plenum chamber cover and plenum chamber bulkhead: Electrical system; Rep. gr. 92 ; Wind screen wiper system; Removing and installing windscreen wiper system . Cut into heads of shear-head bolts so that 2 parallel surfaces are created -arrows-. Remove bolts with grip pliers .

Insert a screwdriver between protective housing -A- and bracket -arrow-.

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Lever up protective housing using screwdriver -A- and pull to side off bracket -arrow-.

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Rep. gr.23 - Mixture preparation - injection

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Bend catch open slightly -1-. Then push engine control unit out of retainer -arrow-. Release now connector from engine control unit, disconnect connector. Installing
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Tighten new shear-head bolts -1- evenly until heads shearhead off. Install plenum chamber bulkhead, plenum chamber cover and wiper arms Electrical system; Rep. gr. 92 ; Windscreen wiper system; Removing and installing windscreen wiper sys tem .
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Removing and installing engine control unit (Golf Plus)


Note

If the engine control unit is to be renewed, connect vehicle diag nostic, testing and information system -VAS 5051B- and perform Renewing engine control unit in guided functions.
Removing: Switch off ignition. Remove plenum chamber bulkhead General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .

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2. Engine control unit

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Loosen securing nuts -arrows-. Release connector from engine control unit, disconnect con nector.

Push bracket -1- off engine control unit in direction of arrow. Installing: Push bracket onto engine control unit.

Tighten securing nuts -arrows- to 10 Nm. Fit connectors and lock in position. Install plenum chamber bulkhead General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
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2.6

Removing and installing anti-theft en gine control unit (Golf Plus)

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Special tools and workshop equipment required Grip pliers Note

If the engine control unit is to be renewed, connect vehicle diagnostic, testing and information system -VAS 5051B- and perform Renewing engine control unit in guided functions. The shear-head bolt threads are coated with locking com pound. To simplify removing, the shear-head bolts can be heated using hot air blower -VAS 1978/14- . When doing this, ensure that no adjacent cables, connectors or components are damaged!
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Removing Switch off ignition.

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Rep. gr.23 - Mixture preparation - injection

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Remove plenum chamber bulkhead General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead . Twist shear-head bolts -arrows- out using grip pliers and re move cover from protective housing. Then remove securing nuts for control unit bracket -arrows-.

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Press catches -1- and -2- outwards. Then pull engine control unit off control unit bracket in direction of arrow. Installing Push engine control unit onto control unit bracket until it en gages in catches. Fit connectors to engine control unit and lock in position.

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Tighten securing bolts -arrows- to 10 Nm.


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2. Engine control unit

245

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Tighten new shear-head bolts -arrows- evenly until heads shear off.

2.7

Removing and installing engine control unit (Touran)

Before removing engine control unit, read control unit identifi cation and, with it, coding of current control unit as well page 240 .

2.7.1

Removing

Switch off ignition. Remove plenum chamber bulkhead. General body repairs; Rep. gr. 50 ; Body - front, plenum chamber bulkhead . Loosen securing nuts -arrows-. Release connector from engine control unit, disconnect con nector.

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

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2.7.2

Installing
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Push bracket onto engine control unit.


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Rep. gr.23 - Mixture preparation - injection

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Tighten securing nuts -arrows- to 10 Nm. Fit connectors and lock in position. Check previous coding and adapt coding of the new control unit page 240 . Read fault memory of new engine control unit and erase fault memory if necessary. page 239 Carry out a road test. Read control unit fault memory again.
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2.8
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Note

If the engine control unit is to be renewed, connect vehicle diag nostic, testing and information system -VAS 5051B- and perform Renewing engine control unit in guided functions.
Removing
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Switch off ignition. Remove plenum chamber bulkhead General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead . Note

The shear-head bolt threads are coated with locking compound. Heating the shear-head bolt with a hot air blower releases the locking effect of the locking compound.
Caution

Cover lines, connections and control units in the vicinity of the engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Turn temperature settings potentiometer -2- to a maximum heat output of 600 C. Set two-stage switch for volume of air -3- to position 3. WARNING

When shear-head bolts are heated up, parts of the protective housing will be subjected to a large amount of heat. Wear pro tective gloves to avoid possible injury.
Place nozzle of hot air blower close to shear bolt. Switch on hot air blower and heat the bolts. Unscrew shear-head bolts -arrows- out using pliers and re move cover from protective housing. Then remove securing nuts for control unit bracket -arrows-.

Release connector from engine control unit, disconnect con nector.


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Press catches -1- and -2- outwards. Then pull engine control unit off control unit bracket -in direction of arrow-. Installing Push engine control unit onto control unit bracket until it en gages in catches. Fit connectors to engine control unit and lock in position.

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Rep. gr.23 - Mixture preparation - injection

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Tighten securing bolts -arrows- to 10 Nm. Install cover of protective housing.

Tighten new shear-head bolts -arrows- evenly until heads shear off. Install plenum chamber bulkhead General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .

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2. Engine control unit

249

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

Engine control unit (Passat)

Removing and installing engine control unit page 250 . Removing and installing anti-theft engine control unit page 251 .

3.1

Removing and installing engine control unit

If the engine control unit is to be renewed, connect vehicle diag nosis, testing and information system -VAS 5051B- and perform guided functions Renewing control unit. DANGER!

For vehicles with heavy duty running gear; vehicle must be re stricted to a maximum of 210 km/h via the engine control unit. Drive shafts can be damaged at speeds above 210 km/h. Per form function Restricting maximum speed in guided function using vehicle diagnostic, testing and information system -VAS 5051B- .
Removing Switch off ignition. Remove wiper arms Rep. gr. 92 . Remove plenum chamber cover Rep. gr. 64 . Pull connector -1- off heated windscreen control unit -J505- . Slide connector locking devices -2- on engine control unit out wards and pull off both connectors. Remove securing bolts -3-.
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Slide engine control unit -1- into retaining frame in -direction of arrow-.

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Fit retainer frame with engine control unit onto retainer -4-. Specified torque of securing nuts for retainer -4-: 6 Nm. Tighten securing bolts -3- to 7 Nm. Fit connectors to engine control unit and slide locking devices -2- inwards. Fit connector -1- to heated windscreen control unit -J505- .
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Install wiper arms Rep. gr. 92 .

3.2

Removing and installing anti-theft en gine control unit

Special tools and workshop equipment required Hot air blower from wiring harness repair set -VAS 1978-

Nozzle attachment from wiring harness repair set -VAS 1978If the engine control unit is to be renewed, connect vehicle diag nosis, testing and information system -VAS 5051B- and perform guided functions Renewing control unit. DANGER!

For vehicles with heavy duty running gear; vehicle must be re stricted to a maximum of 210 km/h via the engine control unit. Drive shafts can be damaged at speeds above 210 km/h. Per form function Restricting maximum speed in guided function using vehicle diagnostic, testing and information system -VAS 5051B- .

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Install plenum chamber cover Rep. gr. 64 .

3. Engine control unit (Passat)

251

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Removing Switch off ignition. Remove wiper arms Rep. gr. 92 . Remove plenum chamber cover Rep. gr. 64 . Note

The shear-head bolt threads are coated with locking compound. Heating the shear-head bolt with a hot air blower releases the locking effect of the locking compound.
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Set two-stage switch for volume of air -3- to position 3. WARNING

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Turn temperature setting potentiometer -2- to maximum heat output (600 C).

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When shear-head bolts are heated up, parts of the protective housing will be subjected to a large amount of heat. Wear pro tective gloves to avoid possible injury.
Place nozzle of hot air blower close to shear-head bolt. Switch on hot air blower and heat bolt for about 20 to 25 sec onds. Unscrew shear-head bolt -2- using pliers on bolt head.
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252

Rep. gr.23 - Mixture preparation - injection

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Lift cover -1- and pull it forwards.

Slide connector locking devices -1- on engine control unit out wards and pull off both connectors. Remove retainer frame with engine control unit from plenum chamber.

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Installing

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Slide engine control unit -1- into retaining frame in -direction of arrow-. Fit retainer frame with engine control unit onto retainer in plenum chamber. Specified torque of securing nuts for retainer: 6 Nm.

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3. Engine control unit (Passat)

253

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Fit connectors to engine control unit and slide locking devices -1- inwards.

Slide cover -1- over engine control unit and press it down wards.

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Tighten new shear-head bolts -2- evenly until bolt head shears off. Fit connector -1- to heated windscreen control unit -J505- . Install plenum chamber cover Rep. gr. 64 . Install wiper arms Rep. gr. 92 .

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Rep. gr.23 - Mixture preparation - injection

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

26
1

Exhaust system
Exhaust system

Assembly overview - front exhaust pipe with catalytic converter Golf, Golf Plus, Touran, Passat page 255 . Assembly overview - front exhaust pipe with particulate filter Golf, Golf Plus, Touran, Passat page 256 . Assembly overview - silencers (vehicles with front-wheel drive) Golf, Golf Plus, Touran page 258 . Assembly overview - silencer with mountings (vehicles with fourwheel drive) page 262 . Assembly overview - silencers (Passat) page 261 .

1.1

Assembly overview - front exhaust pipe with catalytic converter

1 - Front exhaust pipe with cat alytic converter 2 - 40 Nm 3 - Support


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5 - To front silencer 6 - 25 Nm

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4 - Marking For clamp. Installation position of clamp page 256 .

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7 - Mounting Renew if damaged. 8 - 7 Nm

9 - Seal Note installation posi tion. 10 - Clip

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1. Exhaust system

255

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Installation position of clamp Position clamp at distance -a- = 5 mm from marking on front ex haust pipe.

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1.2

Assembly overview - front exhaust pipe with particulate filter


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If the particulate filter or the exhaust gas pressure sensor 1 G450- is changed, the exhaust gas pressure sensor 1 -G450must always be adapted using diagnosis tester : Guided func tions; adapting exhaust pressure sensor 1 -G450- .
Special tools and workshop equipment required Lambda probe open ring spanner set -3337-

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Tool set -T10395-

Note

If the particulate filter or the exhaust gas pressure sensor 1 G450- is changed, the exhaust gas pressure sensor 1 -G450must always be adapted using diagnosis tester : Guided func tions; adapting exhaust pressure sensor 1 -G450- .

256

Rep. gr.26 - Exhaust system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 1 - 8 Nm 2 - Exhaust gas pressure sen sor 1 -G4503 - Bracket For control lines 4 - 10 Nm 5 - Control line, 45 Nm 6 - Lambda probe -G39- , 50 lkswagen o Nm yV db se Grease only therithreads ho ut with high-temperature sa s paste -G 052 112 A3- ; high-temperature paste -G 052 112 A3- must not get into the slots of probe body. To remove use Lambda probe open ring span ner set -3337- .
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7 - Exhaust gas temperature sender bank 2 -G448- , 45 Nm Lubricate thread of sender using high-tem perature paste -G 052 112 A38 - Particulate filter is removed downwards with exhaust gas pres sure sensor 1 -G450 To remove, remove subframe and steering Running gear, axles, steering; Rep. gr. 40 .
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11 - To front silencer 12 - 25 Nm 13 - Mounting Renew if damaged. 14 - Temperature sender after particulate filter -G527 45 Nm Lubricate thread of sender using high-temperature paste -G 052 112 A315 - From turbocharger 16 - Clamp, 7 Nm 17 - Seal Renew. Note installation position.

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10 - Marking For clamp. Installation position of clamp page 258 .

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9 - Front exhaust pipe

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1. Exhaust system

257

Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 18 - 40 Nm 19 - Bracket Bolted to cylinder head. Installation position of clamp
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Position double clamp -a- = 5 mm from marking on front ex haust pipe of particulate filter.

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1.3

Assembly overview - silencer with mountings (vehicles with front wheel drive)

1 - 25 Nm Renew. 2 - Retaining ring Renew if damaged. 3 - Separating point Marked by indentation on exhaust pipe During production, front and rear silencers are installed as a single component. For repairs, front and rear silencers are supplied separately. The connection is made with a clamp. Separating exhaust end pipe page 259 Installation position of rear clamp (repair dou ble clamp) page 259 . Evenly tighten threaded connections of clamping sleeve (repair double clamp) Specified torques for clamp (repair double clamp): M8 = 25 Nm, M10 = 40 Nm Before tightening, align cold exhaust system free of tension page 262

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 4 - Rear silencer 5 - Mounting Renew if damaged. 6 - 25 Nm 7 - Tunnel bridge 8 - Front silencer 9 - Mounting Renew if damaged. Installation position of rear clamp (repair double clamp) Install clamp so that ends of bolts do not protrude beyond bot tom of clamp. Bolt connection faces to left.

1.3.1

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Eye protection Procedure

WARNING

Wear eye protection.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Cut exhaust end pipe at right angles at separating point -arrow 2-. When installing, position repair double clamp -4- at side mark ings -arrow 1- and -arrow 3-.
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Install repair double clamp so that end of bolt does not extend beyond lower edge of clamp. Bolted connection faces rear. Align cold exhaust system free of stress page 262 . Tighten bolts on repair double clamp. Tightening torque M8: 25 Nm Specified torque, M10: 40 Nm

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.4

Assembly overview - silencers (Passat)

1 - From front exhaust pipe 2 - Clamp Before tightening, align cold exhaust system free of tension page 262 Tighten bolted connec tions evenly. Specified torque: M8 = 25 Nm, M10 = 40 Nm. 3 - Front silencer 4 - Mounting Renew if damaged. 5 - 25 Nm Renew. 6 - Separating point Marked by impressions on exhaust pipe. During production, front and rear silencers are installed as a single component. In event of repair, front and rear si lencers are supplied in dividually and with a AG. Volkswagen AG d agen oes clamping sleeve for pur not lksw Vo gu by ara poses of connection d nte ise or eo Cut through exhaust th u ra a c pipe at right angles at ss separating point -arrow A- using e.g. body saw -V.A.G 1523(wear eye protection) During installation, posi tion repair double clamp at side markings -arrows B Evenly tighten threaded connections of clamping sleeve (repair double clamp) Specified torques for clamp (repair double clamp): M8 = 25 Nm, M10 = 40 Nm. Before tightening, align cold exhaust system free of tension page 262
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7 - Retaining ring Renew if damaged. 8 - Rear silencer

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1.5

Assembly overview - silencer with mountings (vehicles with four-wheel drive)

1 - From particulate filter 2 - Clamp Align exhaust system free of stress before tightening clamp page 262 . Installation position n AG. Volkswagen AG do es n wage page 262 . ot g olks yV ua db ran Tighten bolted connec se tee ri ho or tions evenly. aut a
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3 - Bracket For retaining ring 4 - 25 Nm

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5 - Retaining ring Renew if damaged. 6 - Rear silencer 7 - Mounting Renew if damaged.

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Installation position of clamp Install clamp so that ends of bolts do not protrude beyond bot tom of clamp.

1.6
Prerequisite

Aligning exhaust system free of stress

Engine must be cold

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Procedure Loosen bolted connection of clamp between front exhaust pipe and silencer. Position clamp at distance -a- = 5 mm from marking olkswagen . V on front AG gen AG does exhaust pipe and lightly tighten front bolted connection. swa n lk
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Push exhaust end pipe with silencer forwards into clamp until dimension -a- 1517 mm is attained between mounting at tachment points for body and rear silencer. -Arrow- points in direction of travel. Align rear silencer horizontally. With parts in this position, tighten bolted connections of clamp. Specified torque, M8: 25 Nm Specified torque, M10: 40 Nm

Once clamp has been tightened, check distance -a- and cor rect if necessary.
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2
2.1

Exhaust gas recirculation system


Assembly overview - parts of exhaust gas recirculation

Engine codes AVQ, BKC, BRU, BXE, BXF page 264 Engine code BJB page 266 Engine codes BLS and BXJ page 267 Check mechanical exhaust gas recirculation valve AVQ, BKC, BRU, BXE, BXF page 268 .

2.1.1

Engine codes AVQ, BKC, BRU, BXE and BXF

Note The exhaust gas recirculation system is activated by the diesel direct injection system control unit -J248- via exhaust gas re circulation valve -N18- (electric-pneumatic) to the exhaust gas recirculation valve (mechanical). The electro-pneumatic exhaust gas recirculation valve -N18is located in the solenoid valve block. The cone-shaped plunger in the mechanical exhaust gas re circulation valve ensures that various cross sectional openings are possible at different plunger lifts. Pulsed control enables every conceivable valve position. Renew self-locking nuts.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 1 - 22 Nm 2 - Intake manifold With exhaust gas recir culation valve and in take manifold flap motor -V157- . Tighten securing bolts to 22 Nm. 3 - Seal Renew. 4 - Connecting pipe 5 - Radiator For exhaust gas recircu lation. 6 - 10 Nm 7 - Exhaust manifold 8 - Connecting pipe Tightening sequence: 1. Attach to bypass flap 2. Attach to manifold 3. Tighten to bypass flap 4. Tighten to manifold
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9 - Bypass flap When activated, directs exhaust gas to exhaust gas recirculation cooler via the electro-pneu matic exhaust gas recir culation valve -N18- . 10 - Bracket For bypass flap 11 - 5 Nm

Connector assignment on solenoid valve block, engine codes BKC, BRU, BXE and BXF 23456Exhaust gas recirculation valve Bypass flap Air filter Vacuum reservoir Vacuum unit on turbocharger
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1-

Vacuum connection (on non-return valve for brake servo)

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2.1.2
Note

Engine code BJB

The exhaust gas recirculation system is activated by the diesel direct injection system control unit -J248- via exhaust gas re circulation valve -N18- (electric-pneumatic) to the exhaust gas recirculation valve (mechanical). The electro-pneumatic exhaust gas recirculation valve -N18is located in the solenoid valve block. The cone-shaped plunger in the mechanical exhaust gas re circulation valve ensures that various cross sectional openings are possible at different plunger lifts. Pulsed control enables every conceivable valve position. Renew self-locking nuts. 1 - Intake manifold With exhaust gas recir culation valve and in take manifold flap. Tighten securing bolts to 22 Nm. 2 - From charge air cooler 3 - Seal Renew. 4 - 22 Nm 5 - Exhaust manifold 6 - Connecting pipe
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Pin assignment on solenoid valve block for engine code BJB 123456Vacuum connection (on non-return valve for brake servo) Exhaust gas recirculation valve Intake manifold flap Air filter Vacuum reservoir Vacuum unit on turbocharger

2.1.3
Note

Engine codes BLS and BXJ

The exhaust gas recirculation system is activated by the diesel direct injection system control unit -J248- via the exhaust gas recirculation potentiometer -G212- . Renew self-locking nuts. 1 - Coolant hose To connection 2 - Seal Renew. 3 - 22 Nm 4 - Connecting pipe 5 - From exhaust manifold 6 - 25 Nm Renew.
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7 - To connection for exhaust gas recirculation valve -N18with exhaust gas recirculation potentiometer -G212 Assembly overview - in take manifold page 237 .
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8 - Exhaust gas recirculation cooler 9 - 10 Nm 10 - Coolant hose From rear coolant pipe 11 - Connecting hose 12 - Exhaust gas recirculation cooler changeover valve N34514 - Vacuum actuator For bypass flap. Renew only together
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13 - Connecting pipe
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2.2

Checking mechanical exhaust gas re circulation valve

Special tools and workshop equipment required Hand vacuum pump with accessories -V.A.G 1390-

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Test procedure

Pull vacuum hose off exhaust gas recirculation valve. Connect hand vacuum pump with accessories -V.A.G 1390to valve. Operate hand vacuum pump a few times. Pull hand vacuum pump hose off exhaust gas recirculation valve. The diaphragm rod must audibly return to its original position.
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28
1

Glow plug system


Checking glow plug system

Removing, installing and checking glow plugs page 269 Characteristics of ceramic glow plugs page 270 Removing, installing and checking ceramic glow plugs page 271

1.1

Removing, installing and checking glow plugs

Special tools and workshop equipment required Vehicle diagnosis tester

Jointed spanner -3220n AG. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss

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Test requirements Ignition switched on

Battery voltage at least 11.5 V

Checking

The glow plug system is monitored by the engine control unit's self-diagnosis system. The necessary checks are performed with Guided fault finding. Removing glow plugs Installing glow plugs Remove glow plugs using U/J extension and socket -3220- .
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Install glow plugs using jointed extension and socket -3220- . Specified torque: 15 Nm
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1.2

Characteristics of ceramic glow plugs


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WARNING

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The ceramic glow plugs page 270 are sensitive to jolts and bending. For this reason a glow plug which has dropped from a small height (approx. 2 cm) must not be used. Even if no damage is apparent. It is absolutely necessary to follow the installation instructions, otherwise the heater pin of the glow plug can break and cause engine damage.
Visual features of ceramic glow plugs Vehicles with 2 valves per cylinder head -A- = Metal glow plug, colour-coded -arrow-. -B- = Ceramic glow plug with support tube -arrow-, not colourcoded. Vehicles with 4 valves per cylinder head -C- = Metal glow plug, colour-coded -arrow-. -D- = Ceramic glow plug with support tube -arrow-, not colourcoded. Remove and install or check ceramic glow plugs page 271 .
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Golf 2004

Special tools and workshop equipment required Jointed spanner -3220 Torque wrench (5... 50 Nm) -V.A.G 1331 Hand-held multimeter V.A.G 1526 A Auxiliary measuring set V.A.G 1594 C-

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1.3

Removing, installing and checking ceramic glow plugs


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Test prerequisites Engine is cold Ignition switched off

Procedure Note

Do not cant ceramic glow plugs when removing and installing. Remove any components hindering assembly.
Pull connectors off ceramic glow plugs. Remove ceramic glow plugs using U/J extension and socket, 10 mm -3220- . Installation is carried out in the reverse order. When installing, note the following: Before installing the drilling in cylinder head and the threads must completely cleaned of all deposits.

1. Checking glow plug system

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note

Do not oil or grease thread of cylinder head bore or of ceramic glow plugs.
Screw ceramic glow plugs into cylinder head by hand using U/ J extension and socket, 10 mm -3220- . Then tighten the ceramic glow plugs. Specified torque: 15 Nm. WARNING

After installing and before the engine is started, perform a resistance test on all ceramic glow plugs when engine is cold. If the defective ceramic glow plug is broken, remove all fragments from the engine, otherwise these can cause damage to the engine.
Specification: max. 1 If the specification is exceeded, renew the defective ceramic glow plug.

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