6-Cylinder Injection Engine VW Individual

Service
Workshop Manual
Golf 2004
6-cylinder injection engine VW Individual
Engine ID
CBR
A
Edition 10.2009
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
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Technical information should always be available to the foremen and mechanics, because their
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Copyright 2010 Volkswagen AG, Wolfsburg Prote
K0058995820
AG.
Golf 2004
6-cylinder injection engine VW Individual - Edition 10.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1 Removing engine and installing
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1.1 Removing ...... engine
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1.2 Securing engine on engine and gearbox support VAS 6095 . . . . . . . . . . . . . . . . . . . . . . 10
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1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.4 Specified torques for assembly mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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1.1 Part I: assembly overview - chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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1.2 Part II: assembly overview - crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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2 Sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1 Assembly overview - sealing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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2.2 Removing and installing crankshaft seal on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.3 Renewing crankshaft sealing flange -vibration damper side- . . . . . . . . . . . . . . . . . . . . . . . . 25
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2.4 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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2.5 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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3.2 Allocation of crankshaft bearing shells (classification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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3.3 Fitting sender wheel to crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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3.4 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.2 Checking pistons, piston rings and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3 Installing piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3 Assembly overview - cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.4 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.5 Installing camshaft adjuster with timing chain for camshaft drive . . . . . . . . . . . . . . . . . . . . 57
1.6 Installing timing chain for intermediate shaft drive and camshaft drive . . . . . . . . . . . . . . . . 62
1.7 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.8 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.2 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.3 Removing and installing camshaft control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.4 Valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.6 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Contents i
Golf 2004
1 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.2 Assembly overview - sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.3 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.4 Assembly overview - oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.5 Removing and installing oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.6 Assembly overview - oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.7 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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19 - Cooling . . . . . . . . .ol.ks.w.ag.en. A. . . . . . . . n.A.G.do.e.s n.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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1.1 Assembly ut overview - parts of cooling system, body side
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1.2 Assembly
ss overview - cooling system, engine side . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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1.3 Assembly overview - thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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1.4 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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1.5 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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1.6 Removing and installing fan support with fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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1.7 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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1.8 Checking continued coolant circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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1.9 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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1.10 Removing and installing thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.11 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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1.12 Removing and installing coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.13 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
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1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

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3 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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3.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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3.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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3.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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4 Repairing fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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4.1 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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4.2 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.3 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

4.4 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.5 Assembly overview - fuel filter with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.6 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.7 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.8 Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.2 Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
6 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
6.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
6.2 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.1 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.3 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.4 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.5 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
ii Contents
Golf 2004
1.6 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

1.7 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.8 Assembly overview - resonator with resonance air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.9 Checking intake air preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.1 Checking vacuum unit for intake manifold flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.2 Checking injectors for leaks and quantity injected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.3 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3.2 Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

1 Exhaust manifold, front exhaust pipe with catalytic converters and Lambda probes . . . . . . 189
1.1 Assembly overview - exhaust manifold, front exhaust pipe with catalytic converters . . . . 191
1.2 Removing and installing Lambda probe G39 and Lambda probe 2 G108 . . . . . . . . . . . . 192
1.3 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.4 Removing and installing front exhaust pipe with catalytic converters . . . . . . . . . . . . . . . . 195
2 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.1 Assembly overview - silencers with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.2 Checking exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.3 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3 Secondary Aair
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ora motor V101 . . . . . . . . . . . . . . . . . . . . . . . . 204
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Checking combination valve for secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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3.5 Removing and installing combination valve for secondary air system . . . . . . . . . . . . . . . . 205
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28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

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1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

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1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

hole
spec
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

es, in part or in w
1.3 Assembly overview - parts of ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

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1.4 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 208
1.5 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
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Contents iii
Golf 2004
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iv Contents
Golf 2004
00 Technical data
1 Engine number
The engine number (engine code and serial number) is located
next to the vibration damper -arrow- on the cylinder block.
The engine number consists of up to nine characters (alphanu
meric). The first part (maximum 3 characters) makes up the
"engine code", and the second part (6 characters), the "serial
number". If more than 999,999 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.
Additionally, a sticker with engine code and serial number is
attached to the camshaft cover.
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1. Engine number 1
Golf 2004
2 Engine data
Engine code CBRA
Manufactured 06.07
Emissions fulfil LEV2 standard
Cylinder arrangement VR1)
Cylinder angle 15.0
Capacity cm3 3189
Output kW at rpm 184/6300
Torque Nm at rpm 320/2500 3000
Bore mm 84.0
Stroke mm 95.9
Compression ratio 10.85
Valves per cylinder 4
RON 98 unleaded2) min.
Injection, ignition Motronic ME7.1.1
Firing order n AG. Volkswagen AG do
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Knock control d2 knock sensors
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Lambda control utho 4 probes or
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Catalytic converter ss
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Exhaust gas recirculation no
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Turbocharging/supercharging no
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Secondary air system yes
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Electronic power control yes
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Variable intake manifold yes

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Variable valve timing yes 3) t to the co

Leak diagnosis system yes
1)
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VR = V-arrangement in compact in-line design.

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2)In exceptional circumstances min. 95 RON, however with re

duced performance.
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3) Two independently variable camshafts.

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2 Rep. Gr.00 - Technical data

Golf 2004
10 Removing and installing engine

1 Removing and installing engine
Removing engine page 4 .
Securing engine to assembly stand page 10 .
Installing engine page 11 .
Specified torques for assembly mountings page 13 .
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Lifting tackle -3033- ss a c
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Engine bracket -T40074-
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Torque wrench -V.A.G
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1332-
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Engine and gearbox jack -
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V.A.G 1383 A-
Stepladder -VAS 5085-
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1. Removing and installing engine 3

Golf 2004
Spring-type clip pliers -VAS

5024 A-
Engine and gearbox sup
port -VAS 6095- with en
gine bracket -3269-
Workshop crane -VAS
6100-
Drip tray -V.A.G 1306- or
drip tray -VAS 6208-
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Not illustrated:
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Container for removed parts -V.A.G 1698-

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Engine bung set -VAS 6122-

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Cable ties
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High-temperature grease -G 052 133 A2-

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1.1 Removing engine

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The engine is removed downwards with gearbox.

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Before removing, read the fault memories of all control units
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Golf 2004
Note
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Leave ignition key in ignition lock to prevent steering lock from
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engine removal. The vehicle can then be lowered on hoist until
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the brake disc splash plates are just above the floor. This pro
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sibility of engine compartment components.
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Some components cannot be removed, or removed only with
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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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To prevent damage to removed components, place them in
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the container for removed parts -V.A.G 1698- .
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Route all the various lines (e.g. for fuel, hydraulics, acti
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vated charcoal filter system, coolant and refrigerant, brake Cop py
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fluid and vacuum) and electrical wiring in their original po
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To avoid damage to lines/wiring, ensure sufficient clear
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ance to all moving or hot components.
Disconnect earth strap at battery with ignition switched off

Electrical system; Rep. Gr. 27 ; Disconnecting and recon
necting battery .
Completely remove air filter together with connecting hose to
throttle valve module -J338- page 174 .
Remove bracket from air filter.
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 .
Unscrew securing bolts -arrows- of plenum chamber bulkhead
-1- and remove together with resonance air pipe -2-.
Vehicles with anti-theft secured engine control unit
Remove protective housing from engine control unit
page 185 .
Continuation for all vehicles
Pull engine wiring harness connector off engine control unit.

Golf 2004
Release feed-through for engine wiring harness -arrow- and

pull off upwards.
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Unscrew cable frombyalternator
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Unscrew earth cable from longitudinal member -arrow-. rrectness o
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Open wiring guide catches on longitudinal member -arrows-. co Vo
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Separate all connectors between engine wiring harness and
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body and lay engine wiring harness on engine.
WARNING
Fuel supply line is pressurised. Wear eye protection and pro

tective clothing to avoid possible injury and skin contact. Before
loosening hose connections, wrap a cloth around the connec
tion. Then release pressure by carefully pulling hose off con
nection.
Observe rules for cleanliness page 129 .

Golf 2004
Separate fuel supply line -1- (black) and catch escaping fuel
with a cloth.
Disconnect breather line -2- (white) and remove activated
charcoal filter.
Note
Press in securing ring to release fuel lines.

On vehicles with auxiliary heater the fuel line -3- of the meter
ing pump -V54- must also be separated.
Seal line so that fuel system is not contaminated by dirt.
Separate Lambda probe connectors at plenum chamber bulk

head and release cables.
1 - Lambda probe 2 -G108- , 6-pin connector (brown)
2 - Lambda probe -G39- , 6-pin connector (black)
Pull off/disconnect all electrical connections as necessary
from engine/gearbox and lay to one side.
Pull vacuum line for brake servo off intake manifold.
Separate all further connection, vacuum and intake hoses
from engine.
Remove selector mechanism from gearbox 6-speed dual
clutch gearbox 02E; Rep. Gr. 34 ; Selector mechanism .
WARNING
Steam may escape when expansion tank is opened. Wear eye

protection and protective clothing to avoid eye injuries and
scalding. Cover cap with cloth and open carefully.
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Remove noise insulation General body repairs,
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Rep. Gr. 50 ; Noise insulation . s
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Golf 2004
Remove front parts of wheel housing liners General body

repairs, exterior; Rep. Gr. 66 ; Removing and installing wheel
housing liner .
Move lock carrier into its service position General body re
pairs, exterior; Rep. Gr. 50 ; Lock carrier, service position .
Pull connector off oil level and oil temperature sender -G266- .
Pull wiring retainer for oil level and oil temperature sender -
G266- off subframe.
Remove front exhaust pipe with catalytic converters
page 195 .
Note
The flexible joint in the front exhaust pipe must not be bent by
more than 20 - risk of damage. To remove, ask for the assistance
of a second mechanic.
Remove front propshaft Final drive 02D, 0AV; Rep. Gr. 39 ;

Assembly overview - repairing propshaft
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To prevent damage to condenser or to refrigerant lines/hoses, th or
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ensure that the lines and hoses are not stretched, kinked or bent. ss
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To facilitate removing and installing engine without opening re
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Remove poly V-belt page 20 .
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Open refrigerant line brackets on body.
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Remove air conditioner compressor with connected refriger
t to the co
ant lines from ancillary bracket Heating, air conditioning;
Rep. Gr. 87 ; Removing and installing compressor bracket .
rrectness of i
Secure air conditioner compressor -A- to lock carrier as illus
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trated (securing points -1 and 2-.

Remove drive shaft protection for right drive shaft.
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Remove drive shafts Running gear, axles, steering; Rep.

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Gr. 40 ; Removing and installing drive shafts . at

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Golf 2004
Unscrew bolts -13- and remove pendulum support.

Drain coolant page 110 .
Pull coolant hose quick-release couplings off heat exchanger
and radiator.
Pull off coolant hoses to expansion tank.
Vehicles with auxiliary heater
Disconnect coolant hoses to auxiliary heater and to heater
coolant shut-off valve -N279- .
Continuation for all vehicles
Insert engine bracket -T40074- in engine and gearbox jack -
V.A.G 1383 A- .
Remove adapter -T40074/1- from engine support -T40074-

and screw with nut -1- onto cylinder block.
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Position engine support -T40074- on engine as shown and

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retighten adapter -T40074/1- with engine support -T40074-

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Fit engine support -T40074- with M10x25 bolts on exhaust

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side as shown and tighten to approx. 20 Nm on cylinder block

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Lift engine and gearbox lightly using engine and gearbox jack
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Golf 2004
Unbolt engine side of assembly mounting from engine bracket

from above -arrows-.
Unbolt gearbox side of assembly mounting from gearbox

bracket -arrows- from above.
Note
To remove securing bolts use stepladder -VAS 5085- .

Engine with gearbox must be guided carefully when lowered
to prevent damage to bodywork.
Carefully lower engine with gearbox.
1.2 Securing engine on engine and gearbox

support -VAS 6095-
Secure engine to engine and gearbox support -VAS 6095- to car
ry out repairs.
Procedure
Unbolt gearbox. AG. Volkswagen AG d
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Vibration damper end: position 3.
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Flywheel end: position 11.

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Secure engine to engine and gearbox support -VAS 6095- as

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shown.
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When using engine bracket -3269- :

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10
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Rep. Gr.10 - Removing and installing engine
Golf 2004
Bolt engine bracket -3269- to cylinder block as shown.
1.3 Installing engine

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vated charcoal filter system, coolant and refrigerant, brake
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sitions.
To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
rrectness of i
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A needle bearing must be fitted in the crankshaft on vehicles

with DSG. Install needle bearing where necessary
nform
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page 33 .
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Lightly lubricate used needle bearings with high-temperature
ion
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grease -G 052 133 A2- .

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Check whether dowel sleeves for centring engine/gearbox

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have been fitted in cylinder block, insert if necessary.

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When installing engine and gearbox assembly, ensure suffi
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Align engine mountings as follows:
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Golf 2004
There must be a distance of -a- at least 10 mm between engine

support and longitudinal member (right side).
The side surface of the engine support -2- should be located
parallel to the support arm -1-.
Install pendulum support page 13 .
Note
Specified torques for assembly mountings page 13 . agen

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Install drive shafts Running gear, axles, steering;
orise
Rep. Gr. nte
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40 ; Removing and installing drive shafts . auth ra
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Install front propshaft Final drive 02D, 0AV; Rep. Gr. 39 ;
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Assembly overview - repairing propshaft
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Install front exhaust pipe together with catalytic converters
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page 195 .
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Ensure that the exhaust system is installed free of stress
page 200 .
rrectness of i
If necessary, adjust selector lever cable 6-speed dual clutch
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gearbox 02E; Rep. Gr. 34 ; Selector mechanism; Adjusting

selector lever cable .
nform
ercia
Electrical connections and routing Electrical system; Rep.

Gr. 97 .
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Install air conditioner compressor Heating, air conditioning;
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Rep. Gr. 87 .
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Install poly V-belt page 20 .

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Reset service position General body repairs, exterior; Rep.

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Gr. 50 ; Lock carrier, service position . C py
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Install noise insulation General body repairs, exterior; Rep. copy Vo
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Gr. 50 ; Noise insulation. . cted agen
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Replenish coolant page 110 .

Carry out vehicle system test Vehicle diagnosis, testing and
information system VAS 5051 Guided fault finding.
Finish the vehicle system test so that any fault entries stored
during assembly can be deleted automatically.
Generate the readiness code in combination with a road test.
Observe applicable safety precautions during road test.
Carry out road test.
Then carry out vehicle system test again and rectify any faults
which may have occurred.

Golf 2004
Specified torques
Threaded connection Specified torque
Bolts, nuts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M12 60 Nm
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Specified torques for assembly
utho mountings page 13 . or
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1.4 Specified torques for assembly mount
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Engine assembly mountings
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A = 20 Nm + 90 (1/4 turn) further 1)
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B = 40 Nm + 90 (1/4 turn) further 1)
C = 60 Nm + 90 (1/4 turn) further 1)
rrectness of i
1) Renew.
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Gearbox assembly mounting

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1 = 40 Nm + 90 (1/4 turn) further 1)

a
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2 = 60 Nm + 90 (1/4 turn) further 1)

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Pendulum support
Note
Bolt pendulum support to gearbox and then to subframe.
A - Strength rating 8.8 = 40 Nm + 90 (1/4 turn) further 1)
A - Strength rating 10.9 = 50 Nm + 90 (1/4 turn) further 1)
B - = 100 Nm + 90 (1/4 turn) further 1)

1) Renew.

Golf 2004
13 Crankshaft group
1 Dismantling and assembling engine
Note
Secure engine to engine and gearbox support -VAS 6095- to

carry out assembly work page 10 .
Finding metal shavings or a large quantity of small metal par
ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
Thoroughly clean oil channels.
Renew oil spray jets.
Renew oil cooler.
Renew oil filter.
Part I: assembly overview - chain drive page 16

Part II: assembly overview - crankshaft group page 18
Removing and installing poly V-belt page 20 .
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Rep. Gr.13 - Crankshaft group
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Golf 2004
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1. Dismantling and assembling engine 15

Golf 2004
1.1 Part I: assembly overview - chain drive
1 - Valve timing housing

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Lightly lubricate contact s aut ra
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fore installing.
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Removing and installing
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page 73 .
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Dismantling and assem
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bling page 73 .
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spec
Before installing valve
es, in part or in w
timing housing, check
t to the co
strainer for soiling
page 73 .
rrectness of i
2 - 8 Nm
Insert with locking fluid -
l purpos
D 000 600 A2- .

3 - Camshaft timing chain
nform
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Before removing, mark

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at
direction of rotation (in
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stallation position)
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page 18 .
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Installing page 62 .
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4 - Exhaust camshaft adjuster

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Identification: 32A.
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5 - Intermediate shaft
6 - Tensioning plate
For camshaft timing
chain Item 3 (page 16)
7 - Pivot pin, 18 Nm
8 - Chain tensioner, 50 2 Nm
For camshaft timing chain Item 3 (page 16)
Only rotate engine when chain tensioner is installed.
9 - Seal
Renew if damaged or leaking.
10 - Chain sprocket
For timing chain Item 15 (page 17) .
11 - Chain sprocket
12 - 60 Nm + 1/4 turn (90) further
Renew.
Use counterhold -T10069- to loosen and tighten page 62 .
16 Rep. Gr.13 - Crankshaft group

Golf 2004
13 - Chain tensioner with tensioning plate

For timing chain Item 15 (page 17) .
Before installing, release locking splines in chain tensioner using a small screwdriver and press tension
ing plate against chain tensioner.
14 - Drive gear wheel
Built into crankshaft.
Ground down tooth to bearing joint = TDC No. 1 cyl. page 62
15 - Timing chain
Before removing, mark direction of rotation (installation position) page 18 .
16 - Guide rail
Remove and install together with roller chain page 62
17 - Locating pin without collar, 10 Nm
For guide rail Item 16 (page 17) . AG. Volkswagen AG d
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19 - 23 Nm ut
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20 - Inlet camshaft adjuster s
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Identification: 24E
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Rotate engine only with camshaft adjuster installed.
erm
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21 - 60 Nm + 1/4 turn (90) further
hole
spec
Renew.
es, in part or in w
t to the co
Contact surface of sender wheel must be dry around bolt head when installed.
To remove and install, counterhold with 32 mm open-end spanner on camshaft page 73 .
rrectness of i
22 - Guide rail
l purpos

23 - Exhaust camshaft control valve 1 -N318-
nform
ercia
For exhaust camshaft.

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at
Removing and installing page 80 .
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c
Before removing, mark connector belonging to component. in t

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ate
24 - Inlet camshaft control valve 1 -N205-

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For inlet camshaft.

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Before removing, mark connector belonging to component.
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25 - Guide rail
by lksw
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For camshaft timing chain
Clipped into valve timing housing.

Golf 2004
Marking timing chains

Mark roller chains before removing (e.g. with paint, arrow agen
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Note ss a c
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Do not mark chain by way of centre punch, notch or the like.
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1.2 Part II: assembly overview - crankshaft group
nform
mer
atio
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n
c
1 - 45 Nm
i
or
n thi
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2 - Engine bracket
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3 - 5 Nm
en
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Secured to intake mani
Co
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4 - Oil dipstick by c lksw
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The oil level must not be
above the max. mark!
Markings page 89 .
5 - Guide tube
For oil dipstick.
Secured with bolt to in
take manifold.
6 - Cylinder block
sealing flange and dual-
mass flywheel
page 22 .
crankshaft
page 30 .
bling pistons and con
rods page 36 .
7 - Knock sensor 1 -G61-
Fitting location: be
tween cylinder 1 and
cylinder 3.
8 - 20 Nm
The specified torque in
fluences the function of
the knock sensor.

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6-cylinder ed b injection engine VW Individual - Edition
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9 - 10 Nm ss c
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10 - Oil pump drive cover
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11 - O-ring
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Renew.
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Oil before installing.
h re
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spec
12 - Oil pump drive
es, in part or in w
t to the co
13 - Oil non-return valve, 5 Nm
Note installation position.
rrectness of i
Clean if badly soiled
See note page 14 .
l purpos
nform
ercia

m
Fitting location: between cylinder 4 and cylinder 6.
a
com
tion in
16 - Drive shaft
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For oil pump drive.
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17 - Oil pump
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Assembly overview - oil pump page 97
Co
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18 - 23 Nm
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19 - 8 Nm
agen
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Renew.
20 - Oil drain plug, 30 Nm
Renew seal
21 - Oil sump
22 - Oil level and oil temperature sender -G266-
23 - 12 Nm
24 - Oil filter bracket
Assembly overview - oil filter bracket page 95
Coolant hose schematic diagram page 109 .
25 - Fitted bolt, 23 Nm
26 - Bracket for ancillaries
For alternator, air conditioner compressor and power-assisted steering vane pump
27 - Vibration damper
Use counterhold -T10069- to remove and install page 20 .
28 - 100 Nm + 1/2 turn (180) further
Loosening and tightening page 20
29 - Engine speed sender -G28-
30 - Seal
Renew if damaged.

Golf 2004
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Loosening and tightening vibrationthdamper
or
is
securing bolt eo
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To loosen and tighten, lock vibration
ss damper using counter c
ce
le
hold -T10069- .
un
pt
an
d
itte
Clean thread in crankshaft with a threaded chaser M18 x 1.5.
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Renew securing bolt for vibration damper.
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wit
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Tighten securing bolt using torque wrench -V.A.G 1601- .
h re
hole
spec
Specified torque: 100 Nm + 1/2 turn (180).
es, in part or in w
t to the co
Note
rrectness of i
Turning further in several stages is permitted.
l purpos
nform
ercia
1.3 Removing and installing poly V-belt

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Special tools and workshop equipment required
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Locking pin -T10027-
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Removing poly V-belt

Remove noise insulation General body repairs, exterior;
Rep. Gr. 50 ; Noise insulation .
Disconnect breather line -2- (white) and remove activated
charcoal filter from bracket.
Before removing, mark direction of rotation of poly V-belt.

Golf 2004
6-cylinder injection engine
olkswageVW Individual - Edition
es n 10.2009
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V t gu
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Position spanner -1- onto tensioning roller securinghobolt
ris and nte
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turn in -direction of arrow- until locking pin -T10027-
au can be
t ra
c
inserted on tensioning roller. ss
ce
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nl
pt
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Remove poly V-belt.
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Installing poly V-belt
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Note
hole
spec
es, in part or in w
t to the co
Ensure, before installing poly V-belt, that all ancillaries (alter
nator, air conditioner compressor) are secured tightly.
Check that idler rollers turn easily.
rrectness of i
The poly V-belt must not be kinked.
l purpos
When fitting poly V-belt, check direction of belt rotation and
ensure proper seating of belt in pulleys.
nform
mercia
at
Fit poly V-belt as shown.
om
ion
c
in t
or
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Then press tensioning roller slightly in direction of -arrow-, us

at
do
riv
ing spanner -1-. This relieves the locking pin -T10027- in the
p
cum
or
tensioning roller, allowing it to be pulled out.

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After completing repairs always: t. Cop py
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Start engine and check that belt runs properly. yri
p by
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Golf 2004
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2 Sealing flanges and flywheel
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Assembly overview
uth - sealing flange page 22 .
o tee
or
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Removing and installing crankshaft seal on gearbox side ss
ce
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page 23 .
nl
pt
du
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Renewing crankshaft sealing flange -vibration damper side-
erm
ab
page 25 .
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Removing and installing flywheel page 26 .
h re
hole
Removing and installing drive plate page 28 .
spec
es, in part or in w
t to the co
Repairing clutch 6-speed manual gearbox 02Q, four-wheel
drive; Rep. Gr. 30 ; Repairing clutch .
rrectness of i
Note
l purpos
Secure engine to engine and gearbox support -VAS 6095- to car

ry out assembly work page 10 .
nf
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2.1 Assembly overview - sealing flange

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or c
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1 - 100 Nm + 1/2 turn (180)
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rp
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further
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t.
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Renew. C py
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To loosen and tighten, pyri by
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use counterhold -
by lksw
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T10069- page 25 .
AG.
Tighten using torque

wrench -V.A.G 1601- .
2 - Vibration damper
Use counterhold -
T10069- to remove and
install page 20 .
3 - 10 Nm
4 - Sealing flange
Coat sealing surfaces
with sealant -D 176 501
A1- .
With seal.
Renewing page 25 .
5 - Cylinder block
crankshaft
page 30 .
rods page 36 .
6 - Sealing flange
Coat sealing surfaces
with sealant -D 176
501- .
7 - Seal
Remove using extractor
hook -T20143/2- .

Golf 2004
PTFE-type oil seal agen
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Identification: Without
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Do not additionally
auth oil or grease the oil seal sealing lip. eo
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Before installing, remove oil residue from crankshaft journal using a clean cloth.
s
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un
pt
an
d
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erm
8 - Intermediate plate
ab
ility
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9 - Dual-mass flywheel
wit
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ole,
spec
10 - 60 Nm + 1/4 turn (90) further
t to the co
Renew.
To loosen and tighten, use counterhold -T10044- (with 5 mm spacers) or counterhold -T10069- .
rrectne
11 - 25 Nm
ss o
cial p
f in
2.2 Removing and installing crankshaft seal
form
mer
on gearbox side
atio
om
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Fitting sleeves -T10122-

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Cop py
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pyri by
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Prote AG.
Puller hooks -T20143-
2. Sealing flanges and flywheel 23

Golf 2004
6-cylinder injection eengine
n AG. VolVW
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gen AG - Edition 10.2009
ag does
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Removing ed
b ara
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Fit pullerahooks
ut -T20143/2- behind sealing lip of oil seal as ra
c
shown inss illustration.
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nl
pt
du
Support puller hook -T20143/2- on sealing flange and lever
an
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seal out in direction of -arrow-.
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ility
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Installing
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hole
spec
es, in part or in w
t to the co
rrectness of i
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Pull oil seal -A- by the outside over the sleeve -T10122/1- onto
pulling sleeve -T10122/2- .
nform
ercia
Separate the two fitting sleeves.

m
at
Then set pulling sleeve -T10122/2- with dry oil seal onto crank
om
io
shaft journal.
n
c
in t
or
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ate
do
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for
en
ng
t.
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Cop py
t. rig
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pyri by
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Prote AG.
Now drive it into sealing flange to stop using thrust piece -

T10122/3- .

Golf 2004
2.3 Renewing crankshaft sealing flange wa-vibration damper does side-

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Special tools and workshop ho eo
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equipment required ss c
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Counterhold -T10069-
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Assembly tool -T10215-
erm
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1601-
h re
ole,
spec
1332- urposes, in part or in wh
t to the co
Sealant -D 176 501 A1-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
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te
sd
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pr
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Remove vibration damper. To do this, lock vibration damper
using counterhold -T10069- .
Remove sump page 92 .
Unbolt sealing flange.
Remove remaining sealant from sealing surfaces.
Installing
Remove oil residue from crankshaft journal using clean cloth.

Golf 2004
Cut off tube nozzle at forward marking (approx. 3 mm nozzle

).
Apply sealant bead sealant -D 176 501 A1- of about 23 mm
as shown -arrows- to clean sealing surface of sealing flange.
Note
Before applying sealant bead, cover sealing ring with a clean

cloth.
The sealing compound bead must not be thicker that 23 mm.
Otherwise excessive sealing compound will enter the sump
and may block the oil suction pipe strainer.
Observe expiry date of sealing compound.
The sealing flange must be installed within 5 minutes after ap
plying the silicone sealant.
Push guide sleeve -T10215/1- -1- at front onto crankshaft jour

nal -3-.
Now slide sealing flange with oil seal -2- carefully over guide
sleeve.
Bolt sealing flange to cylinder block.

Install oil sump page 92 .
Note
Renew securing bolt for vibration damper.

Tighten securing bolt using torque wrench -V.A.G 1601- .
AG. Volkswagen AG d
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V
Install vibration damper and lock withed bycounterhold -T10069- . gu
ara
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th
Tighten new securing bolt to s100 1
au Nm + /2 turn (180) further. ra
s c
ce
le

un
pt
an
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itte
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rm
ab
pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
2.4 Removing and installing flywheel

l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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t.
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Cop py
ht. rig
rig ht
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26
copy Vo
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Rep. Gr.13 - Crankshaft group cted agen
Prote AG.
Golf 2004
Removing:
AG. Volkswagen AG d
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Note sed b ara
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ri
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To prevent
ss a
damage to the dual-mass flywheel when removing,
c
the bolts -B- must not be removed with an impact wrench or sim
ce
le
un
pt
ilar. The bolts -B- must be unscrewed by hand without power
an
d
itte
tools.
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erm
ab
ility
ot p
Rotate the dual-mass flywheel -A- so that the bolts -B- align
wit
is n
centrally with the holes -arrows-. h re

ole,
spec
When removing bolts -B-, make sure that screw heads do not
jam on flywheel.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
Tighten counterhold -T10044- on cylinder block with washer

i
or
n thi
e
-arrow-. Bring counterhold -T10044- to -position A- to loosen

t
sd
va
flywheel.
i
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pr
cum
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fo
en
Mark position of flywheel in relation to engine.

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t.
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op py
Unbolt flywheel.
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rig by
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Installing:
co Vo
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Prote AG.
Install in reverse order. In the process, note the following:
Renew bolts.

Golf 2004
Bring counterhold -T10044- to -position B- to tighten flywheel.

Specified torque
Component Nm
Flywheel to crankshaft 60 + 901)
1) 90 equals a quarter of a turn
2.5 Removing and installing drive plate

lkswage es n
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un
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spec
Torque wrench -V.A.G 1332-

t to the co
Depth gauge
Straight edge
rrectne
Removing
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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sd
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pr
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Remove drive plate. To do this, lock vibration damper using

fo
en
ng
counterhold -T10069- .
t.
yi Co
Cop py
.
Loosen drive plate securing bolts diagonally and remove.
t rig
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pyri by
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co
Remove drive plate.
by lksw
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Prote AG.
Installing
Fit drive plate on crankshaft.
Insert at least 3 old securing bolts and tighten to 30 Nm.

Golf 2004
Check dimension -a- through the three holes for securing the
torque converter using a straightedge and depth gaugegandn AG. Volkswagen AG do
calculate average. lkswa e es n
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Compare average with specification (measured ris
e
distance + tee
ho
thickness of straight edge). Specification:
au t15.716.5 mm or
ac
ss
If specification is not attained:
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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hole
spec
es, in part or in w
t to the co
Remove drive plate again and fit appropriate shim -1-.
rrectness of i
Note
l purpos
Only one shim of the appropriate thickness may be used for com
pensation.
nf
ercia
orm
When specification is attained:
m
atio
om
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c
Insert new securing bolts and tighten by hand.

or
thi
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Tighten securing bolt to 60 Nm + 90 (1/4 turn) further.

iv
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f
en
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t.
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Cop py
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AG. Volkswagen AG d
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Golf 2004 d by
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6-cylinder
horis
injection engine VW Individual - Edition 10.2009
eo
aut ra
ss c
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e
3 Crankshaft
nl
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Assembly overview - crankshaft page 30 .
ility
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Fitting sender wheel to crankshaft page 33 .
wit
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h re
hole
Pulling needle bearing out of and driving into crankshaft
spec
page 33 .
es, in part or in w
t to the co
Note
rrectness of i
Before removing crankshaft, ensure that a suitable surface for
l purpos
storing crankshaft is prepared to ensure that sender wheel is

not damaged and is not touching any other item.
nform
ercia
When working on engine, secure engine to engine and gear

box support -VAS 6095- or engine and gearbox support -
m
at
om
i
VW 540- with supplementary set for engine and gearbox
on
c
support -VW 540/1 B- .
in t
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ate
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3.1 Assembly overview - crankshaft

p
cum
for
en
ng
t.
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Cop py
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1 - Bearing cap opyri
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ht
Bearing cap 1: vibration by c lksw

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damper end Prote AG.
Bearing cap 5 with re

cesses for thrust wash
ers.
Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
2 - 30 Nm + 1/2 turn (180) fur
ther
Renew.
2 x 90 further is permit
ted.
3 - Bearing shells 17
For bearing cap without
oil groove.
For cylinder block with
oil groove.
Do not interchange
used bearing shells
(mark).
4 - Thrust washer
For bearing cap 5.
Note fixing arrange
ment.
5 - Crankshaft
If the crankshaft is re
newed, the bearing
shells must be realloca
ted page 31
Before removing, see
notes page 30 .
Removing and installing needle bearing page 33

Golf 2004
Axial clearance
New: 0.070.23 mm
Wear limit: 0.30 mm.

Checking radial clearance with Plastigage:
New: 0.020.06 mm

Do not rotate crankshaft when checking radial clearance.
Crankshaft dimensions:
Main bearing: 59.95859.978 mm
Conrod bearing: 53.95853.978 mm

Reworking is not permitted
6 - Sender wheel
For engine speed sender -G28- .
Renew.
7 - 10 Nm + 1/4 turn (90) further
Renew.
8 - Oil spray jet
For crankshaft bearings 27
For piston cooling.
Opening pressure: 2.0 bar agen
AG. Volkswagen AG d
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Removing and installing page 91 . by
Vo gu
ara
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See note page 14 . horis nte
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3.2 Allocation of crankshaft bearing shells
an
d
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(classification)
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ility
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Main bearing shells of the correct thickness are allocated to the
h re
cylinder block and crankshaft at the factory. Coloured dots are
ole,
spec
used to identify the thickness of the bearing shells.
t to the co
If the cylinder block or crankshaft is renewed, the bearing shells
must be reallocated.
Always insert bearing shell for cylinder block (upper bearing shell) rrectne
with yellow colour marking.
s
Determine the correct colour marking for the bearing shell in

s o
bearing cap (lower bearing shell) with regard to the letters on the
cial p
f in
cylinder block and crankshaft.

form
mer
atio
The first letter is allocated to bearing cap one, the second to bear
om
ing cap two, etc.

n
c
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or
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te
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Prote AG.
3. Crankshaft 31
Golf 2004
Cylinder block identification:

The letters are located on the sealing surface of sump.
Crankshaft identification:
The letters are located on the outer crankshaft web of No. 1 cyl
inder.
Make a note of the letters and determine the colour marking
for installation with regard to the table.
AG. Volkswagen AG d
agen oes
olksw not
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Letter on cylinder block Letter on crankshaftrise web Colour marking of bearing Colour nte marking of bearing
ho eo
s aut
shell for bearing cap shell forr a cylinder block
c
s
A, B, C, D, E R red yellow
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A, B, C, D, E G red yellow
itte
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A, B, C, D, E B yellow yellow
ility
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A, B, C, D, E V blue yellow
wit
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h re
G, H, I R red yellow
hole
spec
G, H, I G red yellow
es, in part or in w
t to the co
G, H, I B yellow yellow
G, H, I V blue yellow
rrectness of i
K, L, M R red yellow
l purpos
K, L, M G yellow yellow
K, L, M B blue yellow
nf
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K, L, M V Purple yellow
orm
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or c
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Example:
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Bearing cap 1 2 3 4 5 6 7
o
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Letters on cylinder block G H H H G E G
Co
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Letters on crankshaft web G B B V B B G
gh ht
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Colour marking of bearing shell red yellow yellow blue yellow yellow red
by lksw
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Prote
for bearing cap
AG.

Golf 2004
3.3 Fitting sender wheel to crankshaft

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Locking ed -D 154 100 A1-
ir sfluid
ran
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Procedure
ss
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Ensure that contact surfaces of crankshaft and sender wheel are

un
pt
an
d
free of oil and grease.

itte
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ab
pe
ility
ot
wit
Note
, is n
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hole
spec
The sender wheel must only be installed once, because after fas
es, in part or in w
tening for a second time, the attachment points -arrows- of coun

t to the co
tersunk head bolts -1- in sender wheel -2- are deformed to such
an extent that the bolt heads make contact with the crankshaft
-3- and the sender wheel below the bolts is loose.
rrectness of i
l purpos
Lightly coat contact surfaces of crankshaft and sender wheel

with locking fluid -D 154 100 A1- for additional security.
nform
ercia
Ensure during installation that marking VR6 -arrow- is posi

tioned over single threaded hole.
m
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tion in
First tighten all new securing bolts lightly by hand.

r
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First tighten securing bolt -1- to 10 Nm + 90 (1/4 turn) further.

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Then tighten securing bolts -2- to 10 Nm + 90 (1/4 turn) fur

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3.4 Pulling needle bearing out of and driving

into crankshaft
3. Crankshaft 33
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
Golf 2004 autho eo
ra
6-cylinder injection engine VW Individual - Edition 10.2009 ss c
ce
le
un
pt
an
d
Puller -T10055- with adapter -T10055/3-
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
Centring drift -3176- or drift -VW 207 C-
atio
om
n
c
i
or
n thi
te
sd
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t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
Puller, e.g. Kukko -21/2-

Removing
Pull out using commercially available puller, e.g. Kukko -21/2-
-arrow-, adapter -T10055/3- and puller -T10055- .
Installing
Note
The lettering on the needle bearing must be visible when installed.
Drive in with drift -VW 207 C- or centring mandrel -3176- .

Golf 2004
Installation depth: dimension -a- = 1.5 mm.
lkswage es n
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spec
t to the co
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cial p
f inform
mer
atio
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c
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Cop py
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by
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Prote AG.
3. Crankshaft 35
Golf 2004
4 Pistons and conrods

Assembly overview - pistons and conrods page 36 .
Checking pistons, piston rings and cylinder bores page 38 .
Installing piston page 39 .
Piston and cylinder dimensions page 40 .
4.1 Assembly overview - pistons and conrods
1 - Piston rings
Offset gaps by 120.
Use piston ring pliers to
remove and install.
TOP faces towardswagen AG. Volkswagen AG doe
piston crown y Volks s no
t gu
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Checking ring o
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page a38u .
th eo
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Checking ring-to-groove
ce
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nl
clearance page 38 . pt
du
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2 - Piston
erm
ab
ility
Checking page 38 .
ot p
wit
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Mark cylinder number

h re
and installation position

hole
spec
relative to conrod.
es, in part or in w
t to the co
Low point of piston

crown faces to centre of
cylinder block.
rrectness of i
Installing piston
page 39 .
l purpos
3 - Circlip
nf
ercia
4 - Conrod
orm
m
atio
Renew as set only.

om
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c
Mark cylinder number

or
thi
-B-.
te
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Installation position:
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marks -A- must be

f
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t.
above one another.
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5 - Bearing shell
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Note installation posi
c by lksw
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tion.
Prote AG.
Do not interchange
used bearing shells.
The lugs on bearing shells must fit tightly in the recesses.
Axial clearance:
New: 0.050.31 mm

Checking radial clearance with Plastigage:
New: 0.020.07 mm

Do not rotate crankshaft when checking radial clearance

Golf 2004
6 - Conrod bearing cap

Mark cylinder number -B-.
Installation position: marks -A- must be above one another.
7 - 30 Nm + 1/4 turn (90) further
. Volkswagen AG
Renew. wage
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Oil threads and contact surface. ed
by
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To measure radial clearance, tighten to 30
ut
hNm but not turn further.
o eo
ra
sa c
8 - Cylinder block s
ce
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nl
pt
Checking cylinder bores page 39 .
du
an
itte
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Removing and installing crankshaft page 30 .
erm
ab
ility
Piston and cylinder dimensions page 40 . ot p
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9 - Piston pin
h re
hole
spec
If difficult to remove, heat piston to 60 C.
es, in part or in w
t to the co
Remove and install using drift -VW 222 A- .
rrectness of i
4.1.1 Separating new conrod
l purpos
On a new conrod, it is possible that the breaking point has not

fully separated. Proceed as follows, when the conrod bearing cap
nf
ercia
cannot be removed by hand:
orm
m
atio
Mark cylinder allocation of conrod Item 4 (page 36)
om
n in
c
Lightly clamp the conrod in a vice using aluminium vice

or
thi
e
clamps, as shown in the illustration.

t
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t.
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Note
Co
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To prevent damage to the conrod, only clamp conrod in lightly.
p by
co Vo
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Conrod is clamped below the dashed line.
Prote AG.
Unscrew the two bolts -arrows- approx. 5 turns.
Using a plastic hammer, carefully knock against conrod bear

ing cap in -direction of arrow- until it is loose.
4. Pistons and conrods 37

Golf 2004
4.2 Checking pistons, piston rings and cyl

inder bores
Checking piston ring gap
Special tools and workshop equipment required n AG. Volkswagen AG do

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Feeler gauges byV
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Test procedure utho
or
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Push ring at right angles from above down to approx. 15 mm
s
ce
le
from bottom end of cylinder. Push in using a piston without

un
pt
an
d
rings.
itte
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ab
Piston ring Ring gap
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New Wear limit
h re
ole,
Rectangular-section ring mm 0.20 0.40 1.0
spec
Tapered stepped ring mm 0.20 0.40 1.0
t to the co
Oil scraper ring mm 0.25 0.50 1.0
Checking ring-to-groove clearance
rrectness
o
cial p
f in
Feeler gauges
form
mer
atio
Clean annular groove before check.
om
n
c
i
or
Piston ring Clearance

thi
te
sd
va
New Wear limit

i
o
pr
cum
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fo
Rectangular-section ring mm 0.04 0.09 0.15

en
ng
t.
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Tapered stepped ring mm 0.03 0.06
op
0.15 C py
t. rig
gh ht
Oil scraper ring mm 0.02 0.06 0.15 yri
p by
co Vo
by lksw
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Checking piston
Prote AG.

External micrometer 75100 mm
Measure pistons approx. 6 mm from the lower edge of skirt, at
90 to the piston pin axis.

Golf 2004
Deviations from nominal dimension: 0.04 mm

Checking cylinder bores

Internal dial test indicator 50100 mm
Test procedure
Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
Deviations from nominal dimension: 0.08 mm
AG. Volkswagen AG d
agen
Note olksw
oes
not
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ed
is nte
Cylinder bores must not be umeasured
thor
when the cylinder block is eo
mounted on engine and gearbox support -VAS 6095- or engine
a ra
ss c
and gearbox support -VW 540- , as measurements may be in
ce
le
un
pt
correct.
an
d
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ab
4.3 Installing piston

ility
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wit
is n

h re
ole,
spec
Piston fitting tool -T10147-

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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n thi
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Note ht. Cop py
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If a new piston fitting tool -T10147- is used to install the pistons,
co Vo
by lksw
cted
first pass piston with oiled piston rings twice through the tool and
agen
Prote AG.
then remove any resulting metal shavings. Only then install piston
with piston rings.
4. Pistons and conrods 39

Golf 2004
Procedure
Push piston into oiled piston fitting tool -T10147- by hand. Low
point of piston crown must face lug on the piston fitting tool
-arrow-.
Hold tool (with piston inserted) on upper edge and press piston
in with both thumbs.
Push piston in until it protrudes by approx. 15 mm from the
lower edge of the piston fitting tool.
Place piston in respective cylinder bore. Lug on piston fitting
tool -arrow- must face centre of cylinder block.
Hold fitting tool tightly against cylinder block and push piston
in.
4.4 Piston and cylinder dimensions

Honing dimen Piston Cylinder bore
sion
Basic dimension mm 83.965 84.010
lkswage es n
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
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Vo
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by
cted agen
Prote AG.

Golf 2004
lkswagen AG
G. VoIndividual
swagen AVW - dEdition
oes
10.2009
k not
Vol gu
d by ara
e nte
ris
15 Cylinder head, valve gear tho eo
au ra
ss c
ce
le
un
pt
1 Cylinder head
an
d
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ab
pe
ility
ot
wit
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Note
h re
hole
spec
If an exchange cylinder head is installed, all the contact sur
es, in part or in w
t to the co
faces between the supporting elements, roller rocker fingers
and the running surfaces of the camshafts must be oiled be
fore the cylinder head cover is installed.
rrectness of i
The plastic protectors fitted to protect the open valves must be
removed only immediately before the cylinder head is fitted.
l purpos
When cylinder head is renewed, the complete coolant must be

renewed page 110 .
nform
ercia
Removing and installing intake manifold page 67 .

m
a
com
tion in
Dismantling and assembling intake manifold page 167 .
r
te o
thi
s
iva
do
Assembly overview - cylinder head page 42 .
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rp
cum
fo
en
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Removing and installing cylinder head page 44 .

n
t.
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Cop py
Assembly overview - cover page 53 .
t. rig
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co
Checking valve timing page 54 .
by lksw
cted agen
Prote AG.
Installing camshaft adjuster with timing chain for camshaft drive
page 62 .
Installing timing chain for intermediate shaft drive and camshaft
drive page 62 .
Removing and installing cylinder head cover page 67 .
Checking compression page 69 .
1. Cylinder head 41
Golf 2004
1.1 Assembly overview - cylinder head
1 - 10 Nm
2 - Bracket
For fuel lines
3 - 10 Nm
With spacer sleeve and
seal.
Renew seal if damaged.
4 - Cap
Renew seal if damaged.
5 - O-ring
Renew if damaged.
For ignition coil with out
put stage.
6 - Cylinder head cover
page 67 .
Renew if damaged.
7 - Lifting eye
8 - 23 Nm
wage es n
9 - Timing chain for camshaft yV
olks ot g
ua
drive ir se
d b ran
o tee
Before removing, mark auth or
ac
direction of rotation (in ss
stallation position)
ce
e
nl
pt
du
page 18 .
an
itte
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erm
ab
ility
ot p
10 - Combination valve
wit
, is n
h re
Checking page 205 .

hole
spec

es, in part or in w
page 205 .
t to the co
11 - Inlet camshaft control valve 1 -N205-

For inlet camshaft.
rrectness of i

l purpos

12 - Exhaust camshaft control valve 1 -N318-
nf
ercia
orm

m
atio
m

o
n in
or c

thi
te
sd
iva
o
r
13 - O-ring
rp
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m
f
en
ng
For sealing oil channel. yi

t.
Co
op
Renew.
C py
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Oil before installing. p by
co Vo
by lksw
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14 - Hall sender 2 -G163- Prote AG.

42 Rep. Gr.15 - Cylinder head, valve gear

Golf 2004
16 - Seal
17 - 8 Nm
18 - Oil seals
For inlet camshaft control valve 1 -N205- Item 11 (page 42) and exhaust camshaft control valve 1 -
N318- Item 12 (page 42)
19 - Thermostat housing
Dismantling and assembling page 107 .
20 - Seal
Renew.
21 - Hall sender -G40-
For inlet camshaft.
22 - Cover
Can be removed and installed with engine installed.
If only cover has been removed, prepare cylinder head gasket for assembly page 51 .
With O-ring for sealing oil channel
en AG. V
olk
swItem
agen A13
G
(page 42)
ag does
lksw not
23 - 60 Nm + 1/4 turn (90)
db
y V further
o gu
ara
ise nte
Renew. uthor eo
ra
a
Contact surface
ss of sender wheel must be when installed. dry around bolt head c
ce
e
nl

pt
du
an
itte
y li

erm
ab
ility
ot p
wit
, is n

h re
hole
spec
es, in part or in w
t to the co
25 - Guide rail
Clipped into valve timing housing.
rrectness of i
26 - Inlet camshaft adjuster

l purpos
Identification: 24E
nform
ercia
m
at
om
io
27 - Lifting eye
n
c
in t
or
his
e
28 - Cylinder head gasket

at
do
riv
Metal gasket.
p
cum
for
en
g
Renew.
n
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op py
Preparing cylinder head gasket for assembly page 51 . . C rig
ht ht
rig by
After renewing, renew entire coolant. copy Vo
by lksw
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Prote
29 - Cylinder head
AG.
Check for distortion page 44 .
1. Cylinder head 43
AG. Volkswagen AG d
agen o
Golf 2004 Vol
ksw es n
ot g
by ua
riseVW
d Individual - Edition 10.2009 ran
t ee
ho
ut or
Removing and 44 . installing
ss a page ac
After renewing, renew entire coolant.
ce
e
nl
pt
du
an
itte
30 - Tensioning element
y li
erm
ab
For poly V-belt.
ility
ot p
wit
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h re
hole
31 - Cylinder head bolt
spec
es, in part or in w
Renew.
t to the co
Follow installation instructions and sequence when loosening and tightening page 44 .
32 - Gasket for cylinder head cover
rrectness of i
l purpos
nf
ercia
orm
Checking cylinder head for distortion
m
atio
om
n in
or c
thi
te
sd
iva
o
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Straightedge 500 mm -VAS 6075-
Feeler gauges
Max. permissible distortion: 0.05 mm.
1.2 Removing and installing cylinder head

Removing page 46 .

Golf 2004
Special tools and workshop

equipment required
Camshaft bar -T10068 A-
Torque wrench -
V.A.G 1331-
Torque wrench -
V.A.G 1332-
5024A-
AG. Volkswagen AG d
Puller -T10095 A- ksw
agen oes
not
Vol
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tho eo
au ra
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un
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an
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itte
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ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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t.
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Cop py
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by
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Prote AG.
1. Cylinder head 45
Golf 2004
Lifting tackle -3033-

Workshop crane -VAS 6100-
Prerequisites
The engine must be no more than warm to touch.
1.2.1 Removing
Caution

tions:
AG. Volkswagen AG
fluid and vacuum) and electrical wiringlkswin their original po
agen does
not
sitions.
o
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ar
d e an
ris tee
To avoid damage to lines/wiring,
tho ensure sufficient clear or
au
ance to all moving or hots components.
s ac
ce
le
un
pt
an
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itte
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All cable ties which are opened or cut open when engine is re
erm
ab
moved must be replaced in the same position when engine is ility
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installed.
wit
is n
h re
First check whether a coded radio is fitted. If so, obtain anti-

ole,
spec
theft coding.
t to the co

Electrical system; Rep. Gr. 27 ; Disconnecting and reconnecting
battery .
rrectne
Remove air filter with intake hose page 174 .

s

s o

cial p
f inform
Remove front bumper cover General body repairs, exterior;

mer
atio
Rep. Gr. 63 ; Front bumper .

om
n
c

or
n thi
e

t
sd
iva
o
pr
cum
r
fo
en
ng
WARNING
t.
yi Co
Cop py
ht. rig
Fuel supply lines are under pressure! Wear eye protection and rig ht
py by
gloves to avoid injuries and skin contact. Before loosening
co Vo
by lksw
cted
hose connections, wrap a cloth around the connection. Then
agen
Prote AG.
release pressure by carefully pulling hose off connection.

AG. Volkswagen AG d
lksw
agen oes
not Golf 2004
o
6-cylinder d by injection engine VW Individual - gEdition
V ua
ran 10.2009
e
oris tee
th or
Separate fuel supply line -1- and catch sescaping
au fuel with a ac
cloth. s
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
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Press in securing ring to release fuel line.
h re
hole
spec
Seal lines so that fuel system is not contaminated by dirt.
es, in part or in w
t to the co
Unclip fuel line on cylinder head cover.
Remove intake manifold page 170 .
rrectness of i
Unscrew heat shield over exhaust manifold.
l purpos
Note
nf
ercia
orm
m
atio
Before removing connectors, mark each connector and compo
om
n in
nent to which it belongs.
or c
thi
te
sd
iva
o
r
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cu
Pull connectors off Hall sender -G40- -1- and Hall sender 2 -
o
m
f
en
ng
G163- -2-.
t.
yi Co
op py
Pull off connectors -3- and -4-.
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
If fitted, unscrew support from front exhaust pipe -arrow-.

Unbolt front exhaust pipe from exhaust manifolds
page 191 .
1. Cylinder head 47
Golf 2004
Pull 2 pin connector off coolant temperature sender -G62-

-arrow-.
Remove thermostat housing page 107 .
Unbolt combination valve from cylinder head.
Remove the coolant hose underneath from cylinder head to
heat exchanger.
Unscrew coolant pipes from intake pipe support and from cyl
inder head and, on vehicles with an auxiliary heater, auxiliary
heater coolant pipes on cylinder block.
Separate mounting on cylinder head for engine wiring harness
and pressure hose for combi-valve.
Remove cylinder head cover page 67 .
Set crankshaft to TDC No. 1 cylinder Amarking

G. Volkswa-arrow-
gen AG by turn
ing crankshaft on the vibration agen
damper securing boltdin
oesdirec
olksw not
tion of engine rotation. ed by V gu
ara
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utho eo
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a c
ss
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le
un
pt
an
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itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Cams -A- of cylinder 1 must face each other.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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op
Remove chain tensioner for camshaft timing chain -arrow-. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
Remove securing bolts -arrows- for cover. Remove cover.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Note aut ra
ss c
ce
le
un
pt
Only counterhold at camshaft with 32 mm open-end spanner
an
d
itte
-arrow-. The camshaft bar -T10068 A- must not be fitted when
y li
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ab
camshaft adjuster is loosened or tightened.
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Now remove camshaft adjuster.
h re
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spec
t to the co
rrectne
Remove guide rail securing bolts -arrows- and remove guide
rail -1-.
ss o
Lay camshaft timing chain aside.
cial p
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mer
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Cop py
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Loosen cylinder head bolts in the sequence given starting at cted agen
Prote AG.
the outside and working inwards and then remove completely.
1. Cylinder head 49
Golf 2004
Attach lifting tackle -3033- as described below and carefully

lift off cylinder head with workshop crane -VAS 6100- .
Vibration damper end: -position 3-
Flywheel end: -position 11-.
Note
The positions marked 112 on the bar face the flywheel end.
Adjust length of threaded spindles according to need.
Carefully remove cylinder head.

Place clean cloths in cylinders so that no dirt or emery cloth
particles can get in between cylinder wall and piston.
Also prevent dirt and emery cloth particles from getting into
coolant.
Now carefully clean sealing surfaces of cylinder head and cyl
inder block. When doing this, ensure that surfaces are not
scored or scratched (if abrasive paper is used, grade must not
be less than 100).
1.2.2 Installing
Carefully remove metal particles, emery residue and cloths.
If the piston for No. 1 cylinder is not at TDC:
wage
Turn crankshaft on the vibration damper securing yV
o bolt in di
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rection of engine rotation to TDC No. 1 cylinder
ir se
d b marking ua
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-arrow- while a second mechanic guides th camshaft timing
o tee
or
chain by hand. ss
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Note
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Do not remove new cylinder head gasket from its packing until
wit
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immediately before installing.

h re
hole
spec
Handle new gasket with extreme care. Damage will cause

es, in part or in w
leakage.
t to the co
Apply a 2 mm thick bead of sealant -D 176 501 A1- onto joint

rrectness of i
between cylinder block and sealing flange as shown

-arrows-.
l purpos
Immediately fit new cylinder head gasket. Inscription (Part

No.) must be readable.
nf
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orm
Additionally insert a little sealant -D 176 501 A1- into the two
m
atio
m
3 mm bores in the cylinder head gasket, which lie on the seal

o
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c
ant bead.
or
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Cop py
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pyri by
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by
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Prote AG.

Golf 2004
Ensure that dowel sleeves are inserted into cylinder block

holes 12 and 20, and that cylinder head gasket is located.
Position camshafts in cylinder head to TDC No. 1 cylinder.
The camshaft bar -T10068 A- must engage in grooves in both

shafts.
Fit cylinder head, screw in new cylinder head bolts and tighten
hand tight.
Note wage
es n
olks ot g
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The longer cylinder head bolts must be inserted inorithe
se centre
d ran
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holes of cylinder head. auth or
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un
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Tighten cylinder head bolts in tightening sequence shown
ility
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working from inside to outside:
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Pre-tighten all bolts to 30 Nm.
ole,
spec
Then tighten all bolts to 50 Nm.
t to the co
Then tighten all bolts 1/4 turn (90) further using a rigid wrench.
Then tighten all bolts again 1/4 turn (90) further.
rrectne
Further assembly is basically the reverse of the dismantling se
ss
quence.
o
cial p
f inform
mer
Note
atio
om
n
c
i
or
Ensure that the O-ring for sealing the oil channel and the seal are
thi
te
fitted in the cover.

sd
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pr
cum
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Installing camshaft adjuster with timing chain for camshaft

t.
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drive page 57 . Cop py
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yri
Install cylinder head cover and intake manifold page 67 . p by
co Vo
by lksw
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Fill with new coolant page 110 . Prote AG.
Note
It is not necessary to retighten cylinder head bolts after repairs.
1.2.3 Preparing cylinder head gasket for as

sembly
1. Cylinder head 51
Golf 2004
If only cover was removed:

Remove old sealant from 3 mm holes in cylinder head gasket
-arrows-.
Fill 3 mm holes in the cylinder head gasket with sealant -D 176
501 A1- and coat sealing surfaces on cover with sealant -D
176 501 A1- .
Install cover immediately.
If the cylinder head gasket was renewed
Apply a 2 mm thick bead of sealant -D 176 501 A1- onto joint

between cylinder block and sealing flange as shown
-arrows-.
Immediately fit new cylinder head gasket. Inscription (Part
No.) must be readable.
Additionally insert a little sealant -D 176 501 A1- into the two
3 mm bores in the cylinder head gasket, which lie on the seal. Volkswagen AG
ant bead. swa
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spec
t to the co
rrectness o
cial p
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mer
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n
c
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n thi
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sd
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t.
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Cop py
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pyri by
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by
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Prote AG.

Golf 2004
1.3 Assembly overview - cover
1 - Cable guide
For wiring harness. AG. Volkswagen AG d
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With coolant pipe Volksw not
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Coolant hose schematic rise
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diagram page 109 . autho eo
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2 - Stud, 8 Nm
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For earth connection
an
itte
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3 - Hall sender 2 -G163-
ility
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Before removing, mark
hole
spec
connector belonging to
es, in part or in w
component.
t to the co
For timing chain
rrectness of i
Item 9 (page 42)
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Only rotate engine when

chain tensioner is instal
led.
nf
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or
5 - Seal
m
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atio
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Renew if damaged or
o
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c
leaking.
or
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6 - Bracket
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7 - Oil seals
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For inlet camshaft con Cop py
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trol valve 1 -N205- yri
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Item 11 (page 42) and cop Vo
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exhaust camshaft con
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Prote AG.
trol valve 1 -N318-
Item 12 (page 42)
Renew if damaged or
leaking.
8 - 23 Nm
9 - Bracket
For wiring harness.
Dismantling and assembling page 107 .
11 - Bracket
For wiring harness.
12 - Seal
Renew.
13 - Cover
Coat sealing surfaces with sealant -D 176 501 A1- .
Preparing cylinder head gasket for assembly page 51 .
For inlet camshaft.
1. Cylinder head 53
Golf 2004
15 - O-ring
For sealing oil channel.
Renew.
Installing cover oil seals
lkswage es n
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d ran
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un
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pe
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hole
spec
Fitting sleeve -3378-

es, in part or in w
t to the co
Fitting sleeve -3253/6-

Do not lubricate seals.
rrectness of i
Install oil seal with fitting sleeve -3378- in cover -1- and pull in
l purpos
flush using fitting sleeve -3253/6- .
1.4 Checking valve timing

nform
mercia

a
com
tion in

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Cop py
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by
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Prote AG.
Test procedure
Remove cylinder head cover and intake manifold
page 67 .

Golf 2004
Set crankshaft to TDC No. 1 cylinder marking -arrow- by turn

ing crankshaft on the vibration damper securing bolt in direc
tion of engine rotation.
AG. Volkswagen AG d
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Insert camshaft bar -T10068 A- inorboth
ise shaft grooves. nte
eo
th
au ra
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nl
pt
du
an
itte
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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Note
nf
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The grooves of the camshafts might not be exactly vertical due to

or
the function of camshaft adjusters. Therefore, move the cam

m
m
atio
shafts back and forth slightly if necessary when inserting the

om
n in
camshaft bar -T10068 A- using an open-end spanner.

or c
thi
te
sd
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Check setting marks of camshaft adjusters against marks on con

o
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trol housing:
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Cop py
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Prote AG.
1. Cylinder head 55
Golf 2004
Arrow -1- on the camshaft adjuster of the inlet camshaft must

align with the left notch -2- on the control housing. Markings
on valve timing housing page 57 .
AG. Volkswagen AG d
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Marking -1- on the camshaft adjuster of the exhaust camshaft,
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ab
to which the arrow points, must align with the left notch -2-
ility
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on the control housing. Markings on valve timing housing
wit
page 57 .
is n
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spec
Note
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A slight offset between marking -1- and notch -2- is permissible.
rrectness o
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mer
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om
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The gap between markings of camshaft adjuster must be ex . C rig
ht ht
actly 16 rollers of camshaft timing chain.
rig by
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Prote AG.
Note
Figure shows view with cover removed.
If the markings do not align:

Adjusting valve timing page 62 .
If the markings align:
Install cylinder head cover and intake manifold page 67 .

Golf 2004
Markings on valve timing housing on MPI engines

-A- View from flywheel end
-B- View from vibration damper end
The markings on camshaft adjusters must align with notches
-arrows-.
1.5 Installing camshaft

gen AG
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kswagen AG with timing
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Set crankshaft ho to TDC No. 1 cylinder marks -arrow- by turning
tee
ut o
crankshaftss on the vibration damper securing bolt in directionr ac
a
of engine rotation.
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nl
pt
du
an
itte
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos
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or c
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Cop py
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by lksw
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Prote AG.
1. Cylinder head 57
Golf 2004
Insert camshaft bar -T10068 A- in both shaft grooves. If nec

essary, move the camshafts back and forth slightly with an
open-end spanner.
Note
Both camshaft adjusters (marking: 24E on inlet side and 32A

on exhaust side) can be screwed at camshaft mounting in one
position only -arrows- due to a dowel pin.
Now turn sender wheel -1- on removed inlet camshaft adjuster

to right stop in -direction of arrow- and hold adjuster in this
position.
Note
If inlet camshaft adjuster is bolted to the camshaft, turn adjuster

with chain sprocket to left accordingly and then fit camshaft timing
chain. AG. Volkswagen n AG do
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Ensure the camshaft timing chain is tight against guide rail
ce
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un
-1- and does not sag.

pt
an
d
itte
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It must be possible to easily position adjuster and tighten it hand-

erm
ab
tight with camshaft timing chain positioned tautly on inlet cam

ility
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shaft.
wit
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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t.
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Cop py
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58
copy Vo
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Rep. Gr.15 - Cylinder head, valve gear cted agen
Prote AG.
Golf 2004
Arrow -1- on the camshaft adjuster of the inlet camshaft must

align with the left notch -2- on the control housing. Markings
on valve timing housing page 57 .
lkswage es n
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d ran
ir se tee
tho
u or
Now, from the tooth that is aligned with the s24E
s a marking, ac
count exactly 16 rollers on the timing chain to the right. Mark
ce
e
nl
pt
this roller with a coloured pen.
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
The exhaust camshaft adjuster is locked when at rest. This pre
spec
vents the sender wheel from turning when adjusting the valve
es, in part or in w
t to the co
timing. If the locking mechanism is not engaged (locked) when at
rest, turn the adjuster in both directions by hand until it is locked.
If this is not possible, renew camshaft adjuster.
rrectness of i
l purpos
Insert exhaust camshaft adjuster 32A into camshaft timing

chain with tooth on marking -1- so that the previously counted
nf
ercia
16 rollers lie precisely between marking 24E and 32A, and
or
markings -1- and -2- align.
m
m
atio
m
It must be possible to easily position the exhaust camshaft

o
n in
or c
adjuster onto the exhaust camshaft and tighten it hand-tight.

thi
te
sd
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Cop py
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pyri by
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co lksw
by
cted agen
Prote AG.
1. Cylinder head 59
Golf 2004
Check the position of both camshaft adjusters again to ensure

the setting is correct.
Remove camshaft bar -T10068 A- .
Note
So that the camshaft timing chain does not jump a tooth when the
crankshaft is turned, the tensioner plate must be pressed against
the camshaft timing chain by hand instead of with chain tension
er .
kswage es n
Turn crankshaft two full turns in direction
by V of engine rotation
ol ot g
ua
and check valve timing page 54ris.ed ran
tee
tho
or
If the markings align: ss
au ac
ce
e
nl
pt
du
an
itte
Hold camshaft which is to be tightened using a 32 mm open-
y li
erm
ab
end spanner -arrow-.
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Camshaft bar -T10068 A- must be removed while this is done. t to the co
Tighten securing bolts of inlet and exhaust camshaft adjusters

rrectness of i
to 60 Nm + 90 (1/4 turn) further.

l purpos
If seals in cover are to be renewed page 54 .

Clean sealing surface on cover and cylinder head.
nform
mercia
at
Lubricate O-ring for oil channel seal -1- and insert in cover.
om
ion
c
in t
r
Check that dowel sleeves -2- and -3- are inserted.

o
his
ate
do
riv
Insert seal -4- in cover.

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004

-arrows-.
Fill 3 mm holes in cylinder head gasket with sealant -D 176
501 A1- . Coat sealing surface of cover with sealant -D 176
501 A1- and immediately install cover.
lkswage es n
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d ran
ir se tee
o
First
au insert all securing bolts -arrows- and tighten lightly.
th or
ac
ss
Tighten M8 securing bolts Item 8 (page 53) to 23 Nm. Tight
ce
le
un
pt
en M6 securing bolts Item 2 (page 53) to 8 Nm.
an
d
itte
y li
Install chain tensioner for camshaft timing chain and tighten to
rm
ab
pe
ility
50 2 Nm.
ot
wit
, is n
Turn crankshaft two full turns in direction of engine rotation
h re
hole
and check valve timing again.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 61
Golf 2004
1.6 Installing timing chain for intermediate shaft drive and camshaft drive

equipment required
Torque wrench -
V.A.G 1331-
Torque wrench -
V.A.G 1332-
lkswage es n
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un
pt
an
d
itte
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ab
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f i
Procedure
nform
mer
atio
m
Caution
o
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c
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t
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pr
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tions:
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t.
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op
Route all the various lines (e.g. for fuel, hydraulics, acti C py
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sitions.
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Prote AG.


Golf 2004
lkswage es n
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Note d b ua
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The following procedure is only possible and described
ss
a with en ac
gine removed. You can start with adjustments at the relevant
ce
le
un
pt
point, depending on how far the engine has been dismantled. The
an
d
itte
sump is removed and may only be fitted after installing the sealing
y li
rm
ab
flange.
pe
ility
ot
wit
, is n
Install timing chain and chain tensioner with tensioning plate for
h re
hole
intermediate shaft drive:
spec
es, in part or in w
First set crankshaft to TDC No. 1 cylinder. For this, the ground
t to the co
down tooth of drive sprocket -arrow- must align with bearing
joint.
rrectness of i
Install both pins without collar for guide rail and tighten to
10 Nm. Fit guide rail on studs.
l purpos
Turn intermediate shaft with flattened side upwards.
nform
ercia
Insert timing chain into guide rail and place on crankshaft.

m
a
com
tion in
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te o
thi
s
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rp
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en
Insert large chain sprocket into timing chain so that lug on
ng
t.
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chain sprocket aligns with lug behind on cylinder block -B-. t. Cop py
rig
gh ht
Fit chain sprocket onto intermediate shaft. pyri by
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by
cted agen
When installing, ensure that timing chain runs completely straight Prote AG.
in guide rail from crankshaft to intermediate shaft.
Ground tooth of drive chain sprocket -arrow A- must align with
bearing joint.
Lug on chain sprocket of intermediate shaft must align with lug
behind -arrow B-.
If large chain sprocket cannot be fitted, turn intermediate shaft
slightly.
Note
If timing chain has already been used, note marking for direction
of rotation page 18 .
Fit small chain sprocket of intermediate shaft. Installation is

only possible in one position.
Tighten bolt -arrow- hand-tight only as small chain sprocket
has to be taken off again.
Now install chain tensioner.
1. Cylinder head 63
Golf 2004
To do this, release locking teeth of chain tensioner -A- with a

small screwdriver and press tensioning plate against chain
tensioner.
Install chain tensioner in this position and tighten to 8 Nm

-arrows-.
Installing timing chain for camshaft drive: AG. Volkswagen AG d
agen oes
lksw not
Prerequisites d byV
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ility
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wit
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ole,
spec
The camshaft adjusters are installed.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
r
Insert camshaft bar -T10068 A- in both shaft grooves.

p
cum
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fo
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Cop py
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by lksw
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Prote AG.

Golf 2004
Remove small chain sprocket on intermediate AGshaft.

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AG do
chain sprocket must not be pulled off.swagen es n
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Route chain between tensioning
ris bar and guide rail in direction
ed nte
of valve timing housing. utho eo
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ss
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un
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erm
ab
ility
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is n
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ole,
spec
t to the co
Fit timing chain onto camshaft adjuster so that the 2 individual
copper coloured chain links -C- align with the markings on the
camshaft adjuster. It might be necessary to turn the inlet cam
rrectne
shaft adjuster slightly.
s
Fit small chain sprocket of intermediate shaft into timing chain.
s o
Marking -B- must align with middle copper coloured chain link
cial p
f in
-A-.
form
mer
Fit small chain sprocket with timing chain attached onto inter
atio
m
mediate shaft. Installation is only possible in one position.

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Lock vibration damper using counterhold -T10069- .
Tighten new securing bolt for intermediate shaft chain sprock

et -arrow- to 60 Nm + 90 (1/4 turn) further. Turning further can
be done in several stages.
Check position of crankshaft to intermediate shaft once again.
1. Cylinder head 65
Golf 2004
Ground tooth of drive chain sprocket -arrow B- must align with

bearing joint.
Lug on chain sprocket of intermediate shaft must align with lug
behind -arrow C-.
Check position of copper coloured chain links to adjustment

markings.
Note
The copper coloured chain links no longer align with the adjust
ment markings once the crankshaft has been turned.
AG. Volkswagen AG d
agen oes
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un
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ility
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wit
is n
h re
ole,
spec
Apply sealant -D 176 501 A1- onto clean sealing surface of

sealing flange as shown.

t to the co
Note
rrectne
Observe dowel pins in cylinder block.

ss o
cial p
f in
Immediately install sealing flange.

form
mer
atio
Insert all securing bolts by hand and tighten to 10 Nm.

om
n
c
Now install oil seal for crankshaft in sealing flange

or
n thi
e
page 23 .
t
sd
iva
o
pr
Now install sump page 92 .

um
r
fo
en
ng
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If seals in cover are to be renewed page 54 .
Co
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Golf 2004
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mer
atio
First insert all securing bolts -arrows- and tighten lightly.
om
n
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or
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Tighten M8 securing bolts Item 8 (page 53) to 23 Nm. Tight
thi
te
en M6 securing bolts Item 2 (page 53) to 8 Nm.
sd
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Install chain tensioner for camshaft timing chain and tighten to

fo
en
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50 2 Nm.
t.
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Cop py
.
Turn crankshaft two full turns in direction of engine rotation
ht rig
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and check valve timing again page 54 . copy Vo
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Note
The copper coloured chain links no longer align with the adjust
ment markings once the crankshaft has been turned.
1.7 Removing and installing cylinder head

cover
Spring-type clip pliers -VAS 6340-
1. Cylinder head 67
Golf 2004
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Removing
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Note
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spec
Before carrying out further work, disconnect battery earth strap.
es, in part or in w
t to the co
Check whether a coded radio is fitted. Obtain anti-theft coding first
if necessary.
rrectness of i
With the ignition switched off, disconnect battery earth strap.
l purpos
All cable ties which are opened or cut open when engine is
removed must be replaced in the same position when engine
is installed.
nform
ercia

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com
tion in
Unbolt line guide Item 1 (page 53) .
r
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Unbolt fuel line bracket Item 2 (page 42) . do

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Remove cylinder head cover.

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Installing C py
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Installation is carried out in the reverse order. When installing,
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note the following: Prote
cted AG.
agen
First tighten all securing bolts by hand and then to the prescri
bed specified torque diagonally.
Install intake manifold page 170 .
Note
Renew cylinder head cover or gasket if damaged or leaking.

Bolt intake manifold first to cylinder head. Then tighten the two
bolts for heat shield and the bolts for intake manifold support.
Ensure the fuel hose is fitted securely in the brackets.
Specified torques
Threaded connection Specified torque
Cylinder head cover to cylinder head 10 Nm
Intake manifold to cylinder head 15 Nm
Intake manifold to support 20 Nm
Heat shield to exhaust manifold 23 Nm
Dipstick guide tube to intake manifold 5 Nm

Golf 2004
1.8 Checking compression

equipment required
Spark plug socket and ex
tension -3122 B-
Puller -T10095 A-
1331-
Compression tester -V.A.G
1763-
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Test prerequisites
Engine oil temperature at least 30 C. rrectness of i
The battery voltage must be at least 11.5 V.

l purpos
Test procedure
Place assembly tool -T10118- on locking button -arrow- re
nf
ercia
lease connector locking mechanism and carefully pull con

rm
m
nectors downwards and off ignition coils 16.

atio
om
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1. Cylinder head 69
Golf 2004
Push puller -T10095 A- on from flat side of connector in

-direction of arrow- and pull out ignition coil with output stage.
Remove fuse SC 27 from fuse holder Current flow diagrams,
Electrical fault finding and Fitting locations
Removing fuse SC 27 interrupts the voltage supply to the fuel
pump relay.
The spark plugs are removed using spark plug socket and ex
tension -3122 B- .
Check compression using compression tester -V.A.G 1763- .
Note
Using compression tester Operating instructions.
Operate starter until tester shows no further pressure in

crease.
Compression pressures:
Engine code New Wear limit Difference be
bar bar tween cylin
ders
bar
CBRA 10.0 13.0 7.5 max. 3.0
Then reinstall spark plugs and ignition coils with output stage
again page 208 .
After the test has been completed:
Carry out vehicle system test Vehicle diagnosis, testing and
information system VAS 5051 Guided fault finding.
Finish the vehicle system test so that any fault entries stored en AG. Volkswagen AG
during assembly can be deleted automatically. olks
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Generate the readiness code in combination with raiseroad
d
test. nte
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Observe applicable safety precautions during road
ss test.
a ra
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Carry out road test.

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Then carry out the vehicle system test again and correct any
erm
ab
faults that have been created.

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at
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ion
c
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ate
do
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for
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Golf 2004
2 Valve gear ksw

agen
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Assembly overview page 71 ed b ara
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Removing and installing camshafts page
aut 73 . ra
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Removing and installing camshaft control valves page 80 .
ce
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nl
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Renewing valve stem seals page 83 .
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Checking valve guides page 86 .
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Reworking valve seats page 87 .
h re
hole
spec
2.1 Assembly overview
es, in part or in w
t to the co
1 - 5 Nm + 1/8 turn (45) further
rrectness of i
2 - Exhaust camshaft bearing
l purpos
cap
Installation sequence
nform
ercia
page 73
m
3 - Seal
at
om
ion
Renew if leaking.
c
in t
or
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When installing valve

at
do
riv
timing housing, lightly

p
cum
or
lubricate contact surfa

f
en
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ces of seal.
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When replacing seals,
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rig
do not spread too wide py by
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by lksw
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4 - Exhaust camshaft
Checking radial clear
ance with Plastigage;
wear limit: 0.1 mm.
Runout: max. 0.04 mm.
Checking axial clear
ance page 85 .
Identification and valve
timing page 86
page 73 .
Lightly lubricate contact
surfaces of oil seals be
fore installing.
bling page 73 .
Before installing valve
timing housing, check
strainer for soiling page 73 .
6 - Camshaft timing chain
Before removing, mark direction of rotation (installation position) page 18 .
Only rotate engine when camshaft adjuster is installed and chain is fitted
2. Valve gear 71
Golf 2004
8 - 60 Nm + 1/4 turn (90) further
Renew.
Contact surface of sender wheel must be dry around bolt head when installed.
Identification: 24E
Only rotate engine when camshaft adjuster is installed and chain is fitted
Installing page 62 . . Volkswag AG en AG
agen does
10 - Cylinder head height Vol
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Minimum height: a = 139.9
or
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11 - Valves ss
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Do not rework, only lapping-in is permitted.

nl
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Valve dimensions page 86 .
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12 - Cylinder head
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Check for distortion page 44 .
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hole
spec
Reworking valve seats page 87 .
es, in part or in w
t to the co
After renewing, renew entire coolant.
13 - Support element
rrectness of i
Before installing, check camshaft axial clearance page 85 .
l purpos
Do not interchange.
With hydraulic valve clearance compensation.
nform
ercia
14 - Valve stem seal

m
at
Renewing page 83 .
om
ion
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15 - Securing clip
o
his
ate
Check for secure seating.

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for
16 - Roller rocker finger

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Before installing, check camshaft axial clearance page 85 . C py
t. rig
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Do not interchange. yri
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Check roller bearing for ease of movement. cted agen
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Oil contact surfaces.
When installing, secure to supporting element using securing clip.
17 - Valve spring
18 - Valve spring plate
19 - Valve cotters
20 - Inlet camshaft bearing cap
Installation sequence page 73
21 - Inlet camshaft
Checking radial clearance with Plastigage; wear limit: 0.1 mm.
Runout: max. 0.04 mm.
Checking axial clearance page 85 .
Identification and valve timing page 86

Golf 2004
Dismantling and assembling valve timing housing

1 - Guide rail: clipped into valve timing housing
n AG. Volkswagen A
3 - Inlet camshaft control
olks
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4 - Exhaust
ris camshaft control valve 1 -N318-
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5 - 8ssNm
au (insert with locking fluid -D 000 600 A2- ). ra
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ility
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Checking valve timing housing strainer for soiling.
h re
hole
spec
Unclip strainer -2- from back of valve timing housing -1- and
es, in part or in w
remove any dirt.
t to the co
rrectness of i
l purpos
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2.2 Removing and installing camshafts

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Removing page 74 .
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Installing page 77 . t. Cop py
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(With cylinder head installed) yri
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2. Valve gear 73
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Golf 2004 tho tee
or
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a ac
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equipment required
erm
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1331-
spec
es, in part or in w
t to the co
1332-
Sealant -D 176 501-
rrectness of i
Lubrication paste -G 052
723 A2- l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
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t.
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Cop py
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2.2.1 Removing
Caution

tions:
sitions.
First check whether a coded radio is fitted. If so, obtain anti-

theft coding.
Electrical system; Rep. Gr. 27 ; Disconnecting and reconnecting
battery .

Golf 2004
is installed.
-arrow-.
Now remove thermostat housing page 107 .
Set crankshaft to TDC No. 1 cylinder marks -arrow- by turning

crankshaft on the vibration damper securing bolt in direction
of engine rotation.
Remove chain tensioner for camshaft timing chain -arrow-.

AG. Volkswagen AG d
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Disconnect connectors from the following components
olks
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Inlet camshaft control valve 1 -N205-auth ra
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Exhaust camshaft control valve 1 -N318-
ce
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Hall sender -G40-

itte
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Hall sender 2 -G163-

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Note
spec
es, in part or in w
t to the co

rrectness of i
Move wiring harness clear.

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nform
mercia
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tion in
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Cop py
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2. Valve gear 75
Golf 2004
Now unscrew camshaft cover -arrows-.

First remove exhaust camshaft adjuster.
AG. Volkswagen AG d
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Note
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Only counterhold at camshaft with 32 mm open-end spanner
spec
-arrow-. The camshaft bar -T10068 A- must not be fitted when
es, in part or in w
t to the co
camshaft adjuster is loosened or tightened.
Now remove camshaft adjuster together with camshaft timing
rrectness of i
chain from inlet camshaft.
l purpos
Lay camshaft timing chain aside.
nform
mercia
Unbolt control housing from cylinder head -arrows-.
a
com
tion in
Pull valve timing housing carefully off camshaft seals.
r
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fo
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t.
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Cop py
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rig ht
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A - inlet camshaft
First remove bearing caps 1 and 13.
Remove bearing caps 3 and 11.
Remove bearing cap 7.
Loosen bearing caps 5 and 9 alternately and diagonally.

Golf 2004
B - exhaust camshaft
First remove bearing caps 2 and 14.
Remove bearing caps 4 and 12.
Remove bearing cap 8.
Loosen bearing caps 6 and 10 alternately and diagonally.
Carefully remove camshafts and lay aside on clean surface.
Remove roller rocker fingers together with support elements
and lay aside on a clean surface.
Ensure that roller rocker fingers and support elements are not
interchanged.
2.2.2 Installing
Lightly coat contact surfacesnof
AGbearing
. Volkswagcaps
en AG 7 and 8 with lubri
cating paste -G 052 723
olks
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age before installing. does
no
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Prerequisites rised ran
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When scamshafts
s au
are installed, cams for No. 1 cylinder must ac
point upwards.
ce
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Install supporting elements in cylinder head and fit respective
d
itte
roller rocker finger onto respective valve stem end or support y li

erm
ing element. ab
ility
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spec
Ensure that all roller rocker fingers -1- seat properly on valve
stem ends and are clipped into their respective support ele
t to the co
ments -2-.
Oil cams and running surfaces of camshafts.
rrectne
Carefully place each camshaft in its respective bearing in the

cylinder head. When doing this, observe camshaft identifica
ss
tion page 86 .
o
cial p
f inform
mer
atio
om
n
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Observe fitting position of bearing caps:
ht
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Points of bearing caps -arrow A- of inlet and outlet camshafts
cted agen
Prote AG.
face outwards.
Identification on bearing caps is right side up when viewed
from inlet side.
2. Valve gear 77
AG. Volkswagen AG d
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Golf 2004 d byV gu
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A - inlet camshaft
ce
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un
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an
Tighten bearing caps 5 and 9 alternately and diagonally to
d
itte
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5 Nm + 1/8 turn (45).
rm
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Install bearing caps 1 and 13 and tighten to 5 Nm + 1/8 turn
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(45).
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Install bearing cap 7 and tighten to 5 Nm and turn 1/8 (45)
es, in part or in w
further.
t to the co
Install bearing caps 3 and 11 and also tighten to 5 Nm + 1/8
turn (45).
rrectness of i
l purpos
B - exhaust camshaft
nform
ercia
Tighten bearing caps 6 and 10 alternately and diagonally to

5 Nm + 1/8 turn (45).
m
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tion in
Install bearing caps 2 and 14 and tighten to 5 Nm + 1/8 turn
r
te o
(45).
thi
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Install bearing cap 8 and tighten to 5 Nm and turn 1/8 (45)

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Install bearing caps 4 and 12 and also tighten to 5 Nm + 1/8 C py
ht. rig
turn (45). rig ht
py by
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cted agen
Prote AG.
Place camshafts carefully into cylinder head camshaft bear

ings; cylinder 1 cams -A- must point towards each other.
The camshaft bar -T10068 A- must engage in grooves in both

shafts.
Before installing, check valve timing housing strainer for soil
ing page 73 .
Before installing control housing, lightly lubricate control hous
ing surfaces contacting camshaft seals.
Lightly lubricate camshaft seals and slowly push control hous
ing over camshaft seals.

Golf 2004
Install timing housing and insert securing bolts -arrows- with

locking fluid -D 000 600 A2- and tighten to specified torque of
8 Nm.
Installing camshaft adjuster with timing chain for camshaft
drive page 57 .

-arrows-.
olkswagen AG
en AG. V
Fill 3 mm holes in cylinder kswhead gasket with sealant
ag does
-D
no 176
Vol t
501 A1- . Coat sealing
ed b surface of cover with sealant -Dgu176
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501 A1- and immediately
ho
ris install cover. nte
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au ac
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t to the co
Then tighten M8 securing bolts Item 8 (page 53) to 23 Nm

and M6 securing bolts Item 2 (page 53) to 8 Nm.
rrectness of i
Install chain tensioner for camshaft timing chain

Item 15 (page 42) and tighten to 50 2 Nm.
l purpos
Install cylinder head cover page 67 and intake manifold

nform
ercia
page 170 .
m
at
om
ion
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or
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ate
do
priv
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for
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2. Valve gear 79
Golf 2004
2.3 Removing and installing camshaft control valves

equipment required
1783-
Torx bit set -V.A.G 1766-
1/4" drive ratchet -VAS
6234-
Special wrench, long reach
-T10072-
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-arrow-.
hole
spec

es, in part or in w
t to the co

Remove cylinder head cover page 67 .
rrectness of i
l purpos
Note
nform
ercia

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tion in
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Cop py
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cted
Rep. Gr.15 - Cylinder head, valve gear
agen
Prote AG.
Golf 2004
Pull connectors off Hall sender -G40- -1- and Hall sender 2 -
G163- -2-.
Pull off connectors -3- and -4-.
Move wiring harness clear.
AG. Volkswagen AG d
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olksw not
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Remove schain
sa tensioner for camshaft timing chain -arrow-. r ac
ce
le
un
pt
an
d
itte
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rm
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ility
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es, in part or in w
t to the co
rrectness of i
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Unscrew securing bolts -arrows- for cover.

When all securing bolts have been removed, cover can be
nform
ercia
carefully levered off.

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tion in
Caution
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do
The securing bolts of the camshaft control valves should

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not be unscrewed completely, so that when the valve is

fo
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pulled out it is not canted.

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Cop py
Cover lower chain housing carefully so that no parts can
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2. Valve gear 81
Golf 2004
Unscrew securing bolts for camshaft control valves approx.

3 mm (5 turns) with socket -T10072- -arrows-.
Pull camshaft control valve out of seat in control housing and
slide it along loosened bolts.
Completely remove securing bolts and pull camshaft control
valve out of control housing.
Installing:
Caution
The valve seat in the control housing must not be scored

or scratched.
The camshaft control valves and the control housing must
be free of dirt and soiling.
Ensure the camshaft control valves are protected from
knocks and impacts.
Only unpack the new camshaft control valves immediately
prior to installation.
The camshaft control valves must not be pulled into their
seat with the securing bolts. Only insertion by hand is per
mitted.
Moisten seals with clean engine oil.

Carefully insert camshaft control valve into housing and push
vertically to valve axis to stop by hand.
Tighten securing bolts -arrows- to 3.8 Nm.

AG. Volkswagen AG d
agen
-1- Camshaft control valve 1 -N205- . olksw
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-2- Exhaust camshaft control valve 1 -N318- . orise nte
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Clean sealing surface on cover and cylinder
ss a
head. c
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erm
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ility
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es, in part or in w
t to the co
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nf
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or c
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Golf 2004

-arrows-.

Then tighten M8 securing bolts Item 8 (page 53) to 23 Nm
and M6 securing bolts Item 2 (page 53) to 8 Nm.
Install chain tensioner for camshaft timing chain
Item 15 (page 42) and tighten to 50 2 Nm.
Install cylinder head cover page 67 and intake manifold
page 170 .
quence. swa
gen AG
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does
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2.4 Valve stem oil seals ss c
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Removing page 84 .
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es, in part or in w
t to the co
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2. Valve gear 83
Golf 2004

equipment required
Valve lever -VW 541/1 A-
with thrust piece for VW
541 / 1 A and 2037 -VW
541/6-
Valve assembly device
-2036- with adapter plates
-2036/1-
Spark plug socket and ex AG. Volkswagen AG d
tension -3122 B- agen oes
olksw not
V gu
d by ara
Valve stem seal puller orise nte
-3364- aut
h eo
ra
ss c
Valve stem seal fitting tool
ce
le
un
pt
-3365-
an
d
itte
y li
Adapter -T40012- and
rm
ab
pe
ility
adapter -T40012/1-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Torque wrench -V.A.G 1331- op Vo
by c lksw
cted agen
Prote AG.
2.4.1 Removing
Remove camshafts page 73 .
Remove roller rocker fingers together with support elements
and lay aside on a clean surface.
Remove spark plugs using spark plug socket and extension
-3122 B- .
Set piston of respective cylinder to bottom dead centre.

Golf 2004
Set up valve assembly device -2036- with adapter plates

-2036/1- and adjust mounting.
Screw adapter -T40012- or adapter -T40012/1- in spark plug
thread.
Connect to compressed air line with a commercial adapter and
apply a constant pressure of at least 6 bar.
Remove valve springs using valve lever -VW 541/1 A- and
thrust piece for VW 541 / 1 A and 2037 -VW 541/6- .
Note
Tight cotters can be loosened by tapping lightly on lever.
Pull off valve stem seals using valve stem seal puller -3364- .
2.4.2 Installing
To prevent damage to new valve stem seals, place plastic
sleeve -A- on valve stem. olkswage es n
o V t gu
by ara
Lubricate sealing lip of valve stemrseal
ise -B-, place it in the valve
d
nte
stem oil seal fitting tool -3365- uand
tho push carefully onto valve eo
ra
guide. ss
a c
ce
le
un
Install camshafts page 73 .
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
Camshafts, checking axial clearance

atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Universal dial gauge bracket -VW 387-
Dial gauge
Test procedure
Perform measurements with support elements and roller rocker
fingers removed.
Middle bearing cap of respective camshaft installed.
2. Valve gear 85
Golf 2004
Wear limit: max. 0.40 mm

Camshaft identification, valve timing
Camshaft identification
Identification between cam pair for cylinders 4 and 5 of respective
camshaft.
Camshaft Identification
A - exhaust camshaft 022
101 Index
B - inlet camshaft 022
102 Index
Valve timing at 1 mm valve lift
lkswage es n
y V Inlet valve Exhaust valve
o ot g
d b ua
ran
ir se tee
Opens BTDC uth o --- 211.5 or
a ac
Closes BTDCss
--- 6.5
ce
le
un
Opens ATDC 18.50 ---
pt
an
d
itte
y li
Closes ATDC 223.5 ---
rm
ab
pe
ility
ot
wit
, is n
Valve dimensions
h re
hole
spec
es, in part or in w
Note t to the co
Valves must not be reworked. Only lapping-in is permitted.

rrectness of i
Valve dimensions for inlet valves

l purpos
Dimension short long

inlet valve inlet valve
nform
ercia
a mm 33.20 33.20
m
a
com
tio
b mm 5.98 5.98
n in
r
te o
thi
c mm 102.46 136.36
s
iva
do
r
44 40' 4440'
rp
cum
fo
en
ng
t.
yi
Valve dimensions for exhaust valves
Co
Cop py
t. rig
gh ht
Dimension yri
short long
p by
o Vo
exhaust valve exhaust valve
c by lksw
cted agen
Prote AG.
a mm 30.20 30.20
b mm 5.97 5.97
c mm 102.20 136.20
44 40' 44 40'
2.5 Checking valve guides


Golf 2004
Universal dial gauge bracket -VW 387-
AG. Volkswagen AG d
Dial gauge agen oes
olksw not
byV gu
ara
d
Test procedure orise nte
h eo
ut ra
Insert new valve into guide. The end of the
ss a valve stem must c
be flush with the guide. On account of differing stem diame
ce
e
nl
pt
ters, only use inlet valve in inlet guide and exhaust valve in
du
an
itte
exhaust guide.
y li
erm
ab
ility
Determine rock.
ot p
wit
, is n
Wear limit: 0.8 mm.
h re
hole
spec
If rock tolerance is exceeded:
es, in part or in w
t to the co
Renew cylinder head.
rrectness of i
l purpos
2.6 Reworking valve seats
nf
ercia
orm
m
Depth gauge
atio
om
n in
c
Valve seat refacing tool

or
thi
te
sd
a
Procedure
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
Note C py
ht. rig
rig ht
py by
When repairing engines with leaking valves, it is not sufficient
co Vo
by lksw
cted agen
to rework or renew valve seats and valves. Particularly on high Prote AG.
mileage engines, it is necessary also to check valve guides for
wear page 86 .
Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking di
mensions. If the reworking dimension is exceeded, the hy
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
Remove camshafts page 73 .

The max. permissible reworking dimension is calculated as fol
lows:
Insert valve and press firmly against seat.
2. Valve gear 87
Golf 2004
Note
If the valve is to be renewed as part of a repair, use a new valve

for the calculation.
Measure distance -a- between end of valve stem and upper

edge of cylinder head.
Calculate maximum permissible reworking dimension from
measured distance -a- andagminimum
en AG. V dimension.
olkswagen AG
d w oes
olks not
Minimum dimension: d by V gu
ara
ise nte
or eo
Short inlet valveau
th mm 31.8 ra
ss c
Long inlet valve mm 10.2
ce
le
un
pt
Short exhaust valve mm 31.8
an
d
itte
y li
rm
Long exhaust valve mm 10.2
ab
pe
ility
ot
wit
Measured distance -a- minus minimum dimension = maximum
, is n
h re
permissible reworking dimension.
hole
spec
Example:
es, in part or in w
t to the co
Measured distance 10.6 mm
Minimum dimension 10.2 mm
rrectness of i
= Max. permissible reworking dimension 0.4 mm
l purpos
Reworking inlet valve seat

nform
ercia
a - = 32.8 mm
m
a
com
b - = max. permissible reworking dimension

ion in
r
te o
c - = 0.91.5 mm
thi
s
iva
do
d - = max. 38.0 mm
r
rp
cum
fo
en
g
r2 - = radius 2.0 mm
n
t.
yi Co
Cop py
Z - = bottom surface of cylinder head
t. rig
gh ht
pyri by
Vo
o
- 45 valve seat angle
by c lksw
cted agen
Prote AG.
- 30 upper correction angle
- 60 lower correction angle
Reworking exhaust valve seat

a - = 29.8 mm
b - = max. permissible reworking dimension
c - = 1.21.7 mm
d - = max. 35.0 mm
r2 - = radius 2.0 mm
Z - = bottom surface of cylinder head
- 45 valve seat angle
- 30 upper correction angle
- 60 lower correction angle

Golf 2004
17 Lubrication
1 Parts of lubrication system
Note
The oil level must not be above the max. mark - danger of
damage to catalytic converter!
Finding metal shavings or a large quantity of small metal par
ticles during engine repair could indicate athat
gen Athe
G. Vcrankshaft
olkswagen AG
does
bearings or conrod bearings are damaged. olksw To prevent this not
y V gu
from causing further damage, rperform
ise
d b
the following repairs: ara
nt ee
tho or
Thoroughly clean oil channels.
sa
u ac
s
ce
le
Renew oil non-return valve.

un
pt
an
d
itte
Renew oil spray jets.
y li
rm
ab
pe
ility
Renew oil cooler.
ot
wit
, is n
Renew oil filter.
h re
hole
spec
es, in part or in w
Engine oil page 89 .
t to the co
Assembly overview - sump page 90 .
Removing and installing sump page 92 .
rrectness of i
Assembly overview - oil filter bracket page 95 .
l purpos
Removing and installing oil filter bracket page 96 .
nform
ercia
Assembly overview - oil pump page 97 .

m
a
com
Checking oil pressure and oil pressure switch page 99 . tion in

r
te o
1.1 Engine oil

thi
s
iva
do
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rp
Oil capacities
um
fo
en
ng
t.
yi
Without oil filter: 5.0 l
Co
Cop py
t. rig
With oil filter 5.5 l
gh ht
pyri by
Vo
co lksw
by
Engine oil specifications cted agen
Prote AG.
Maintenance ; Booklet 38 ; Service tables .

Markings on oil dipstick
1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched field: engine oil can be topped-up.
c - Area from min. mark up to hatched field: Must be topped up,
max. 0.5 l of engine oil!
1. Parts of lubrication system 89

Golf 2004
1.2 Assembly overview - sump
1 - 5 Nm
Secured to intake mani
fold.
2 - Oil dipstick
The oil level must not be
above the max. mark!
Markings page 89 .
3 - Guide tube
For oil dipstick. agen
AG. Volkswagen AG d
oes
o lksw not
Secured with boltd bto
y Vin gu
ara
take manifold.orise nte
e
h
ut or
4 - Cylinder block
ss
a ac
ce
le

un
pt
an
sealing flange and dual-
d
itte
y li
mass flywheel
rm
ab
pe
page 22 .
ility
ot
wit
, is n
h re
crankshaft page 30 .
hole
spec
es, in part or in w

t to the co
rods page 36 .
5 - Oil non-return valve rrectness of i

l purpos
page 92 .
tion.
nform
ercia
Clean if badly soiled

m
a
com
tio
6 - 8 Nm
n in
r
te o
thi
7 - Oil pump drive cover

s
iva
do
r
rp
cum
8 - O-ring
fo
en
ng
t.
yi
Renew.
Co
Cop py
.
ht rig
rig ht
py by
co Vo
9 - Oil pump drive
by lksw
cted agen
Prote AG.
11 - Oil spray jet
For crankshaft bearings 27
For piston cooling.
Opening pressure: 2.0 bar
See note page 89 .
12 - Drive shaft
For oil pump drive.
13 - Oil pump
Assembly overview - oil pump page 97
14 - 8 Nm
Insert with locking fluid -D 000 600 A2- .
90 Rep. Gr.17 - Lubrication

Golf 2004
15 - 23 Nm
AG. Volkswagen AG d
Renew if seal is attached agen oes
olksw not
V gu
by ara
17 - Oil sump rised
nte
ho eo
Removing and installing page 92 . aut ra
c
ss
18 - Oil level and oil temperature sender -G266-
ce
le
un
pt
an
d
itte
19 - 12 Nm
y li
rm
ab
pe
20 - 23 Nm
ility
ot
wit
, is n
h re
hole
Assembly overview - oil filter bracket page 95
spec
es, in part or in w
t to the co
22 - Seal
Renew.
rrectness of i
l purpos
23 - 10 Nm
Insert with locking fluid -D 000 600 A2- .
nform
ercia
24 - Baffle plate
m
a
com
tion in
25 - 8 Nm
r
te o
thi
Renew.
s
iva
do
r
rp
c
26 - Seal
um
fo
en
ng
t.
Renew if damaged.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
Removing and installing oil spray jet
cted agen
Prote AG.

4 mm drift
6 mm drift
Note
Oil spray jets are installed in main crankshaft bearings 27.
Removing
Press oil spray jet out towards bearing using a 4 mm drift.

Golf 2004
Installing
To install, press oil spray jet in by hand using a 6 mm drift
-arrow-.
Removing and installing oil non-return valve
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Bolt -M8 x 1,5-
wit
, is n
h re
Removing
hole
spec
Screw commercially available M8 x 1.5 bolt about 4 full turns
es, in part or in w
into valve -arrow- and pull it out of bore.
t to the co
Installing
rrectness of i
Before installing, moisten O-ring with oil. Press valve into oil
channel by hand.
l purpos
1.3 Removing and installing oil sump
nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Bit XZN 8 -T40159-
Not illustrated:
Used oil collection and extraction unit -V.A.G 1782-

Silicone sealant -D 176 501 A1-

Golf 2004
Hand drill with plastic brush attachment

Flat scraper
Eye protection
Removing
Pull 3-pin connector off oil level and oil temperature sender -
G266- (if fitted).
Unbolt secondary air pump motor -V101- retainer from sump.
Drain engine oil.
Note
Follow disposal regulations for engine oil!

On vehicles with DSG gearbox the flywheel has an indenta
tion -A- to fit the sump bolts. Turn flywheel so that the bolt head
is accessible.
Remove sump bolts on the gearbox side -arrows- using bit

XZN 8 -T40159- .
Remove remaining sump bolts and remove sump.
Loosen sump with light blows of a rubber headed hammer if
necessary.
Remove sealant residue from cylinder block with a flat scraper.
Remove sealant residue on sump with a rotating brush, e.g. a

hand drill with a plastic brush attachment (wear protective
glasses). AG. Volkswagen gen AG do
swa es n
Clean sealing surfaces; they must be free of oil
by
and
Volk grease. ot g
ua
ed ran
Installing ris tee
tho or
au ac
ss
ce
le
un
Note
pt
an
d
itte
y li
erm
ab
Observe expiry date of sealing compound.

ility
ot p
wit
The sump must be installed within 5 minutes of applying sili

is n
h re
cone sealing compound.

ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004
Cut off tube nozzle at forward marking (approx. 3 mm nozzle

).
Apply sealant -D 176 501 A1- , as shown, to clean sump seal
ing surface. Sealant bead must be:
23 mm thick.
Run bead along inner side of bolt holes -arrows-.
Note
The sealant bead must not be thicker, otherwise excessive

sealant enters the sump andwamay
gen Ablock
G. Volksthe
wagoil
en Asuction
G do
es n
pipe
strainer. y Volks ot g
u b ara
ed
Let sealing compound
tho
ris dry for approx. 30 minutes after instal
nte
e
ling oil sump. Only
sa
u then fill with engine oil. or
ac
s
ce
le
un
pt
an
d
Apply sealant -D 176 501 A1- as shown in figure to clean seal

itte
y li
ing surface of sump.
rm
ab
pe
ility
ot
Install sump immediately and tighten all sump bolts lightly.
wit
, is n
h re
Tighten bolts between sump and gearbox by hand so that
hole
spec
sump rests on gearbox.
es, in part or in w
t to the co
Note
rrectness of i
If gearbox is removed, sump must align smoothly with cylinder
l purpos
block.
nform
ercia
Tighten oil sump bolts to 12 Nm.

m
Tighten bolts securing sump to gearbox to 45 Nm.

a
com
tion in

r
te o
thi
quence.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004
1.4 Assembly overview - oil filter bracket agen

AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
ise nte
1 - Plug, 15 Nm thor eo
au ra
If seal is leaking, nip ss c
open and renew.
ce
e
nl
pt
du
an
itte
2 - Oil pressure switch -F1- , 20
y li
erm
ab
Nm
ility
ot p
0.9 bar switch
wit
, is n
h re
If seal is leaking, nip
hole
open and renew.
spec
es, in part or in w
Checking page 99 .
t to the co
With non-return valve.
rrectness of i
Opening pressure: 0.05
l purpos
bar
4 - O-ring
nf
ercia
o
Renew.
rm
m
atio
om
n in
or c
5 - Oil cooler
thi
te
sd
iva
Ensure clearance to ad
o
r
rp
cu
jacent components.
o
m
f
en
ng
t.
See note page 89 .
yi Co
Cop py
Coolant hose schematic
t. rig
gh ht
yri
diagram page 109 .
p by
co Vo
by lksw
cted agen
6 - Seal
Prote AG.
Renew.
7 - Oil cooler cover, 25 Nm
8 - Oil cooler seal
Renew.
tion page 96 .
Insert into lugs on oil cooler
9 - 23 Nm
10 - Oil filter element
Observe change intervals.
See note page 89 .
11 - Screw cap, 25 Nm

Golf 2004
Installation position of oil cooler seal

Insert seal moistened with oil into oil cooler as illustrated.
When doing this note installation position.
1.5 Removing and installing oil filter bracket

Hose clamps up to 25 mm -3094- wage
es n
olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Removing yri
p by
co Vo
by lksw
cted agen
Prote AG.
WARNING
Steam or hot coolant may escape when expansion tank is

opened. Cover cap with cloth and open carefully.
Open cap for coolant expansion tank.

Remove secondary air pump motor -V101- page 204 .

Golf 2004
Detach coolant hoses -2- and -3- using hose clips -3094- .
Disconnect electrical connector -1- at oil pressure switch using
assembly tool -T10118- .
Detach coolant hoses -2- and -3- on oil filter bracket.
Unscrew bolts -arrows- and remove oil filter bracket.
Installing
Note
Renew seals. swage

es n
olk ot g
byV ua
d ran
Fill with coolant page 110 . o
ir se tee
th or
u
Specified torque ss
a ac
ce
le
un
pt
Component Nm
an
d
itte
y li
Oil filter bracket to cylinder block 23
erm
ab
ility
ot p
wit
is n
1.6 Assembly overview - oil pump
h re
ole,
spec
t to the co
Note
When installing the oil pump, note the following: first tighten all
rrectne
securing bolts by hand. Then tighten oil pressure pipe
Item 7 (page 98) to cylinder block and then to oil pump
s
Item 3 (page 98) . Finally tighten oil pump with securing bolts
s o
cial p
Item 4 (page 98) .
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
1 - Shim
2 - Drive shaft
For oil pump drive.
3 - Oil pump housing
4 - 23 Nm
5 - Oil pump cover with pres
sure relief valve
Opening pressure:
5.35.7 bar.
Clean strainer if soiled.
6 - Gears
Checking backlash
page 98 .
Checking axial clear
ance page 99 .
7 - Oil pressure pipe n AG. Volkswagen AG do
wage es n
On oil pump housing yV
olks ot g
ua
coat with AMV 188 001 ir se
d b ran
02 utho tee
or
a ac
Secure only with new ss
microencapsulated
ce
e
nl
pt
du
bolts
an
itte
y li
erm
ab
8 - 8 Nm
ility
ot p
Renew.
wit
, is n
h re
9 - Seal
hole
spec
Renew if damaged.
es, in part or in w
t to the co
10 - 8 Nm
rrectness of i
l purpos
nform
ercia
Checking oil pump backlash

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Feeler gauges

Golf 2004

Checking oil pump axial clearance
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Straight edge
ot
wit
, is n
Feeler gauges
h re
hole
spec
es, in part or in w
t to the co
1.7 Checking oil pressure and oil pressure
switch
rrectness of i
Checking oil pressure switch page 100 .
l purpos
Checking oil pressure page 101 .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004

equipment required
Oil pressure tester -V.A.G
1342-
Adapter -V.A.G 1342/14-
Voltage tester -V.A.G
1527B-
Auxiliary measuring set -
V.A.G 1594C-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
o
r
Functional check and repair of the optical and acoustic oil pres
rp
cu
o
sure warning Current flow diagrams, Electrical fault finding and

f
en
ng
t.
Fitting locations.
yi Co
Cop py
ht. rig
rig ht
by
Test prerequisites copy Vo
by lksw
cted agen
Prote
Engine oil level OK.
AG.
Engine oil temperature at least 80 C (radiator fan must have

run once)
1.7.1 Checking oil pressure switch

Unscrew sealing plug Item 1 (page 95) from oil filter bracket.
Collect leaking engine oil.
Seal inspection hole for oil pressure switch on oil pressure
tester -V.A.G 1342- using sealing plug for oil filter bracket,
Screw oil pressure tester -V.A.G 1342- into oil filter bracket in
place of plug using adapter -V.A.G 1342/14- .

Golf 2004
Note
Observe installation position of adapter: the conical connecting

piece of adapter must be screwed into pressure hose of tester.
Connect brown wire of tester to earth (-).

Connect voltage tester -V.A.G 1527B- with cables from auxil
iary measuring set -V.A.G 1594C- to battery positive (+) (con
nection in engine compartment -arrow-) and oil pressure
switch.
AG. Volkswagen AG d
LED must not light up. agen oes
olksw not
y V gu
b ara
If the LED lights up: rise d
nte
tho eo
u
Renew oil pressure
ss a switch -F1- Item 2 (page 95) . ra
c
ce
le
If LED does not light up:

un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
Observe tester and LED while starting, as switching point of oil
hole
spec
pressure switch may already be exceeded when starting.
es, in part or in w
t to the co
Start engine and run at idling speed.
At 0.71.1 bar the LED must light up; otherwise renew oil
rrectness of i
pressure switch -F1- Item 2 (page 95) .
l purpos
1.7.2 Checking oil pressure nform

ercia
Procedure
m
a
com
ti
Screw oil pressure tester -V.A.G 1342- with adapter -V.A.G

on in
1342/14- into oil filter bracket in place of sealing plug

r
te o
thi
page 100 .
s
iva
do
r
rp
Check oil pressure at different revolutions:

um
fo
en
ng
t.
yi
1500 rpm: at least 1.7 bar
Co
Cop py
t. rig
gh
2000 rpm: 3.05.5 bar
ht
pyri by
Vo
co lksw
by
Over 2000 rpm: maximum 7.0 bar
cted agen
Prote AG.
If the specifications are not attained:

Check strainer in oil suction pipe for contamination/soiling.
Check pressure pipe between oil pump and cylinder block for
leaks.
Note
Mechanical damage, e.g. to bearings, could also be the cause for

oil pressure being too low.
If no fault can be found despite oil pressure being too low:

Renew oil pump page 97 .
Oil pressure must not exceed 7.0 bar.
If 7.0 bar is exceeded:
Check oil channels.
Pressure relief valve in oil pump may be stuck.

Golf 2004
Renew oil pump page 97n A. G. Volkswagen A

age G do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
19 Cooling
1 Removing and installing parts of cool
ing system
Caution

tions:
sitions.
Ensure that there is sufficient clearance to all moving or
hot components.
WARNING
olkswagen AG
en AG. V
Steam may escape when expansion tank ksw is opened. Wear eye es not
ag do
Vol
protection and protective clothing d b to avoid eye injuries and
y gu
ara
scalding. Cover cap with cloth
ho
riand
se open carefully. nte
e
t or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Removing and installing parts of cooling system 103

Golf 2004
Note
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 6340- or spring-type clip pliers -
VAS 5024A- are recommended for installation of spring-type
clips.
When installing coolant hoses, position them so they are free
of tension and do not come into contact with other compo
nents.
The arrows on the coolant pipes and on the ends of the hoses
must be aligned with each other.
Renew gaskets and seals. AG. Volkswagen AG d
agen oes
o lksw not
yV gu
Test for leaks in cooling system using cooling
ised system tester -
b ara
nte
V.A.G 1274- and adapters -V.A.G 1274/8- hor and -V.A.G 1274/9- . eo
aut ra
s c
Assembly overview - cooling system, s body side page 104 .
ce
e
nl
pt
du
Assembly overview - cooling system, engine side page 106 .
an
itte
y li
erm
ab
Assembly overview - thermostat housing page 107 .
ility
ot p
wit
, is n
h re
hole
Draining and filling with coolant page 110 .
spec
es, in part or in w
Coolant mixture ratios page 110 , draining and filling with cool
t to the co
ant.
Removing and installing fan support with fans page 113 .
rrectness of i
Removing and installing radiator page 115 .
l purpos
Checking continued coolant circulation pump page 116 .

Removing and installing coolant pump page 118 .
nf
ercia
orm
m
Checking cooling system for leaks page 126 .

atio
om
n in
or c
1.1 Assembly overview - parts of cooling

thi
te
sd
iva
system, body side

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
Note ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
104 Rep. Gr.19 - Cooling

Golf 2004
1 - Upper coolant hose

From thermostat hous
ing.
2 - O-ring
Renew if damaged.
3 - Radiator
page 115 .
After renewing, renew
entire coolant. AG. Volkswagen AG d
agen oes
lksw not
4 - Gasket d byV
o gu
ara
ise nte
r
5 - Cap ut
ho eo
ra
a
Pressure relief valve ss c
ce
le
must open at between
un
pt
1.41.6 bar.
an
d
itte
y li
erm
Checking page 126 .
ab
ility
ot p
6 - Connector
wit
is n
h re
ole,
7 - 3 Nm
spec
8 - Expansion tank
t to the co
Checking cooling sys
tem for leaks
page 126 .
rrectne
9 - Bracket
ss
For radiator.
o
cial p
f in
10 - 7 Nm
form
mer
atio
11 - Support
om
n
c
i
12 - 5 Nm
or
n thi
te
sd
va
13 - Fan support
i
o
pr
cum
r
fo
en
ng
t.
fan support with fans page 113 .
yi Co
Cop py
ht. rig
14 - 5 Nm rig ht
py by
co Vo
by lksw
15 - Radiator fan 2 -V177- Prote
cted AG.
agen

16 - Connector
17 - Radiator fan -V7-
With radiator fan control unit -J293-
18 - Lower coolant hose
To thermostat housing.
19 - Retaining clip
20 - Radiator outlet coolant temperature sender -G83-
21 - O-ring
Renew.

Golf 2004
1.2 Assembly overview - cooling system,

engine side
Note

Fitting locations of non-return valves page 109 , coolant
hose schematic diagram
1 - From auxiliary heater

Vehicles with optional
equipment only
2 - To auxiliary heater
equipment only
3 - 45 Nm
4 - From bottom of expansion
tank
5 - 10 Nm
6 - To top of expansion tank
7 - From heater coolant shut-
off valve -N279-
equipment only
8 - 10 Nm
9 - To heater coolant shut-off agen
AG. Volkswagen AG d
oes
valve -N279- Volksw not
gu
by ara
Vehicles with optional rised
nte
o
equipment only aut
h eo
ra
ss c
10 - To heat exchanger
ce
e
nl
pt
du
an
11 - From gearbox oil cooler

itte
y li
erm
ab
12 - To gearbox oil cooler

ility
ot p
wit
, is n
13 - 8 Nm
h re
hole
spec
es, in part or in w
Assembly overview -
t to the co
thermostat housing
page 107
rrectness of i
15 - Bracket
l purpos
16 - O-ring
Renew.
nform
ercia
17 - Radiator outlet coolant temperature sender -G83-

m
at
om
18 - Retaining clip
ion
c
in t
r

o
his
ate
do
riv
19 - From bottom of radiator.

p
cum
for
en
g
20 - To top of radiator
n
t.
yi Co
op py
21 - O-ring
t. C rig
gh ht
yri by
Renew.
op Vo
by c lksw
cted agen
Prote AG.

Golf 2004

With oil cooler
23 - 23 Nm
24 - Coolant pipe
To thermostat housing.
25 - Continued coolant circulation pump -V51-
Bolted to ancillary unit bracket to 8 Nm.
To remove, remove bracket for ancillaries Heating, air conditioning system; Rep. Gr. 87 .
Location of continued coolant circulation pump -V51- page 107
Checking continued coolant circulation pump -V51- page 116
26 - Coolant pump
Check for ease of movement.
Removing and installing page 118 . agen
AG. Volkswagen AG d
oes
olksw not
V
27 - Belt pulley ed by gu
ara
ris nte
For coolant pump. ut
ho eo
ra
a
Removing and installing page 118 , Removing and installing coolant pump ss c
ce
le
un
pt
28 - 20 Nm
an
d
itte
y li
rm
29 - 8 Nm
ab
pe
ility
ot
wit
, is n
h re
hole
Location of continued coolant circulation pump -V51-
spec
es, in part or in w
The continued coolant circulation pump -V51- is secured to an
t to the co
cillary unit bracket -arrow-.
To remove, ancillary bracket must be removed from cylinder
rrectness of i
block.
l purpos
Bolt-tightening sequence for ancillary bracket:

First tighten both fitted bolts -2- and -4- hand tight.
nform
ercia
Then tighten bolts -1-, -3- and -5- by hand

m
a
com
tio
Then tighten all bolts evenly and diagonally.

n in
r
te o
thi
Specified torque: 23 Nm.

s
iva
do
r
rp
cum
fo
1.3 Assembly overview - thermostat hous

en
ng
t.
yi Co
op
ing C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
Note
AG.

Golf 2004
1 - O-ring
Renew.
2 - Retaining clip
Check for secure seat
ing.
page 120 .
4 - 8 Nm
5 - Coolant pipe n AG. Volkswagen AG do
lkswage es n
o ot g
To gearbox oil cooler d byV ua
ran
ir se tee
6 - Bracket autho
or
ac
ss
7 - Thermostat
ce
le
un
pt
an
d
itte
y li
page 123 .
erm
ab
ility
Checking: heat thermo
ot p
wit
stat in water.
is n
h re
ole,
Opening begins at ap
spec
prox. 80 C.
t to the co
Ends at approx. 105 C
Opening lift min. 7 mm
rrectne
8 - Connection
9 - Seal
ss
Renew.
o
cial p
f inform
10 - Coolant temperature
mer
sender -G62-
atio
om
11 - Plug
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
1.4 Coolant hose schematic diagram
1 - Expansion tank
2 - Non-return valve
tion.
Arrow on non-return
valve points in direction
of flow
Integrated in coolant
hose, not visible from
outside
4 - Heat exchanger for heater
unit
If renewed, refill system
with fresh coolant.
5 - Heater coolant shut-off
valve -N279-
Vehicles with optional Volkswa
equipment onlyswa
gen AG
. gen AG
does
k not
Vol gu
6 - Thermostat by
d housing ara
se ri nte
ho eo
7 - Gearbox
au oil cooler
t ra
c
ss
8 - Lower coolant hose
ce
le
un
pt
an
d
itte
9 - Upper coolant hose

y li
erm
ab
10 - Radiator
ility
ot p
wit
is n
11 - Oil cooler
h re
ole,
For engine oil.

spec
t to the co
12 - Continued coolant circula

tion pump -V51-
13 - Cylinder block
rrectne
14 - Coolant pump
ss
15 - Cylinder head
o
cial p
f in
16 - Auxiliary heater
form
mer
Vehicles with optional equipment only

atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
1.5 Draining and filling coolant

equipment required
Refractometer -T10007- AG. Volkswagen AG d
agen oes
olksw not
yV gu
Adapter for cooling system ed b ara
nte
is
tester -V.A.G 1274/8- hor eo
aut ra
c
Drip tray -V.A.G s1306- or
s
ce
e

nl
pt
du
an
itte
y li
erm
ab
1331-
ility
ot p
wit
, is n
h re
5024A-
hole
spec
Cooling system charge unit
es, in part or in w
t to the co
-VAS 6096-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Drain coolant:
Note
Collect drained coolant in a clean container for re-use or dis

posal.
Observe waste disposal regulations.
WARNING

Carefully open cap on coolant expansion tank.


Golf 2004
Release quick-release coupling -arrow- and remove lower

coolant hose from radiator.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004
Remove additional bottom coolant hose to continued coolant

circulation pump -V51- -arrow- and allow remaining coolant to
drain out.
Note
Follow disposal regulations for coolant!
Filling with coolant:
Caution
agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b ar
For mixing, only potable risewater may be used. Soiled water does ante
d
not have the requiredau
t quality to ensure the coolant's function.
ho eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
In vehicles as of model year 2008, only G 12 plus-plus ac
h re
cording to TL VW 774 G may be used as coolant additive.
hole
spec
es, in part or in w
The coolant additive G 12 plus-plus can be mixed with the
t to the co
previous coolant additive G 12 plus. Identification: both are
coloured purple.
Coolant additives marked according to TL VW 774 G or ac
rrectness of i
cording to TL VW 774 F prevent frost and corrosion damage,
l purpos
scaling. Such additives also raise the boiling point of the cool
ant. Therefore, the cooling system must be filled all year round
with coolant additive.
nform
ercia
Because of its higher boiling point, the coolant improves en

m
at
om
gine reliability under heavy loads, particularly in countries with

ion
c
tropical climates.
in t
or
his
ate
The frost protection must be guaranteed to approx. -25 C. In

do
riv
countries with an arctic climate, to approx. -35 C.

p
cum
for
en
ng
t.
The coolant concentration must not be reduced by adding wa
yi Co
op
ter even in warmer seasons and in warmer countries. The
C py
t. rig
gh
coolant additive concentration must be at least 40 %.
ht
pyri by
Vo
co lksw
by
If a stronger anti-freeze mixture is necessary due to harsher
cted agen
Prote AG.
weather conditions, it can be increased using G 12 plus-plus.
It may only be strengthened, however, to 60 % (antifreeze
protection to about -40 C). Otherwise, the antifreeze protec
tion will be reduced again and the cooling effect will be im
paired.
The refractometer -T10007- is recommended for determining
the current anti-freeze density.
If radiator, heat exchanger, cylinder head or cylinder head
gasket is renewed, do not reuse old coolant.
Recommended mixture ratios:

Frost Anti-freeze G 12 plus- Tap water 1)
protection to proportion plus
G 12 plus1)
-25 C 40 % 3.6 l 5.4 l
-35 C 50 % 4.5 l 4.5 l
1) The quantity of coolant can vary depending upon vehicle equipment.
Procedure

Golf 2004
Reconnect coolant hose to continued coolant circulation pump

-V51- -arrow-.
. Volkswagen AG
gen AG does
swa
Push lower coolant hose onto radiator unionband y V secure.
olk not
gu
d ara
ise nte
Screw adapter for cooling system tester tho-V.A.G
r 1274/8- onto eo
expansion tank. s au ra
c
s
ce
le
Fill coolant circuit using cooling system charge unit -

un
pt
VAS 6096- Operating instructions for cooling system charge
an
d
itte
y li
unit VAS 6096.
erm
ab
ility
ot p
wit
is n
WARNING
h re
ole,
spec

t to the co
rrectne
Check coolant level and top-up if necessary. When the engine
ss
is at normal operating temperature, the coolant level must be
o
cial p
f
at the upper mark; when the engine is cold, in the middle of
inform
the shaded field.
mer
atio
Install noise insulation General body repairs, exterior; Rep.
om
n
Gr. 50 ; Noise insulation. .
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.6 Removing and installing fan support
with fans

Golf 2004
Removing
Unclip coolant hose from fan support.
Remove air duct system from air filter page 174 .
Separate connector -1- and remove fan support securing bolts
-arrows-.
Remove fan support with fans.
Separate connection -1- and free wiring.

Remove securing nuts -arrows- and remove fans.
Installing
note the following:
Specified torques:
Component agen
AG. Volkswagen AG d
oes Nm
olksw not
Radiator fans to fan support ed
by V gua
ran 5
ris tee
Fan support to radiator ut
ho
o5r
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004
1.7 Removing and installing radiator

equipment required
Refractometer -T10007-
Adapter for cooling system
tester -V.A.G 1274/8-
AG. Volkswagen AG d
Torque wrench -V.A.G agen oes
olksw not
V
1331- d by gu
ara
rise nte
o
Spring-type clip pliers -VAS auth eo
ra
5024A- ss c
ce
le
un
pt
Cooling system charge unit
an
d
itte
-VAS 6096-
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Remove front bumper General body repairs, exterior; Rep.
Gr. 63 ; Front bumper .
Pull all coolant hoses off radiator.
Remove fan support with fans page 113 .

Golf 2004
Remove bolts -1- from radiator mounting.

Swing radiator slightly to rear.
Remove condenser securing bolts -2-.
Unscrew lateral securing bolt -arrow- from condenser on ra

diator.
Remove radiator upwards.
Installing
note the following:
AG. Volkswagen AG d
agen oes
lksw not
Note by Vo gu
ara
d
rise nte
ho eo
If a new radiator
s a is installed, the old coolant may not be reused.
ut ra
c
s
ce
le
un
pt
Fill cooling system with coolant page 110 .

an
d
itte
y li
rm
ab
Component Nm
pe
ility
ot
Radiator mounting to lock carrier 5

wit
, is n
h re
Condenser to radiator 5
hole
spec
Fan support to radiator 5

es, in part or in w
t to the co
1.8 Checking continued coolant circulation

rrectness of i
pump
l purpos

Voltage tester -V.A.G 1527B-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
Auxiliary measuring set -V.A.G 1594C-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
Current flow diagram
pe
ility
ot
Test prerequisite
wit
, is n
h re
hole
Fuses must be OK Current flow diagrams, Electrical fault
spec
finding and Fitting locations
es, in part or in w
t to the co
Test procedure
rrectness of i
l purpos
Pull 2-pin connector off continued coolant circulation pump -

V51- .
nform
ercia
Connect contacts of continued coolant circulation pump -V51-

to battery using adapter cables from auxiliary set -V.A.G
m
a
com
1594C- .
tion in
r
te o
The continued coolant circulation pump must run.
thi
s
iva
do
If the continued coolant circulation pump -V51- does not run:
r
rp
cum
fo
en
g
Renew continued coolant circulation pump -V51- .

n
t.
yi Co
Cop py
If the continued coolant circulation pump -V51- runs: ht. rig
rig ht
py by
o Vo
Switch ignition off and on again. by c lksw
cted agen
Prote AG.
Connect voltage tester -V.A.G 1527B- to connector detached

from continued coolant circulation pump -V51- using auxiliary
cables from adapter set -V.A.G 1594C- .
The LED must light up.
Note
This check must be performed within 10 minutes of ignition being

switched off.
If LED does not light up:

Locate and eliminate open circuit referring to current flow di
agram Current flow diagrams, Electrical fault finding and
Fitting locations.

Golf 2004
1.9 Removing and installing coolant pump

equipment required
Support bracket -10 - 222
A- with hooks -10 - 222 A /
10- , shackle -10 - 222 A /
12- and adapter -10 - 222
A /13- and adapter -10 - 222
A /18-
Refractometer -T10007-
1331-
AG. Volkswagen AG d
agen oes
Torque wrench -V.A.G olksw not
y V gu
1332- ise
d b ara
nte
or eo
h
Spring-type clip pliers -VAS s aut ra
c
5024 A- s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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Removing
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Co
Cop py
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gh
Remove front right part of wheel housing liners General
ht
pyri by
Vo
o
body repairs, exterior; Rep. Gr. 66 ; Removing and installing
c by lksw
cted agen
wheel housing liner . Prote AG.

Golf 2004
Fit support bracket -10 - 222 A- with hooks -10 - 222 A /10- ,
shackle -10 - 222 A /12- , adapter -10 - 222 A /13- and adapter
-10 - 222 A /18- as shown and take up weight of engine in
installation position at right lifting eye.
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
u ra
Unbolt engine side of assembly mounting from engine
ss a
bracket c
-arrows-.
ce
e
nl
pt
du
an
Lower engine 40 mm using support bracket -10 - 222 A- .
itte
y li
erm
ab
Remove coolant pump belt pulley. To do this, counterhold belt
ility
ot p
pulley with a drift (commercially available).
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Unscrew coolant pump securing bolts -1-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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o
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Cop py
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pyri by
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co lksw
by
cted agen
Prote AG.

Golf 2004
Swing out coolant pump -A- as illustrated.

Installing
Installation is carried out in the reverse order. When installing, n AG. Volkswagen AG do
note the following: olks
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Moisten new O-ring with coolant. db ara
rise nte
tho eo
Fit coolant pump. ss
au ra
c
ce
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Tighten securing bolts for coolant pump. Specified torque:
nl
pt
du
an
8 Nm.
itte
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erm
ab
Install belt pulley for coolant pump. Specified torque: 20 Nm.
ility
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wit
Raise engine again using support bracket -10 - 222 A- and fit
, is n
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with new securing bolts to assembly mounting.
hole
spec
Align engine mountings as follows:
es, in part or in w
t to the co
There must be a distance of -a- at least 10 mm between engine
support and longitudinal member (right side).
rrectness of i
The side surface of the engine support -2- should be located
l purpos
parallel to the support arm -1-.
nform
ercia
Note
m
at
om
ion
Specified torques for assembly mountings page 13 .
c
in t
or
his
ate
do
riv

p
cum
for
en
g
Replenish coolant page 110 .

n
t.
yi Co
Cop py
ht. rig
ht
1.10 Removing and installing thermostat
rig by
copy Vo
by lksw
housing
cted agen
Prote AG.

Hose clip pliers -V.A.G 1921-

Golf 2004
Drip tray for workshop hoist -VAS 6208-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
Removing
es, in part or in w
t to the co
rrectness of i
necting battery .
l purpos
Pull cover -1- off air duct. Release fasteners on side for this.
nf
ercia
Unclip air duct -2-.
orm
m
atio
om
n in
or c
thi
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sd
iva
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o
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f
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Remove air filter housing and connecting hose. To do this,

unscrew bolt -A-, pull off connector -B- and loosen spring-type
clips -C-. Note marking -D- when reinstalling.
Pull off air filter housing upwards.
Pull off vacuum hose -arrow- from positioner element for var
iable intake manifold changeover.
Unscrew bolts -1- and -2- and pull off positioner element from
intake manifold.

Golf 2004
Disconnect electrical connector -arrow- on coolant tempera

ture sender -G62- .
Detach secondary air hose at position marked by -arrow-.

Place air hose on bracket to one side.
. Volkswagen AG
gen AG does
Detach coolant hoses at positions marked
Vol
ksby
wa -arrows-. not
y gu
db ara
rise nte
tho eo
au ra
c
ss
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
Unscrew bolts -arrows-.

rrectness of i
Pull bracket for coolant pipe of gear oil cooler to left.

l purpos
Swivel bracket for secondary air hose forwards.

nf
ercia
orm
m
atio
om
n in
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thi
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sd
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Golf 2004
Remove bolt -arrow- on bracket for wiring harness.
Caution
Use lever to push coolant pipe in direction of coolant pump

when pulling off thermostat housing so that pipe is not pulled
off as well.
Pull off coolant thermostat housing -2-. Push coolant pipe -1-
towards coolant pump with a lever when doing this.
Installing
Note
Renew seals and gaskets.
Fill with coolant page 110 .

Connect battery. Necessary measures Rep. Gr. 27 .
Specified torques
Component Nm
Thermostat housing to engine 10
Wiring harness bracket to engine 10
AG. Volkswagen AG d
agen
Air filter housing on body 10 olksw
oes
not
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1.11 Removing and installing thermostat h eo
aut ra
ss c
ce
le
Removing
un
pt
an
d
itte
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ab
pe
Note ility
ot
wit
, is n
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Collect drained coolant in a clean container for re-use or disposal.
hole
spec
es, in part or in w

t to the co
Unscrew bolts -arrows- and remove union -1-.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004
Remove O-ring -3- with thermostat -2- from thermostat hous

ing -1-.
Installing
Note agen
AG. Volkswagen AG d
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olksw not
V gu
by ara
Renew gaskets and seals. ed
ris nte
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aut ra
s c
Clean sealing surface for O-ring. s
ce
le
un
pt
Install thermostat.
an
d
itte
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ab
Installation position: Align breather valve -arrow- as shown in
pe
ility
illustration.
ot
wit
, is n
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Moisten new O-ring -1- with coolant.
hole
spec
Screw on union to thermostat housing.
es, in part or in w
t to the co
Install thermostat housing page 120 .
Specified torque
rrectness of i
Component Nm
l purpos
Union to thermostat housing 10
nform
ercia
1.12 Removing and installing coolant pipe

m
a
com
tion in
Removing
r
te o
thi
s
iva
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rp
cum
Note
fo
en
ng
t.
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op py
Collect drained coolant in a clean container for re-use or disposal. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Caution
Observe notes on procedure for disconnecting the battery

Rep. Gr. 27 .

Remove secondary air pump motor -V101- page 204 .
Disconnect electrical connector -1- for magnetic coupling on
air conditioner compressor and place electric cable to one
side.
WARNING
The air conditioner refrigerant circuit must not be opened.
Remove bolts -arrow- for air conditioner compressor.

Tie up air conditioner compressor with refrigerant lines con
nected to front of side member.

Golf 2004
Unhook connector -arrow- for engine speed sender -G28-

from bracket on dipstick guide tube.
Unscrew bolt -3- and pull out dipstick guide tube -2-.
Unscrew bolt -4- and pull vacuum reservoir -1- off gintake
en AG. Vmaniagen AG doe
olksw
swa
fold. yV
olk s no
t gu
b ara
ed
Place vacuum reservoir to side (hoses
tho
ris remain attached). nte
e or
au ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
Separate electrical connection -3- on continued coolant circu
t to the co
lation pump -V51- -item 2-.
Pull pump downwards out of rubber hoops of bracket. Spray
rrectne
rubber hoops with non-silicon lubricant if necessary.
Unscrew bracket of continued coolant circulation pump -V51- .
ss o
cial p
Unclip right wiring harness bracket from coolant pipe.
f inform
mer
Detach left wiring harness on coolant pipe from bracket.

atio
m
Pull coolant hose off coolant pipe for oil cooler.

o
n
c
i
or
n thi
e
Pull out coolant pipe from cylinder block.

t
sd
iva
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pr
Installing
um
r
fo
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
py by
co Vo
Note
by lksw
cted agen
Prote AG.
Renew O-rings.
Before installing, clean or buff sealing surface for O-ring in

cylinder block.

Golf 2004
Lubricate new O-ring -1- with coolant and push onto coolant
pipe -2-.
Push coolant pipe into hole on cylinder head.
Install thermostat housing page 120 .
Install air conditioner compressor Rep. Gr. 87 .
Fill with coolant page 110 .
Specified torque
Component Nm
Bracket for coolant pump to bracket for ancilla 10
ries
1.13 Checking cooling system for leaks

Checking pressure relief valve in cap page 127
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
Special tools and workshop rised ara
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equipment required ut
ho eo
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s a c
Cooling system tester - s
ce
le
V.A.G 1274-
un
pt
an
d
itte
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rm
ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Test prerequisite
Engine at operating temperature.

Golf 2004
Test sequence:
WARNING

Open cap for coolant expansion tank.

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.
1.13.1 Checking pressure relief valve in filler

cap
Attach cooling system tester -V.A.G 1274- with adapter -
V.A.G 1274/9- to cap.
AG. Volkswagen AG d
Operate hand pump. agen oes
olksw not
y V gu
b ara
The pressure relief valve should
orise open at a pressure of 1.4
d
nte
1.6 bar. auth eo
ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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cum
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
20 Fuel supply system

1 Safety precautions when working on
fuel supply system
WARNING
AG. Volkswagen AG d
agen oes
olksw not
The fuel system is pressurised! Wear eye protection and d by V gu
ara
protective clothing to avoid possible injury and skin conhorise nte
eo
tact. Before loosening hose connections, wrap a clothaut ra
around the connection. Then release pressure by carefully
ss c
ce
le
pulling hose off connection.
un
pt
an
d
itte
For safety reasons, when the battery is not disconnected,
y li
erm
ab
the fuse for the fuel pump must be removed before open
ility
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ing the fuel system, otherwise the fuel pump could be
wit
is n
activated by the driver door contact switch. Fuse assign
h re
ole,
ment Current flow diagrams, Electrical fault finding and
spec
Fitting locations
t to the co
Caution
rrectne
ss
o
cial p
f
tions:
inform
mer
atio
m

o
n
c
i
or
n thi
e
sitions.
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um
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Cop py
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When removing and installing fuel gauge sender or fuel pump cop Vo
by lksw
(fuel delivery unit) from a full or partly full fuel tank, observe the
cted agen
Prote AG.
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 m/h can be used
providing that motor is not in air flow.
Prevent skin contact with fuel! Wear fuel-resistant gloves!
128 Rep. Gr.20 - Fuel supply system

Golf 2004
2 Rules for cleanliness

When working on the fuel supply and injection systems, pay care
ful attention to the following 5 rules for cleanliness:
Thoroughly clean all unions and adjacent areas before dis
connecting.
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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Rules for cleanliness 129

Golf 2004
3 Fuel tank
Safety precautions when working on fuel supply system
. Volkswagen AG
page 128 . swa
gen AG does
k not
Vol gu
Rules for cleanliness page 129se.d by ara
nte
ri
ho eo
Assembly overview - fuel tank
au page 130 .
t ra
c
ss
Draining fuel tank page 132 .
ce
e
nl
pt
du
an
itte
Removing and installing fuel tank page 137 .
y li
erm
ab
Removing and installing fuel delivery unit page 141
ility
ot p
wit
, is n
Removing and installing fuel gauge sender -G- page 146 .
h re
hole
spec
Removing and installing fuel gauge sender 2 -G169-
es, in part or in w
page 144 .
t to the co
Removing and installing suction jet pump page 146 .
rrectness of i
3.1 Assembly overview - fuel tank
l purpos
1 - Supply line
nform
ercia
Black.
m
at
om
io
ing.
n
c
in t
or
his
e
2 - Return line
at
do
riv
Blue.
p
cum
for
en
g

n
t.
yi Co
ing. t. Cop py
rig
gh ht
yri
3 - Seal p by
o Vo
by c lksw
Renew.
cted agen
Prote AG.
When installing, fit dry in
fuel tank opening.
Moisten with fuel only
when installing flange.
4 - Fuel delivery unit
page 141 .
If fuel delivery unit was
renewed, adapt engine
control unit to fuel pump
Vehicle diagnosis,
testing and information
system VAS 5051 Gui
ded functions
Checking fuel pump
page 150 .
tion on fuel tank
page 132 .
With fuel gauge sender
-G- .
fuel gauge sender
page 144 .
Clean strainer if soiled.
5 - Locking ring, 110 Nm

Golf 2004
Remove and install using wrench -T10202- .
6 - Breather line
From gravity valve to activated charcoal filter
Clip on bracket in wheel housing AG. Volkswagen AG d
agen oes
olksw
To pull off, press release button on connection. not
yV gu b ara
ed
7 - Cap horis nte
e
t or
Renew if damaged. au ac
ss
ce
le
8 - Securing bolt
un
pt
an
d
itte
y li
9 - Tank flap unit
rm
ab
pe
ility
With rubber cup.
ot
wit
, is n
Removing and installing General body repairs, exterior; Rep. Gr. 55 ; Tank flap unit; Removing and
h re
installing fuel tank flap unit .
hole
spec
es, in part or in w
10 - Earth connection
t to the co
11 - 10 Nm
rrectness of i
12 - Protective plate
l purpos
For fuel filler neck

Ensure that earth connection is securely seated
nform
ercia
13 - 10 Nm
m
a
com
tio
14 - Cable retainer
n in
r
te o
thi
Clipped onto protective plate.
s
iva
do
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rp
c
15 - Fuel gauge sender 2 -G169-
um
fo
en
g

n
t.
yi Co
op py
Note installation position on fuel tank page 132 .
t. C rig
gh ht
pyri by
Vo
16 - Suction-jet pump
o
by c lksw
cted agen
Prote
Clipped onto fuel gauge sender 2 -G169- .
AG.

17 - Fuel tank
When removing, support using engine and gearbox jack -V.A.G 1383 A- .
18 - Securing strap
19 - 25 Nm
Renew.
To secure the securing straps for the fuel tank, only bolts with loose washers must be used. If different
bolts are used, the securing straps might twist during tightening. Bolts ETKA (electronic parts cata
logue) .
20 - Heat shield
Riveted to exhaust pipe mounting
21 - 3 Nm
22 - Breather line
White
From activated charcoal filter to activated charcoal filter solenoid valve 1 -N80- .
Do not kink.
To pull off, press release button on connection.
Clipped onto fuel tank.
3. Fuel tank 131

Golf 2004
23 - Vacuum line
Green.
From fuel system diagnosis pump -V144- to intake manifold.
Clipped onto fuel tank.
24 - Supply line
To fuel rail.
25 - Fuel filter
Installation position: arrow indicates direction of flow.
26 - 8 Nm
Installation position of flange for fuel delivery unit and fuel gauge
sender 2 -G169-
The 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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
Location of fuel filter aut ra
c
ss
Pin -2- on filter housing must engage in notch of guide -1- in filter
ce
le
un
pt
bracket.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
3.2 Emptying fuel tank

nform
ercia
Fuel extractor -VAS 5190-

m
a
com
tion in
r
te o
thi
s
iva
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004
Wrench -T10202-
lk swage es n
o ot g
byV ua
d ran
ir se tee
tho
Torque wrench (40200
au Nm) -V.A.G 1332- or
ac
ss
ce
Note safety precautions before beginning work page 128 .
e
nl
pt
du
an
itte
Emptying fuel tank with fuel pump intact page 133 .
y li
erm
ab
ility
Emptying fuel tank if it is more than 3/4 full page 134 .
ot p
wit
, is n
h re
Emptying fuel tank if less than 3/4 full page 135
hole
spec
es, in part or in w
3.2.1 Emptying fuel tank with fuel pump intact
t to the co
rrectness of i
Adapter for fuel extraction -VAS 5190 /3-
l purpos
Test instrument adapter/DSO (5-pin) -VAS 5565-

Remote control -V.A.G 1348/3A-
nf
ercia
orm
m
atio
WARNING
om
n in
or c
thi
Fuel supply line is pressurised. Wear eye protection and

te
sd
a
protective clothing to avoid possible injury and skin con

iv
o
r
rp
cu
tact. Before loosening hose connections, wrap a cloth

o
m
f
en
around the connection. Then release pressure by carefully

ng
t.
yi Co
pulling hose off connection. t. Cop py
rig
gh ht
Connect fuel extractor -VAS 5190- earth wire to vehicle pyri by
Vo
co
earth.
by lksw
cted agen
Prote AG.
Pull off supply line (metal coupling) -arrow- and catch escaping
fuel with a cloth.
Note
3. Fuel tank 133

olkswagen AG
Golf 2004 wage
n AG. V does
olks not
6-cylinder injection engine VW Individual - Edition
db
y 10.2009
V gu
ara
e nte
ris
ho eo
Connect fuel extractor -VAS 5190- with adapterutfor fuel ex ra
sa c
tractor -VAS 5190 /3- to fuel supply line. s
ce
e
nl
pt
du
Open cover of relay and fuse holder of engine compartment
an
itte
y li
electronics box.
erm
ab
ility
ot p
Pull fuse SB6 on socket F6 off hose holder. Fuse assignment
wit
Current flow diagrams, Electrical fault finding and Fitting lo
, is n
h re
cations
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Connect remote control -V.A.G 1348/3 A- with adapter cable

-V.A.G 1348/3-3- to left terminal (viewed looking forwards) of
fuse socket F6 -arrow-.
nf
ercia
orm
Tape off 2nd connector contact of adapter cable -
m
atio
m
V.A.G 1348/3-3- with insulating tape to prevent short circuits.

o
n in
or c
Connect crocodile clip to vehicle battery (+).
thi
te
sd
iva
o
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rp
cu
o
m
f
Note
en
ng
t.
yi Co
Cop py
t. rig
This step serves only to have the fuel pump running when the gh ht
yri by
engine is stopped. cop Vo
by lksw
cted agen
Prote AG.
Remove filler cap from fuel tank filler neck.

Operate remote control -V.A.G 1348/3A- and shut-off tap on
fuel extractor -VAS 5190- until fuel tank is empty.
3.2.2 Emptying fuel tank if it is more than 3/4

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

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

Golf 2004
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.
AG. Volkswagen AG d
agen
Note olksw
oes
not
byV gu
ara
ed
is nt
A ball valve -2- is located at the bottom of the filler neck in the fuel ee or
or
h
ut
tank -1-; it must notss be damaged by the extraction hose -3-.
a ac
Therefore push hose into filler neck only as far as marking
ce
e
nl
pt
-arrow-.
du
an
itte
y li
erm
ab
Drain fuel tank as much as possible through fuel filler neck.
ility
ot p
wit
, is n
Carefully pull out extraction hose.
h re
hole
spec
es, in part or in w
Note
t to the co
When no more fuel is extracted, the tank is emptied just
rrectness of i
enough for the sender flange to be opened without danger.
The tank may be removed while containing remaining fuel.
l purpos
Emptying the fuel tank completely page 135 .

nf
ercia
orm
3.2.3 Emptying fuel tank if it is less than 3/4 full

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om
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or c
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sd
a
Note
iv
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f
en
ng
To drain fuel tank completely: fuel must be extracted from fuel

t.
yi Co
op
delivery unit flange and also from fuel pump sender 2 -G169- C py
ht. rig
flange. rig ht
py by
co Vo
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cted agen
Prote
Remove bench seat General body repairs, interior; Rep.
AG.
Gr. 72 ; Rear seats; Removing and installing bench seat .
3. Fuel tank 135

Golf 2004
Remove cover from fuel delivery unit.
Note
For vehicles with auxiliary heater the metering pump -V54- con
nector must be disconnected additionally.
WARNING
The fuel system is pressurised! Wear eye protection and pro

nection.
Pull connector -1- and fuel lines -2 and 3- off flange.
Note

Vehicles with an auxiliary heater have an additional fuel line
(with smaller diameter) for the metering pump -V54- , this must
also be disconnected from the flange.
lkswage es n
o ot g
byV ua
ed ran
Open locking ring using or wrench -T10202- .
is tee
th or
u
Lift sender flange. ss a ac
ce
le
un
Insert extraction hose of fuel extractor -VAS 5190- as deeply

pt
an
d
as possible into fuel tank and extract fuel.

itte
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erm
ab
Draining fuel tank at fuel gauge sender 2 -G169- flange

ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Remove cover -1- and pull 3-pin connector -arrow- off flange.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
Open locking ring using wrench -T10202- .

Lift 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 132 .
3.3 Removing and installing fuel tank
Note
Vehicles up to 06/2007 are fitted with a two-part propshaft. For

these vehicles it is sufficient to remove the rear propshaft. Vehi
cles from 06/2007 are fitted with a single part propshaft. For these
vehicles the complete propshaft must be removed.

Torque wrench (550 Nm) -V.A.G 1331-
AG. Volkswagen AG d
agen oes
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rise nte
tho eo
au ra
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le
un
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an
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itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Engine and gearbox jack -V.A.G 1383 A-

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Removing fuel tank page 137

en
ng
t.
yi Co
op
Installing fuel tank page 139 C py
t. rig
gh ht
yri by
3.3.1 Removing fuel tank
cop Vo
by lksw
cted agen
Prote AG.
If necessary, empty fuel tank using fuel extractor -VAS 5190-
page 132 .
Remove rear right wheel.
3. Fuel tank 137

Golf 2004
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 tank flap unit securing bolt and remove tank flap unit
General body repairs, exterior; Rep. Gr. 55 ; Tank flap unit .
Unbolt filler neck from body -arrows-.
Unclip electrical wiring -2- from filler neck.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
Remove covers and separate electrical connectors -arrows-.
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
nector must be separated additionally.
Remove centre and rear silencers.
rrectness of i
Remove front exhaust pipe with catalytic converters
l purpos
page 195 .
Remove complete propshaft Propshaft and rear final drive;
nform
ercia
Rep. Gr. 39 ; Repairing propshaft - Golf .

m
a
com
tion in
WARNING
r
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thi
s
iva
do

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cum
fo

en
ng
t.
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op
C py
t. rig
gh
nection.
ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Disconnect breather line -1- (white) and fuel line -2- (black) at
connecting point.
Note
Vehicles with auxiliary heater, the fuel line of the metering pump
-V54- must also be separated.

Golf 2004
Pull off adapter cable on four-wheel drive control unit -J492- .
Unscrew securing straps and securing bolts. First support fuel

tank with engine and gearbox jack -V.A.G 1383 A- .
Slowly lower fuel tank.
Note AG. Volkswagen AG d

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The filler neck must be guided out isedbetween body and rear axle.
b ara
nte
To do this, take the fuel tank off
ut
hoengine
r
and gearbox jack -V.A.G eo
1383 A- with the assistancessof a 2nd mechanic.
a ra
c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
3.3.2 Installing fuel tank
ot p
wit
, is n
h re
Clip in cable for four-wheel drive control unit -J492- on fuel
hole
spec
tank.
es, in part or in w
t to the co
With the assistance 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- .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
Raise the fuel tank slowly up to the installation position and

do
priv
secure -arrows-.
um
for
en
ng
t.
yi Co
Cop py
Note ht. rig
rig ht
py by
co Vo
by lksw
To secure the securing straps for the fuel tank, only bolts with
cted agen
Prote AG.
loose washers must be used. If different bolts are used, the se
curing straps might twist during tightening. Bolts ETKA (elec
tronic parts catalogue) .
3. Fuel tank 139

Golf 2004
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 and return lines (return line blue or
with blue markings, supply line black).
Ensure wiring/line connections are secured properly by pulling
back on connection.
Check earth connection on fuel tank and body to filler neck.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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om
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or c
thi
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sd
iva
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f
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004
4 Repairing fuel supply
Note
Fuel hoses on engine must be secured only with spring-type

clips which conform to production standard.
Spring-type clip pliers -VAS 6340- or space saving hose clip
pliers -VAS 6362- are recommended for installing and remov
ing spring-type clips.
Safety precautions when working on fuel supply system

page 128 .
Rules for cleanliness page 129 .
Removing and installing fuel delivery unit page 141 .
Removing and installing fuel gauge sender -G- page 146 .
Removing and installing fuel filter page 148 .
Assembly overview - fuel filter with attachments page 148 .
Check fuel pump page 150 .
Bleeding fuel system page 157 .
Checking fuel pressure regulator and holding pressure
page 181 .
4.1 Removing and installinglksfuel

wage delivery
es n
ot g
unit ise
d by Vo ua
ran
r tee
ho
Special tools and workshop equipment
au
t
required or
ac
ss
Wrench -T10202-
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Torque wrench (40200 Nm) -V.A.G 1332-

nf
ercia
orm
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Repairing fuel supply 141

Golf 2004
Removing
Caution
Prerequisites:
Fuel tank must not be more than 3/4 full. This ensures that
the fill level is below the flange of the fuel delivery unit.
Note
After removing fuel delivery unit, check fuel tank for heavy
soiling and clean if necessary.
page 132 .

AG. Volkswagen AG d
Remove covers from fuel pump
lksunit.
wage
n oes
not
o
yV gu
edb ara
ris nte
Note tho eo
au ra
c
ss
ce
e
nl
pt
du
an
nector must be disconnected additionally.

itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
First check that the connector -arrow- is fitted securely by pull

ing the connector without pressing the catch. The connector
rrectness of i
can cause a fault if it has not been fitted correctly.

l purpos
Now pull off connector.

Check the contacts on the connector and on the fuel delivery
nf
ercia
unit for damage.

rm
m
atio
om
n in
c
WARNING
or
thi
te
sd
iva
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rp
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f
en
ng
t.
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op py
. C rig
ht ht
nection.
rig by
copy Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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rise
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Golf 2004 ara
nte
6-cylinder injection
autho
engine VW Individual - Edition 10.2009 eo
ra
ss c
ce
e
Pull fuel lines -1- and -2- off flange.
nl
pt
du
an
itte
y li
erm
ab
Note
ility
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wit
, is n
h re
hole
spec
Vehicles with auxiliary heater, the fuel line of the metering
es, in part or in w
t to the co
pump -V54- must also be separated.
rrectness of i
l purpos
Open locking ring using wrench -T10202- and raise flange
nform
ercia
slightly.
m
at
Pull fuel delivery unit and seal out of the opening in fuel tank.
om
ion
c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
When removing fuel delivery unit, ensure that fuel gauge

t.
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op
sender is not bent. C py
t. rig
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yri by
If delivery unit is to be renewed, drain old delivery unit before cop Vo
by lksw
disposal. cted agen
Prote AG.
Installing
Renew seal.
Insert seal for fuel delivery unit dry into opening of fuel tank.
Coat inner side of seal with fuel.
When inserting fuel delivery unit, ensure that fuel gauge send
er is not bent.
Press sealing flange down against spring pressure, and move

sealing flange to installation position.
Tab -2- on sealing flange must be between lugs -1- and -3- on
fuel tank.
The -arrow- points forwards.
Tighten sealing flange.
Specified torque: 110 Nm.
Reconnect supply line-1- (black).

Reconnect fuel return line -2- (blue or blue marking).

Golf 2004
Reconnect connector -arrow-.

Ensure push-fit couplings and electrical connectors are se
cured properly by pulling back on coupling/connector.
Further installation is performed in the reverse sequence. In the
process, note the following:
lk swage es n
Vo ot g
Observe installation position of fuel feed line to auxiliary
ed
by heater ua
ran
Auxiliary heater; Rep. Gr. 82 ; Fuel feed Thermothoris
Top V . tee
or
a u ac
Ensure wiring/line connections are securedssproperly by pulling
ce
e
back on connection.
nl
pt
du
an
itte
Arrow on cover points in direction of normal travel -2-.
y li
erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
4.2 Removing and installing fuel gauge
sender 2 -G169-
l purpos
Fuel tank must not be more than 1/2 full.
nform
mercia
at
om
io
Note
n
c
in t
or
his
ate
Ensure that the fuel gauge sender is not bent.

do
priv
cum
or

f
en
ng
t.
yi
page 132 .
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing:
Remove left cover (as seen facing direction of normal travel)
from fuel gauge sender 2 -G169- .
Disconnect electrical connectors.

Golf 2004
. Volkswage
VW Individual - Edition 10.2009
AG n AG d
agen oes
olksw not
Open locking ring using wrench -T10202-db
yV . gu
ara
rise nte
tho eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Pull fuel gauge sender 2 -G169- upwards slightly and unclip it
rrectness of i
from the suction-jet pump.
l purpos
Installing:
nf
ercia
o
Caution
rm
m
atio
om
n in
When installing do not bend fuel gauge sender 2 -G169- float
or c
arm.
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te
sd
iva
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cu
o
m
f
en
ng
Place fuel gauge sender 2 -G169- in fuel tank.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Fit suction-jet pump on sender on inside of fuel tank. Locating
co Vo
by lksw
cted
lugs must engage.
agen
Prote AG.
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 132 .
Check correct position of seal.
Tighten locking ring using wrench -T10202- . Specified torque:

110 Nm.
Fit connectors.
Install cover.
Install seat bench General body repairs, interior; Rep. Gr.
72 ; Rear seats; Removing and installing seat bench .

Golf 2004
4.3 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 unit
due to the shape of the fuel tank. A suction-jet pump pumps
fuel from left chamber to right chamber of fuel tank.
Checking fuel gauge sender 2 -G169- 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 141 .
Remove fuel gauge sender 2 -G169- page 144 .
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.
4.4 Removing and installing fuel gauge

sender -G-
Note
AG. Volkswagen AG d
agen oes
olksw not
Gradual introduction of fuel d bdelivery units with revised fuel gauge
y V gu
ara
senders -G- . horise nte
eo
ut ra
s a c
s
Removing (old version):
ce
e
nl
pt
du
an

itte
y li
erm
ab
Note colour co-ordination of cables for reinstallation.

ility
ot p
wit
, is n
Release connectors -arrows- and pull off connectors

h re
-1, 2 and 3-. Then bend back locking lugs of connectors.

hole
spec
es, in part or in w
Raise retaining tabs -4- and -5- using a screwdriver and pull
t to the co
fuel gauge sender -G- off downwards -arrow-.

Installing:
rrectness of i
Insert fuel gauge sender -G- into guides on fuel delivery unit
and press upwards until it engages.
l purpos
Connect connectors -13-. Observe colour co-ordination.

nf
ercia
Check connectors are secured properly by pulling back on

rm
m
connector.
atio
om
n in
c
Install fuel delivery unit page 141 .

or
thi
te
sd
a
Removing (new version):

iv
o
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rp
cu
o

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
ir se
d ran
tee Golf 2004
o
auth 6-cylinder injection engine VW Individualor
ac - Edition 10.2009
ss
ce
le
Pull fuel gauge sender -G- slightly to side and upwards at the
un
pt
an
same time
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
If the sender cannot be released in this way, the retaining tabs
nform
ercia
-arrows- must also be pushed to the side slightly.

m
a
com
t
Note colour co-ordination of cables for reinstallation.
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Release electrical connectors -13- and pull them off. Then

bend back locking lugs of connectors.
Installing:
Connect connectors -13-. Observe colour co-ordination.

Check connectors are secured properly by pulling back on
connector.
Insert fuel gauge sender -G- into guide on fuel delivery unit
and press down until it engages.
Install fuel delivery unit page 141 .

Golf 2004
4.5 Assembly overview - fuel filter with at

tachments
Note
wage es n
From October 2005, the fuel pressure regulator has been intey Vo lks ot g
grated in the fuel filter and cannot be renewed individually.ised b ua
ran
tee
or
th or
au ac
ss
ce
le
1 - Fuel filter
un
pt
an
d
itte
Direction of flow is
y li
rm
ab
marked with arrows.
pe
ility
Do not interchange con
ot
wit
, is n
nections.
h re
hole
spec
es, in part or in w
page 148 .
t to the co
Installation position: Pin
on filter housing must
engage in notch of guide
rrectness of i
in filter bracket
page 149
l purpos
2 - Fuel supply line
nform
ercia
Black.
m
From fuel tank
a
com
tion in
To pull off, press release
r
te o
button on connection.
thi
s
iva
do
r
3 - Fuel return line

rp
cum
fo
en
g
Blue.
n
t.
yi Co
op
To fuel tank.
C py
t. rig
gh ht
yri
To pull off, press release p by
co Vo
lksw
by
cted agen
Prote AG.

Black.
To engine.
To pull off, press release
5 - 3 Nm
6 - Bracket
For fuel filter.
Secured to fuel tank.
4.6 Removing and installing fuel filter

Receptacle for fuel
Removing
Observe safety precautions page 128 .
Place container under fuel filter.

Golf 2004
WARNING

nection.
Pull off fuel lines -1-, -2- and -5- by pressing release button.
Remove bolt -4-.
Remove fuel filter.
swage es n
Installing byV
olk ot g
ua
d ran
ir se
Installation is carried out
tho in the reverse order. When installing, tee
or
note the following: s au ac
s
ce
e
Direction of flow is indicated with an arrow on filter housing.

nl
pt
du
an
itte
y li
Bleed fuel system page 157 .
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Installation position
es, in part or in w
t to the co
Pin -2- on filter housing must engage in notch of guide -1- in filter
bracket.
rrectness of i
Specified torque:
l purpos
Component Nm
Retaining clamp for fuel filter 3
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
4.7 Checking fuel pump

equipment required
Pressure gauge -VAS
6550-
Remote control -V.A.G
1348/3A-
Test instrument adapter/
DSO (5-pin) -VAS 5565-
Hand-held multimeter -
V.A.G 1526D- or pickup
clamp -V.A.G 1526B/2-
Wrench -T10202-
1332-
Measuring container, ca
pacity 2 litres
Vehicle diagnosis tester
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
Checking function and voltage supply page 150 .

itte
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erm
ab
Checking fuel delivery rate page 152 .

ility
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wit
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Checking current draw page 155 .

h re
hole
spec
Check fuel pump non-return valve page 156 .

es, in part or in w
t to the co

page 181 .
4.7.1 Checking function and voltage supply

rrectness of i
l purpos
Fuel pump relay -J17- OK

Battery voltage at least 11.5 V.
nf
ercia
or
Fuse for fuel pump OK. Fuse assignment Current flow dia
m
m
atio
grams, Electrical fault finding and Fitting locations

om
n in
or c
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te
sd
iva
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f
en
ng
t.
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Cop py
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co
150
by lksw
cted agen
Rep. Gr.20 - Fuel supply system Prote AG.
Golf 2004
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Note orise d
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h eo
aut ra
Function of fuel pump is checked using final control diagnosis.
s c
s
ce
le
un
pt
The engine must be started briefly before final control diagno
an
d
itte
sis can be re-selected a second time.
y li
rm
ab
pe
ility
ot
Connect vehicle diagnosis tester as follows:
wit
, is n
h re
hole
Push diagnostic cable connector onto diagnostic connection
spec
in driver footwell.
es, in part or in w
t to the co
Switch on ignition.
Press buttons on display one after the other for Vehicle
rrectness of i
self-diagnosis , Self-diagnosis , Engine electronics
and Final control diagnosis .
l purpos
Press right arrow button on display until fuel pump relay -
nform
J17- is actuated.
mercia
Fuel pump -G6- must be actuated in pulses.
a
com
tion in
Switch off ignition.
r
te o
thi
s
iva
If fuel pump does not run: do

r
rp
cum
fo

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
Remove cover from fuel delivery unit.
copy Vo
by lksw
cted agen
Prote AG.
First check that the connector -arrow- is fitted securely by pull

ing the connector without pressing the catch. If connector was
not inserted correctly, repeat functional check of fuel pump.
unit for damage.

Golf 2004
Connect test instrument adapter/DSO (5-pin) -VAS 5565- to

connector and fuel delivery unit.
Connect multimeter -V.A.G 1526D- to cables -1- and -5- of test
instrument adapter/DSO (5-pin) -VAS 5565- .
Initiate final control diagnosis again and measure voltage at
fuel pump.
Specification: approx. 2 volt less that battery voltage.
Voltage supply not OK: agen
AG. Volkswagen AG d
oes
olksw no
Locate and eliminate openedcircuit
by
V
referring to current flow di t guara
agram Current flow diagrams,
ho
ris Electrical fault finding and nte
eo
Fitting locations. aut ra
c
ss
Voltage supply OK:
ce
le
un
pt
an
d
itte
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erm
ab
WARNING
ility
ot p
wit
is n
h re
ole,
spec
t to the co
nection.
rrectne
Pull fuel lines -1- and -2- off flange.
ss o
cial p
f in
Note
form
mer
atio
m

o
n
c
i
or
n thi
On vehicles with auxiliary heater the connector and the fuel

te
sd
a
line of the metering pump -V54- must also be separated.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Open locking ring using wrench -T10202- .
Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
Fuel pump defective, renew fuel delivery unit page 141 .
4.7.2 Checking fuel delivery rate

Voltage supply OK.
Fuel pressure regulator and holding pressure OK, checking
page 181 .
Fuel filter OK.
electronics box.

Golf 2004

cations
Note
This step serves only to have the fuel pump running when the
engine is stopped.
Delivery rate of fuel pump must be measured at 4 bar. There
fore, test fuel pressure before measuring delivery rate.
WARNING

nection.
lkswage es n
o ot g
byV ua
d
Pull off return line -1- from fuel pressure
o
ir se regulator. ran
tee
th or
au ac
ss ce
e
Note
nl
pt
du
an
itte
y li

erm
ab
ility
ot p
wit
, is n
Connect adapter set -VAS 6550/1- to fuel pressure regulator

h re
and hold end of adapter in measuring container.

hole
spec
es, in part or in w
Operate remote control -V.A.G 1348/3A- about 5 seconds to

t to the co
fill fuel filter.

Empty measuring container.
rrectness of i
The delivery rate of the fuel pump depends on the voltage.

l purpos
Therefore, connect multimeter to battery.

Operate remote control for 30 seconds while measuring bat
nform
ercia
tery voltage.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
Compare quantity of fuel delivered with specification.

*) Minimum delivery rate cm/30 s
**) Voltage at fuel pump with engine not running and pump run
ning (approx. 2 volts less than battery voltage).
Example:
During the test a voltage of 12.5 volts is measured at the battery.
As the voltage at the pump is approx. 2 volts less than the battery
voltage, this will equate to a minimum delivery rate of approx. 580
cm/30 s.
If the specification is not attained:
Check supply line to filter for possible restrictions (kinks) or
blockages.
If fuel line is OK
Remove cap from fuel filler neck and repeat check. If fuel de
livery rate is now reached, check fuel tank breather.
If the specifications are still not attained:
Check fuel filter. Proceed as follows:
WARNING
Fuel supply line is pressurised. Wear eye protection and pro G. Volkswagen AG d
tective clothing to avoid possible injury and skin contact. Before lkswagen A oes
not
loosening hose connections, wrap a cloth around the connec by
Vo gu
ara
tion. Then release pressure by carefully pulling hose offoricon
sed
nte
nection. au
th eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
Pull fuel supply line -arrow- off fuel filter.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004
Connect pressure tester -VAS 6550- to fuel supply line with

adapter -VAS 6550/1- . Hold adapter -VAS 6550/2- in a meas
uring container.
Make sure that drain tap is closed and cut-off taps are open.
Operate remote control -V.A.G 1348/3A- . Then slowly close
shut-off tap -A- until a pressure of 4 bar is displayed on pres
sure gauge. From this point on do not move position of shut-
off tap.
Drain measuring container.
Repeat delivery rate check.
If the minimum delivery rate is now attained:
Renew fuel filter.
If the minimum delivery rate is again not attained
Remove fuel delivery unit and check filter strainer for soiling.
Only if still no fault has been detected:
Renew fuel delivery unit page 141 .
. Volkswagen AG
Reconnect all disconnected fuel lines.kswagen AG does
not
Vol
y gu
Bleed fuel system page 157is.ed b ara
nte
or eo
h
If fuel delivery rate has beens aattained,
ut but nevertheless you sus ra
c
pect a fuel supply system fault
s (e.g. intermittent failure of fuel
ce
e
supply system):
nl
pt
du
an
itte
y li
Measure current draw of fuel pump page 155 .
erm
ab
ility
ot p
wit
4.7.3 Checking current draw
, is n
h re
hole
spec
es, in part or in w

t to the co
Remove cover from fuel delivery unit. rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
First check that the connector -arrow- is fitted securely by pull t. C rig
gh ht
ing the connector without pressing the catch. The connector yri
p by
o Vo
can cause a fault if it has not been fitted correctly. by c lksw
cted agen
Prote AG.
unit for damage.

Golf 2004
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 pick- wage
es n
up clamp for test instrument adapter/DSO (5-pin) -VAS yV
olks ot g
ua
5565- . ised b ran
r tee
ho
Start engine and run at idling speed. aut or
ac
ss
Measure current draw of fuel pump.
ce
le
un
pt
an
d
itte
Specification: max. 9 amps.
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
The starting current for the fuel pump can lie briefly above
es, in part or in w
t to the co
specifications when starting the engine.
If the fault in the fuel system is not always evident, the check
can also be carried out during a road test. A 2nd person is
rrectness of i
required to do this, however.
l purpos
If the current draw is exceeded:
nform
ercia
Fuel pump defective, renew fuel delivery unit page 141 .

m
a
com
tio
4.7.4 Checking non-return valve for fuel pump
n in
r
te o
thi
s
iva
do
r
electronics box.
rp
cum
fo
en
ng

t.
yi Co
op
C py
ht. rig
cations rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
WARNING

nection.
Pull fuel supply line -arrow- off fuel filter.

Golf 2004

adapter -VAS 6550/1- . Hold adapter -VAS 6550/2- in a meas
uring container.
Close pressure gauge -VAS 6550- shut-off tap -A- (lever at
right angles to direction of flow).
Operate remote control at short intervals until a pressure of
approx. 4 bar has built up.
WARNING
Danger of spray when shut-off tap is opened. Wear eye pro

tection and protective clothing to avoid injuries and skin con
tact. Hold container before free connection of pressure tester.
If pressure builds up too high, relieve excess pressure by

carefully opening shut-off tap.
Watch pressure drop on pressure gauge. After 10 minutes,
pressure must not drop below 3 bar.
If the pressure drops further:
Check line connections for leaks.
If no fault can be found on the lines:
Fuel pump non-return valve is defective, renew fuel delivery
unit page 141 .
AG. Volkswagen AG d
agen oes
lksw not
4.8 Bleeding fuel system
Vo gu
d by ara
ise nte
or eo
h
aut ra
ss c
Note
ce
e
nl
pt
du
an
itte
In order to prevent damage to the catalytic converter, the fuel

y li
erm
ab
system without return pipe must be bled after working on the

ility
ot p
fuel pipes or the fuel filter. Do not start the engine until the fuel
wit
, is n
system has been bled.

h re
hole

spec
es, in part or in w
t to the co

Diesel extractor -VAS 5226-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2004
WARNING
AG. Volkswagen AG d
agen oes
lksw not
The fuel system is pressurised! Wear eye protection and pro d by Vo gu
ara
orise nte
loosening hose connections, wrap a cloth around the connec th eo
au ra
tion. Then release pressure by carefully pulling hoses off con
s c
nection.
ce
le
un
pt
an
d
itte
y li
erm
ab
Unscrew protective cap Item 9 (page 173) from bleeder
ility
ot p
valve Item 8 (page 173) .
wit
is n
h re
ole,
Turn valve on T-piece -arrow- anti-clockwise until it is entirely
spec
open.
t to the co
Screw adapter -V.A.G 1318/201- onto adapter -V.A.G
1318/20- .
rrectne
Now screw assembled adapter -V.A.G 1318/20- hand-tight
onto bleeder valve.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
Connect hose of diesel extractor -VAS 5226- as illustrated.

iv
o
pr
cum
r
fo
Screw valve (on T-piece) clockwise to stop into bleed valve.

en
ng
t.
yi Co
op
Check adapter and hose connections for leaks. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Note Prote AG.
Function of fuel pump is checked using final control diagnosis.

The engine must be started briefly before final control diagno
sis can be re-selected a second time.

Golf 2004
Connect vehicle diagnosis tester as follows:

Push diagnostic cable connector onto diagnostic connection
in driver footwell.
Switch on ignition.
Press buttons on display one after the other for Vehicle
self-diagnosis , Self-diagnosis , Engine electronics
and Final control diagnosis .
Press right arrow button on display until fuel pump relay -
J17- is actuated. This actuates the fuel pump.
Finish final control diagnosis and switch off ignition once fuel
flows out of breather valve without bubbles.
Turn valve on T-piece -arrow- anti-clockwise until it is entirely

open again.
Clamp off hose from diesel extractor -VAS 5226- (e.g. using
hose clips up to 25 mm -3094- ) and pull it off adapter -V.A.G
1318/201- .
Unscrew adapter -V.A.G 1318/20- from bleed valve.
Screw protective cap Item 9 (page 173) of bleeder valve on
again.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
5 Electronic power control (EPC)

Assembly overview - accelerator module page 160
Removing and installing accelerator module page 160
5.1 Assembly overview - accelerator module
1 - Connector
Black, 6-pin.
2 - Accelerator position sender
-G79- with accelerator position agen
AG. Volkswagen AG d
oes
sender 2 -G185- olksw not
V gu
d by ara
Not adjustable. orise nte
eo
h
ut
The accelerator position ss a ra
c
sender passes the posi
ce
le
un
tion of the accelerator
pt
an
d
on to the engine control

itte
y li
erm
unit.
ab
ility
ot p
-A- openings for release
wit
is n
tool .
h re
ole,
spec
page 160 .
t to the co
3 - 10 Nm
4 - Cap
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5.2 Removing and installing accelerator

module

Golf 2004
For left-hand drive vehicles: release tool -T10238-
or
For right-hand drive vehicles: release tool -T10240-
Removing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
Remove steering column cover -arrows-.
ility
ot p
wit
, is n
Lever out cap Item 4 (page 160) using a screwdriver.
h re
hole
spec
Remove securing bolt Item 3 (page 160) .
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
Push release tool -T10238- (for right-hand drive vehicles re

o
n in
c
lease tool -T10240- ) into intended holes as shown to stop and

or
thi
remove accelerator module.

te
sd
iva
o
r
rp
cu
Pull connector off accelerator module. Press connector se

o
m
f
curing element downwards for this.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Electronic power control (EPC) 161

AG. Volkswagen AG d
agen oes
Golf 2004 olksw not
byV gu
ara
rised
- Edition 10.2009 nte
ho eo
aut ra
Installing ss c
ce
le
un
pt
Reconnect connector -2- to accelerator module.
an
d
itte
y li
rm
The connector must audibly engage.
ab
pe
ility
ot
Press accelerator module onto securing pins -6-.
wit
, is n
h re
Insert centring pin -7- into hole in floor of vehicle.
hole
spec
es, in part or in w
Secure accelerator module with bolt -3-, specified torque
t to the co
10 Nm and install cap -4-.
Install steering column trim.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004
6 Activated charcoal filter system
Note
Hose connections are secured with either spring-type or

clamp-type clips.
Hose clip pliers -VAS 6362- are recommended to install
spring-type clips.
Assembly overview - activated charcoal filter system

page 163 .
Checking fuel tank breather page 164 .
6.1 Assembly overview - activated charcoal filter system
1 - Activated charcoal filter

2 - 8 Nm
3 - Sleeve
olkswagen AG
en AG. V
4 - Activated charcoal filter olks
wag does
not
yV gu
Location: down in spare ed
b ara
nte
ris
wheel well u tho eo
a ra
ss c
5 - 6 Nm ce
le
un
pt
6 - Bracket
an
d
itte
y li
rm
ab
7 - Support
pe
ility
ot
wit
8 - Bracket
, is n
h re
hole
9 - 4 Nm
spec
es, in part or in w
10 - Rubber grommet
t to the co
11 - Washer
rrectness of i
12 - 8 Nm
l purpos
13 - Vacuum line
To engine.
nform
ercia
14 - Fuel system diagnostic

pump -V144-
m
a
com
tio
Location: in rear right

n in
r
wheel housing beneath

te o
thi
liner.
s
iva
do
r
rp
Checking fuel system

um
fo
en
g
for leaks page 164 .

n
t.
yi Co
op py
15 - 4 Nm
. C rig
ht ht
rig by
py Vo
16 - Connecting hose
co lksw
by
cted agen
Prote AG.
17 - Clamp
18 - Air filter
For fuel system diagnostic pump -V144-
19 - Bracket
20 - Connecting pipe
Clip onto bracket.
6. Activated charcoal filter system 163

Golf 2004
21 - Breather line
To filler neck on fuel tank
22 - Breather line
23 - Breather line
AG. Volkswagen AG d
To activated charcoal filter solenoid valve 1 -N80- ksw
agen oes
not
ol
To pull off, press release button on connection. byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
6.2 Checking fuel tank breather
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Hand vacuum pump -VAS 6213-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Test prerequisite
Ignition must be switched off.
Test sequence:
Pull off breather line -2-. To do this, press release button.
Note
The connection -1- is only installed on vehicles with auxiliary

heater.

Golf 2004
Then connect hand vacuum pump -VAS 6213- -1- to breather

line -2- for activated charcoal filter as shown.
Operate hand vacuum pump -VAS 6213- several times. Vac
uum must not build up. wage
es
ks not
Vol gu
If vacuum builds up: ed by ara
nte
ris
Check breather opening -arrow-
utho on activated charcoal filter for
eo
ra
a
soiling and clean if necessary.
ss c
ce
le
un
pt
If pressure does not build up:
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Seal breather hole -arrow- and operate vacuum pump again
spec
several times. Vacuum must build up.
es, in part or in w
t to the co
If vacuum does not build up:
Renew activated charcoal filter.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Activated charcoal filter system 165

Golf 2004
6-cylinder injection engine VW Individual - Edition
olksw
10.2009
AG. V agen AG
agen does
olksw not
yV gu
24 Mixture preparation - injection

db ara
rise nte
tho eo
au ra
c
ss
ce
e
1 Repairing injection system
nl
pt
du
an
itte
y li
General notes on the injection system page 166 .
erm
ab
ility
ot p
Safety precautions page 128 .
wit
, is n
h re
Rules for cleanliness page 129 .
hole
spec
es, in part or in w
Technical data page 166 .
t to the co
Assembly overview - intake manifold page 167 .
Removing and installing intake manifold page 170 .
rrectness of i
Assembly overview - fuel rail page 173 .
l purpos
Assembly overview - air filter page 174 .
nform
ercia
Assembly overview - resonator with resonance air pipe

page 175 .
m
at
om
ion
1.1 General notes on the injection system
c
in t
or
his
ate
do
riv
Fuel hoses in engine compartment must be secured only with

p
c
spring-type clips which conform to production standard. The
um
for
en
g
use of clamp or screw-type clips is not permissible.

n
t.
yi Co
Cop py
Spring-type clip pliers -VAS 6340- or spring-type clip pliers -
t. rig
gh ht
yri
VAS 5024 A- are recommended for installation of spring-type p by
o Vo
by c lksw
clips. Prote
cted AG.
agen
The battery must be disconnected only with ignition switched

off. If a coded radio is installed, ascertain code before discon
necting battery.
Observe required procedures after reconnecting battery
necting battery .
For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam
age the Lambda probe.
If, after fault finding, repairs or component tests, the engine
starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
In this case, the control unit must be adapted.
To complete work, read fault memory of engine control unit.
Delete all fault entries which may have occurred during tests
and repairs. If the fault memory was cleared, the readiness
code must be generated Vehicle diagnosis, testing and in
formation system VAS 5051 Guided functions.
Vehicles with an airbag are fitted with a crash fuel shut-off. It
reduces the danger of a fire in a crash as the fuel pump is
switched off via the fuel pump relay.
When driver door is opened, the fuel pump is activated for 2
seconds to develop pressure in the fuel system. This improves
the quality of the start behaviour.
1.2 Technical data

Engine code CBRA
Idling check
166 Rep. Gr.24 - Mixture preparation - injection

Golf 2004
6-cylinder injection
wage n AGengine
. VolkswaVW
gen AIndividual
G doe - Edition 10.2009
ks s no
Vol t gu
d by ara
Engine code ris
e CBRA
nte
tho eo
Idling speed2) au rpm 590 850
ra
c
ss
ce
e
Engine control unit
nl
pt
du
an
System designation Motronic ME 7.1.1
itte
y li
erm
ab
Part number Electronic parts catalogue
ility
ot p
wit
Governed speed rpm approx. 7000
, is n
h re
hole
spec
es, in part or in w
t to the co
2) The idling speed cannot be adjusted.
1.3 Assembly overview - intake manifold
rrectness of i
Connection for variable intake manifold changeover valve -N156-
l purpos
page 169
nform
ercia
1 - Intake manifold
m
Vacuum reservoir
at
om
ion
Check vacuum reser
c
in t
or
voir for leaks with hand
his
ate
vacuum pump -VAS
do
priv
c
6213- .
um
for
en
ng

t.
yi Co
op
intake manifold C py
t. rig
page 170 .
gh ht
pyri by
Vo
o
by c lksw
2 - From cylinder head cover. cted agen
Prote AG.
3 - Crankcase breather valve

With crankcase breath
er heater element -
N79- .
4 - Seal
Renew.
5 - 10 Nm
6 - Bearing cap
For intake manifold
change-over barrel
7 - Seal
Renew.
8 - 20 Nm
9 - Vacuum connection
For brake servo.
To exhaust flap 1 valve
-N321-
To vacuum reservoir.
12 - Rear intake manifold support
For activated charcoal filter system solenoid valve 1 -N80-
14 - Vacuum hose for fuel system diagnostic pump -V144-
Vehicles for USA/Canada only
1. Repairing injection system 167

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Golf 2004 autho eo
ra
6-cylinder injection engine VW Individual - Edition 10.2009 ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Black connector faces towards T piece
ility
ot p
wit
16 - From exhaust flap 1 valve -N321-
, is n
h re
page 199
hole
spec
es, in part or in w
17 - Throttle valve module -J338-
t to the co
Including throttle valve drive (electric throttle operation) -G186- , angle sender 1 for throttle valve drive
rrectness of i
(electric throttle operation) -G187- and angle sender 2 for throttle valve drive (electric throttle operation)
-G188-
l purpos
If renewed, adapt engine control unit to throttle valve module Vehicle diagnosis, testing and information
system VAS 5051; Guided function .
nform
ercia
18 - Bracket
m
at
om
i
19 - 10 Nm
on
c
in t
or
20 - Vacuum unit
his
ate
do
riv
For intake manifold change-over.

p
cum
for
Checking vacuum unit for intake manifold flaps page 177 .
en
ng
t.
yi Co
op
21 - To intake manifold changeover valve -N156- .
C py
t. rig
gh ht
yri
Item 7 (page 169)
p by
co Vo
by lksw
cted agen
22 - Positioning lever
Prote AG.
For change-over barrel.

23 - Change-over barrel
24 - Gasket
Renew if damaged.
25 - Vacuum reservoir
For intake manifold change-over.
Check vacuum reservoir for leaks with hand vacuum pump -VAS 6213- .
26 - Dowel sleeve
To secure intake manifold.
To locate seal.
27 - 13 Nm

Golf 2004
1.3.1 Assembly overview - vacuum system
1 - Intake manifold
2 - Vacuum unit
For intake manifold
change-over.
Checking vacuum unit
for intake manifold flaps
page 177 .
3 - To intake manifold
Item 11 (page 167)
4 - To left combination valve
For secondary air.
Item 2 (page 203)
5 - To right combination valve
For secondary air.
Item 12 (page 203)
6 - Secondary air inlet valve -
N112-
Clipped to vacuum res
ervoir
To remove, bring lock
carrier into service posi
tion General body re
pairs, exterior; Rep. Gr.
50 ; Lock carrier; service
position
7 - Variable intake manifold
changeover valve -N156- AG. Volkswagen AG d
agen
Clipped to vacuum res Volksw
oes
not
gu
ervoir ed by ara
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ris
To remove, bring ut
ho lock eo
ra
carrier intossservice posi
a c
tion General body re
ce
le
un
pt
pairs, exterior; Rep. Gr.

an
d
itte
50 ; Lock carrier; service position

y li
erm
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ility
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Installation position (light/dark side): as shown in illustration

h re
ole,
spec
9 - Connector
t to the co
10 - Secondary air inlet valve 2 -N320-

Clipped to vacuum reservoir
To remove, bring lock carrier into service position General body repairs, exterior; Rep. Gr. 50 ; Lock
rrectne
carrier; service position

s
11 - Vacuum reservoir
s o
cial p
f i
12 - 10 Nm
nform
mer
atio
om
n
c
i
or
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te
sd
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fo
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Cop py
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Prote AG.

Golf 2004
1.4 Removing and installing throttle valve

module -J338-
Removing
Pull cover -1- off air duct. Release fasteners on side for this.
Remove air filter housing and connecting hose. To do this,

unscrew bolt -A-, pull off connector -B- and loosen spring-type
Disconnect electrical connector on throttle valve module -
J338- .
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d by ara
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or eo
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aut ra
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ce
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nl
pt
Unbolt throttle valve module -J338- from intake manifold
du
an
itte
-arrows-. y li
erm
ab
ility
Installing
ot p
wit
, is n

h re
hole
spec
If a new throttle valve module -J338- was installed, adapt the

es, in part or in w
engine control unit to throttle valve module -J338- Vehicle

t to the co
diagnosis, testing and information system VAS 5051 guided

functions.
rrectness of i
l purpos
nform
ercia
1.5 Removing and installing intake manifold

m
at

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ion
c
in t
r

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ate
do
priv
cum
for
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t.
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Cop py
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Prote AG.

Golf 2004
Puller -T10095 A-
Removing
Note

Assembly overview - intake manifold page 167 .
is installed.
Caution

tions:
vated charcoal filter system, coolant and refrigerant, brake AG. Volkswagen AG d
fluid and vacuum) and electrical wiring in their original
lksw po
agen oes
not
sitions.
o
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ar
d e an
ris tee
To avoid damage to lines/wiring, ensure thosufficient clear or
au
ss ac
ce
le
un
pt
an
d
itte
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erm
ab

ility
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necting battery .
wit
is n
h re
Remove throttle valve module -J338- page 174 .

ole,
spec
Pull connector off crankcase breather heater element -N79-

t to the co
and off activated charcoal filter solenoid valve 1 -N80- .

Remove wiring harness for ignition coils with output stages
from intake manifold.
rrectne
Remove ignition coils with output stage page 208 .

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
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t.
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Cop py
ht. rig
rig ht
py by
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by lksw
171
cted agen
Prote AG.
1. Repairing injection system
Golf 2004
Pull vacuum lines -arrows- off intake manifold.

Unbolt intake manifold supports on left and right of intake
manifold.
Remove bolt -1- for intake manifold support, rear (exhaust
side).
Pull crankcase breather connection hose off cylinder head
cover.
Bring lock carrier into service position General body repairs;
Rep. Gr. 50 ; Lock carrier, service position .
Pull vacuum hose off intake manifold flap vacuum unit.
Unscrew securing bolt from oil dipstick guide tube -1-.

Unscrew bolt -2- and pull vacuum reservoir -1- off intake mani
fold.
Remove intake manifold securing bolts Item 27 (page 168)
from cylinder head.
Remove intake manifold and place it on a suitable surface so
that the vacuum unit will not be damaged.
Note
Seal intake ports in intake manifold and in cylinder head with a

clean cloth.
Installing
note the following:
wage
Note yV
olks es n
ot g
d b ua
ran
ir se tee
Tighten intake manifold to cylinder headuth first, specified torque:
o
or
13 Nm ss
a ac
ce
e
nl
Then tighten the two bolts of intake manifold support on left

pt
du
an
and right: specified torque: 20 Nm

itte
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erm
ab
Then tighten rear intake manifold support: specified torque: 20

ility
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Nm
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
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horis Golf 2004
eo
ut
6-cylinder
ss ainjection engine VW Individual - Edition 10.2009 ra
c
ce
le
un
pt
1.6 Assembly overview - fuel rail
an
d
itte
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rm
ab
pe
ility
ot
1 - 10 Nm
wit
, is n
h re
hole
spec
From fuel tank
es, in part or in w
t to the co
3 - Fuel rail
4 - Injector, cylinder 6 -N84-
rrectness of i
Checking page 179 .
l purpos
5 - Cylinder head
6 - Seal
nform
Renew. mercia
a
com
tio
Before installing, mois
n in
r
ten lightly with clean en
te o
thi
gine oil.
s
iva
do
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rp
cum
7 - Retaining clip
fo
en
ng
t.
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Co
op py
ing. t. C rig
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pyri by
8 - Breather valve
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For checking fuel pres
AG.
sure
For bleeding fuel sys
tem
9 - Protective cap
10 - Connector
Black, 2-pin.
ing.
11 - Wiring harness
With connectors for in
jectors.
Clipped into wiring
channel

Golf 2004
1.7 Assembly overview - air filter
1 - To resonance air pipe

Assembly overview -
resonator with reso
nance air pipe
page 175
2 - Connecting hose
To throttle valve module
-J338- .
3 - Filter element
4 - Housing
For air mass meter -
G70-
5 - 3 Nm
6 - Air mass meter -G70-
7 - O-ring
AG. Volkswagen AG d
Renew. agen oes
olksw not
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8 - 2 Nm orise nte
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9 - Air filter upper part ss a c
ce
le
10 - 2 Nm
un
pt
an
d
itte
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11 - Connection
rm
ab
pe
ility
Clipped into air filter up
ot
wit
per part
, is n
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hole
12 - 8 Nm
spec
es, in part or in w
13 - Cover
t to the co
14 - Air duct
Secured to lock carrier. rrectness of i
15 - 5 Nm
l purpos
16 - Gasket
nform
ercia
Renew if damaged.
m
17 - Rubber bush
com
tion in
18 - 10 Nm
r
te o
thi
s
iva
do
19 - Bracket
r
rp
cum
fo
For air filter

en
ng
t.
yi Co
op
20 - Mounting pin, 9 Nm C py
ht. rig
rig ht
21 - Air filter lower part
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004
1.8 Assembly overview - resonator with resonance air pipe
1 - 10 Nm
2 - Plenum chamber bulkhead
AG. Volkswagen AG d
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3 - Rubber bush olksw not
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ara
ed
4 - Spacer sleeve horis nte
eo
aut ra
5 - From connecting hose ss c
ce
le
For air filter/ throttle
un
pt
an
d
valve module -J338-
itte
y li
Item 1 (page 174)
erm
ab
ility
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6 - 10 Nm
wit
is n
h re
7 - Resonance air pipe
ole,
spec
8 - Connecting hose
t to the co
9 - Bracket
For feed-through on ple
rrectne
num chamber
10 - Resonator
ss o
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11 - Bracket
f inform
For resonator
mer
atio
om
n
c
i
or
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te
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fo
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t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
1.9 Checking intake air preheating

Chilling spray (commercially available)
Note
Only installed on vehicles for cold climate zones.
Checking regulating flap:

Remove air filter upper part and filter element page 174 .

Golf 2004
Check regulating flap position

gen A-1-.
G. Volkswagen AG d
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olks not
Spray thermal element
db
y V -arrow- with chilling spray. gu
ara
e nte
ris
At above +14C,
tho the regulating flap must have completely e or
au
closed thesshot air connection. ac
ce
le
un
At below + 0 C, the regulating flap must have completely
pt
an
d
opened the hot air connection.

itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Golf 2004
2 Checking components
Check vacuum unit for intake manifold flaps page 177 .
Checking injectors for leaks and quantity injected page 179 .
page 181 .
2.1 Checking vacuum unit for intake mani

fold flaps
Note
Perform this test only if torque is insufficient, that is when elasticity

or pulling power is inadequate.

Hand vacuum pump -VAS 6213- or hand vacuum pump with
accessories -V.A.G 1390-
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ho eo
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nl
pt
du
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itte
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erm
ab
ility
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wit
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Prerequisites
h re
hole
spec
The variable intake manifold changeover valve -N156- is tes

es, in part or in w
ted with the vehicle diagnosis, testing and information system

t to the co
-VAS 5051B- in Guided fault finding.

Test procedure
rrectness of i
If the variable intake manifold changeover valve -N156- is OK:

l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Checking components 177

Golf 2004
Have second person abruptly increase engine speed (throttle

burst). Observe vacuum unit for intake manifold change-over:
The actuator must switch.
If the changeover does not function as described:
Check vacuum system for leaks including vacuum reservoir
on intake manifold.
Check mechanical change-over components for ease of
movement. To do this, operate rods by hand.
Check that vacuum lines are connected correctly.
Check vacuum hoses for porosity.
If no fault was found:
Remove air filter page 174 .
Pull vacuum hose off vacuum unit.
Connect hand vacuum pump -VAS 6213- to vacuum unit.
n AG. Volkswagen AG
Move slide ring -1- on hand vacuum olkpump
swa
ge -VAS 6213- to po
does
not
sition -A- for vacuum. d by V gu
ara
e nte
ris
Operate hand vacuum pump
ut repeatedly.
ho eo
ra
a c
ss
The operating rod must move.
ce
le
un
pt
an
d
Pull hand vacuum pump from vacuum unit.

itte
y li
rm
ab
The operating rod must move back to its original position.

pe
ility
ot
wit
, is n
If the operating rod does not move as described:

h re
hole
Renew vacuum unit.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004
2.2 Checking injectors for leaks and quantity injected

equipment required
Remote control for V.A.G
1348 -V.A.G 1348/3
agen
A-G. Volkswagen AG do
A
w es n
olks ot g
Adapteredcable
by
V
-V.A.G ua
ran
1348/3
hor - 2-
is tee
t or
au ac
Injection
ss rate tester -V.A.G
1602-
ce
e
nl
pt
du
an
itte
Auxiliary measuring set -
y li
erm
ab
V.A.G 1594 C-
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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cted agen
Prote AG.
Checking for leaks page 179 .

Checking injection rate page 180 .
2.2.1 Checking for leaks
WARNING

nection.
The fuel pressure must be in order, checking page 181 .

Procedure
Pull connectors off injectors.

Golf 2004
Now remove complete fuel rail (fuel lines remain connected)

page 173 .
cations
Connect left terminal (viewed looking forwards) of fuse socket
F6 and battery positive (+) using auxiliary cables from auxiliary
measuring set -V.A.G 1594 C- so that fuel pump runs.
AG. Volkswagen AG d
agen oes
Note olksw not
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This step serves only to have the fuel pump runningut when the
ho eo
ra
engine is stopped. s a c
s
ce
e
nl
pt
du
an
Check injectors for leaks (visual check).
itte
y li
erm
ab
No more than 1 to 2 drops per minute must escape from each
ility
ot p
valve when fuel pump is running.
wit
, is n
h re
If the fuel loss is greater:
hole
spec
es, in part or in w
Separate connection between fuse socket and battery positive
t to the co
and renew leaking injector page 173 .
Install injectors in reverse order. In the process, note the follow
ing:
rrectness of i
Renew O-rings on all injectors and lightly moisten with clean
l purpos
engine oil.
Insert injectors vertically and in the correct position into the fuel
nf
ercia
o
rail and secure with retaining clips.
rm
m
atio
m
Fit fuel rail with secured injectors on cylinder head and press
o
n in
c
in evenly.
or
thi
te
sd
iva
o
r
rp
cu
o
m
Note
f
en
ng
t.
yi Co
op py
If injectors are renewed, clear learnt values and adapt engine
t. C rig
gh ht
yri
control unit again Vehicle diagnosis, testing and information p by
co Vo
system VAS 5051 Guided functions.
by lksw
cted agen
Prote AG.
2.2.2 Checking quantity injected

The fuel pressure must be in order, checking page 181 .
Intake manifold removed.
Injectors installed in fuel rail and fuel line connected.
Procedure
Insert injector to be checked into measuring glass from injec
tion rate tester -V.A.G 1602- .
cations

Golf 2004
Connect left terminal (viewed looking forwards) of fuse socket

F6 and battery positive (+) using auxiliary cables from auxiliary
measuring set -V.A.G 1594 C- so that fuel pump runs.
Note
This step serves only to have the fuel pump running when the
engine is stopped.
Connect a contact of injector to be tested to engine earth using G. Volkswagen AG d

auxiliary cables from auxiliary measuring set -V.A.G 1594 C- . agen A
lksw
oes
n o ot g
yV ua
Connect second injector contact with auxiliary cableritose remote
db ran
tee
control for V.A.G 1348 -V.A.G 1348/3 A- using adapter
tho cable or
-V.A.G 1348/3 - 2- . au ac
ss
ce
le
Connect crocodile clip to battery positive (positive pole in en

un
pt
an
d
gine compartment).
itte
y li
rm
ab
Operate remote control for V.A.G 1348 -V.A.G 1348/3 A- for
pe
ility
ot
30 seconds.
wit
, is n
h re
Repeat check on other injectors. Use new measuring beakers.
hole
spec
es, in part or in w
After all injectors have been activated, place measuring beak
t to the co
ers on a level surface and compare the quantity injected.
Specification: 128140 ml per injector.
rrectness of i
When checking the quantity injected, check the spray pattern as
well.
l purpos
The spray patterns must be the same for all injectors.
nform
ercia
If the measured values of one or more injectors are above or be

m
low the prescribed specifications:
a
com
tion in
Separate connection between fuse socket and battery positive
r
te o
thi
and renew defective injector page 173 .
s
iva
do
r
rp
c
Install injectors in reverse order. In the process, note the follow
um
fo
ing: en
ng
t.
yi Co
op py
Renew O-rings on all injectors and lightly moisten with clean t. C rig
gh ht
engine oil. yri
p by
co Vo
by lksw
cted
Insert injectors vertically and in the correct position into the fuel
agen
Prote AG.
rail and secure with retaining clips.
Fit fuel rail with secured injectors on cylinder head and press
in evenly.
Note
If injectors are renewed, clear learnt values and adapt engine

control unit again Vehicle diagnosis, testing and information
system VAS 5051 Guided functions.
2.3 Checking fuel pressure regulator and

holding pressure

Golf 2004
Pressure gauge -VAS 6550-
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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Note
ce
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nl
pt
du
an
itte
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The fuel pressure regulator regulates the fuel pressure to ap
erm
ab
prox. 4.0 bar.
ility
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wit
, is n
The fuel pressure regulator is located on the fuel filter. From
h re
October 2005, the fuel pressure regulator has been integrated
hole
spec
in the fuel filter and cannot be renewed individually.
es, in part or in w
t to the co
Always follow safety precautions page 206 .
rrectness of i
l purpos
WARNING
nform
ercia

m
at
om
ion
c
in t
or
his
e
nection.
at
do
priv
cum
for
en
ng
t.
Pull off supply line (metal coupling) -arrow- and catch escaping
yi Co
op
fuel with a cloth.
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Note
Prote AG.

Golf 2004

adapter -VAS 6550/1- and -VAS 6550/2- .
Make sure that drain tap is closed and cut-off taps are open.
Note
If engine does not start, activate fuel pump with final control di
agnosis page 150 .
Read fuel pressure on pressure gauge. Specification: 3.8

4.2 bar.
If fuel pressure is OK, check holding pressure page 183 .
If the specification is exceeded:
Check fuel return line between fuel filter and flange for possible
restrictions (kinks) or blockages.
If no fault is found:
Fuel pressure regulator defective. Renew fuel pressure regu
. Volkswagen AG
lator and/or fuel filter. swa
gen AG does
olk not
yV gu
If the specification is not
ise
d battained: ara
nte
r
ho e
Check fuel lines
au for possible restrictions (kinks) or
t
blockages. or ac
ss
If no fault is found:
ce
e
nl
pt
du
an
itte
Renew fuel pressure regulator and/or fuel filter.

y li
erm
ab
ility
Repeat check.
ot p
wit
, is n
If the specifications are still not attained:

h re
hole
spec
Fuel pump is defective. Renew fuel delivery unit page 141 .

es, in part or in w
t to the co
If the specification is attained, check holding pressure.

Checking holding pressure
rrectness of i
Prerequisites:
l purpos
Fuel pressure on pressure gauge 3.8 4.2 bar

nf
ercia
orm
m
atio
Watch pressure drop on pressure gauge. After 10 minutes,

om
pressure must not drop below 3.0 bar.

n in
or c
thi
e
If the pressure drops further:

t
sd
iva
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rp
cu

o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
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cted agen
Prote AG.

Golf 2004
Switch off ignition and close shut-off tap -B- of pressure tester
immediately.
If the pressure does not drop now:
Search for leak on engine side. Repeat holding pressure test. This
time, close shut-off tap -A- to check whether leak actually is on
engine side.
Check fuel rail and injectors for leaks.
If the pressure drops again:
(Leak - fuel tank side)
Check fuel lines for leaks.
If no fault can be found on the fuel lines:
Check fuel pump non-return valve page 156 .
If no fault is found
Renew fuel pressure regulator and/or fuel filter.
When the pressure tester is removed after the test has been
completed:
Wrap a cloth around the joint to catch any escaping fuel.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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o
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f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004
3 Engine control unit

Removing and installing engine control unit page 185 .
Removing and installing anti-theft engine control unit
page 185 .
3.1 Removing and installing engine control

unit
Note
If the engine control unit is to be renewed, connect. Vvehicle diag

olkswagen AG
nosis, testing and information system -VAS wa5051B-
gen AG and perform does
ks
Renewing engine control unit in guided
by
Vol functions.
not
gu
a
ed ran
ris tee
ho
Removing au
t or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
chamber bulkhead: Electrical system; Rep. Gr. 92 ; Wind
ility
ot p
wit
wiper system .
, is n
h re
hole
Release front connector -1- from engine control unit and pull
spec
it off.
es, in part or in w
t to the co
Lever up catch -2- slightly.
Then push engine control unit out of retainer -arrow-.
rrectness of i
Then release rear connector on engine control unit and pull it
l purpos
off.
Installing
nform
ercia
Fit rear connector to engine control unit and lock in position.

m
at
om
io
Push engine control unit onto bracket.

n
c
in t
or
his
e
Fit front connector to engine control unit and lock it in position.

at
do
priv
cum
Install plenum chamber bulkhead, plenum chamber cover and

for
en
g
wiper arms Electrical system; Rep. Gr. 92 ; Windscreen

n
t.
yi Co
wiper system; Removing and installing windscreen wiper sys Cop py
t. rig
tem . opyri
gh by
Vo
ht
c by lksw
cted agen
3.2 Removing and installing anti-theft en
Prote AG.
gine control unit

Saw set -V.A.G 1561/14-
Grip pliers
3. Engine control unit 185

Golf 2004
Electric cutter -V.A.G 1561 A-
Hot air blower from wiring harness repair set -VAS 1978 B-
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
Small nozzle attachment from wiring harness repair set -VAS
1978 B-
rrectness of i
l purpos
Note
If the engine control unit is to be renewed, connect vehicle diag

nform
ercia
nosis, testing and information system -VAS 5051B- and perform

m
Renewing engine control unit in guided functions.

a
com
tion in
r
te o
thi
Removing
s
iva
do
r

rp
cum
fo
en
ng

t.
yi Co
op
chamber bulkhead: Electrical system; Rep. Gr. 92 ; Wind C py
t. rig
gh
ht
pyri by
wiper system .
co Vo
by lksw
cted agen
Prote AG.
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 (scorching/
melting of plastics etc.).
Perform settings on hot air blower -4- as shown:

Golf 2004
Turn temperature settings potentiometer -2- to a maximum

heat output of 600 C. wage
es ks not
Vol gu
Set two-stage switch for volume of air -3- to position
ed
by 3. ara
nte
ris
utho eo
ra
a
WARNING ss c
ce
le
un
pt
an
d
When shear-head bolts are heated up, parts of the protective
itte
y li
housing will be subjected to a large amount of heat. Wear pro
erm
ab
tective gloves to avoid possible injury.
ility
ot p
wit
is n
h re
ole,
spec
Place nozzle of hot air blower close to shear-head bolt.
t to the co
Switch on hot air blower and heat the bolts.
Remove bolts with grip pliers .
rrectnes
Note
s o
cial p
f inform
If the bolts will not move, saw into heads of shear-head bolts so
mer
that two parallel slots are created -arrows- and then remove the
atio
m
bolts.
o
n
c
i
or
n thi
te
sd
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cum
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fo
en
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t.
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Cop py
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Prote
Insert a screwdriver between protective housing -A- and
AG.
bracket -arrow-.
Lever up protective housing using a screwdriver -A- and pull

to side off bracket -arrow-.
3. Engine control unit 187

Golf 2004
Release front connector -1- from engine control unit and pull
it off.
Lever up catch -2- slightly.
Then push engine control unit out of retainer -arrow-.
Then release rear connector on engine control unit and pull it
off.
Installing
Fit rear connector to engine control unit and lock in position.
Push engine control unit onto bracket.
Fit front connector to engine control unit and lock it in position.
Push protective housing onto bracket.
Tighten new shear-head bolts -1- evenly until head shears 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 .
AG. Volkswagen AG d
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au ra
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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te
sd
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f
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
26 Exhaust system
1 Exhaust manifold, front exhaust pipe
with catalytic converters and Lambda
probes
Caution

tions:
sitions.
Ensure that there is sufficient clearance to all moving or
hot components.
Note
After working on the exhaust system, ensure that the system

has sufficient clearance to the bodywork. If necessary, loosen
double clamp on front exhaust pipe and realign silencer and
exhaust pipe.
Do not use sealants containing silicone. Silicone particles
drawn into the engine will not be burnt in the engine and will
damage the Lambda probes.n AG. Volkswagen A ge G do
swa es n
Renew self-locking
by
Vol nuts.
k ot g
ua
ed ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
en
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t.
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Cop py
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pyri by
Vo
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by
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Prote AG.
1. Exhaust manifold, front exhaust pipe with catalytic converters and Lambda probes 189
Golf 2004

equipment required
Lambda probe open ring
spanner set -3337-
1331-
1332-
AG. Volkswagen AG d
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pt
du
an
itte
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erm
ab
ility
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wit
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
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te
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Cop py
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Assembly overview - exhaust manifold, front exhaust pipe with Prote AG.
catalytic converters page 191
Removing and installing Lambda probe -G39- and Lambda probe
2 -G108- page 192
Removing and installing front exhaust pipe with catalytic convert
ers page 195
Assembly overview - silencers with mountings page 198
190 Rep. Gr.26 - Exhaust system

Golf 2004
1.1 Assembly overview - exhaust manifold, front exhaust pipe with catalytic
converters
AG. Volkswagen AG d
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1 - Connector d byV
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ara
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Black, 6-pin. horis
eo
aut ra
2 - Lambda probe -G39- , 55 ss c
ce
le
Nm
un
pt
an
d
Bank 1, probe 1
itte
y li
rm
ab
Installed in exhaust gas
pe
ility
stream of cylinders 1, 2
ot
wit
, is n
and 3
h re
hole
Grease only the threads
spec
with high-temperature
es, in part or in w
t to the co
paste -G 052 112 A3- ;
high-temperature paste
-G 052 112 A3- must not
rrectness of i
get into the slots of
probe body.
l purpos
Remove and install with

Lambda probe open
nform
ercia
ring spanner set -3337- .

m
3 - Lambda probe 2 -G108- , 55
a
com
tio
Nm
n in
r
te o
thi
Bank 2, probe 1
s
iva
do
Installed in exhaust gas
r
rp
cum
stream of cylinders 4, 5
fo
en
ng
and 6
t.
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Cop py
Grease only the threads ht. rig
rig ht
with high-temperature py by
co Vo
lksw
paste -G 052 112 A3- ;
by
cted agen
Prote
high-temperature paste
AG.
-G 052 112 A3- must not

get into the slots of
probe body.
Remove and install with
Lambda probe open
ring spanner set -3337- .
4 - Connector
Brown, 6-pin
5 - 40 Nm
Renew.
6 - Lambda probe 2 after catalytic converter -G131- , 55 Nm
Bank 2, probe 2
Installed in exhaust gas stream of cylinders 4, 5 and 6
Grease only the threads with high-temperature paste -G 052 112 A3- ; high-temperature paste -G 052
112 A3- must not get into the slots of probe body.
Remove and install with Lambda probe open ring spanner set -3337- .
7 - Connector
Brown, 4-pin
8 - Lambda probe after catalytic converter -G130- , 55 Nm
Bank 1, probe 2
Installed in exhaust gas stream of cylinders 1, 2 and 3
Grease only the threads with high-temperature paste -G 052 112 A3- ; high-temperature paste -G 052
112 A3- must not get into the slots of probe body.
Remove and install with Lambda probe open ring spanner set -3337- .
Golf 2004
9 - Connector
Black, 4-pin.
10 - 20 Nm
11 - Front intake manifold support agen
AG. Volkswagen AG d
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12 - Heat shield d by V gu
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13 - Rear intake manifold support autho eo
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14 - 20 Nm
ce
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nl
pt
du
an
15 - 25 Nm
itte
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erm
ab
16 - Gasket
ility
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wit
Renew.
, is n
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hole
17 - Exhaust manifold
spec
es, in part or in w
18 - 25 Nm
t to the co
Renew.
19 - To centre silencer
rrectness of i
Item 4 (page 198)
l purpos
20 - 25 Nm
nform
ercia
21 - Mounting
For front exhaust pipe
m
at
om
ion
22 - Catalytic converter
c
in t
or
his
e
Installed in exhaust gas stream of cylinders 1, 2, 3 right and 4, 5 and 6 left

at
do
priv
c
23 - Front exhaust pipe
um
for
en
ng
t.
With flexible connection (de-coupling element).
yi Co
Cop py
Flexible joints must not be bent more than 20 when removing - risk of damage.
t. rig
gh ht
pyri by
Removing and installing front exhaust pipe with catalytic converters page 195
co Vo
by lksw
cted agen
Prote AG.
1.2 Removing and installing Lambda probe

-G39- and Lambda probe 2 -G108-
Lambda probe open ring spanner set -3337-

Golf 2004
Removing
Pull off cover -1- for air duct. Disengage locking clasps on side
to do this.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
Remove air filterss housing with connection hose. To do this, c
unscrew bolt -A-, pull off connector -B- and detach spring-type
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
Separate electrical connectors -1- and -2- for Lambda probe -
s o
G39- and Lambda probe 2 -G108- .
cial p
f inform
mer
Move electrical wiring to Lambda probes clear.

atio
om
n
c
i
or
n thi
te
sd
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cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Unscrew Lambda probe 2 -G108- -1- and Lambda probe -

G39- -2-.
Installing
note the following:
On used Lambda probes, grease thread with high-tempera
ture paste. There must be no paste on the slots of the probe
body
Restore wiring to original position.
Golf 2004
1.3 Removing and installing exhaust mani

fold
Removing
Note
All cable ties which are opened or cut open when engine is re
moved must be replaced in the same position when engine is
installed.

Unbolt heat shield above exhaust manifold -arrows-.
AG. Volkswagen AG d
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un
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If fitted, unscrew bracket from front exhaust pipe -arrow-.
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
The flexible joints in the front exhaust pipe must not be bent more
t to the co
than 20 - risk of damage.
rrectness of i
l purpos
nform
mercia
Unbolt front exhaust pipe from exhaust manifolds -arrows- and
a
com
tio
push pipe back slightly.
n in
r
te o
thi
s
iva
do
r
Note
rp
cum
fo
en
ng
t.
yi
The Lambda probes remain in situ.
Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004
Unscrew 7 nuts each -arrows- on both exhaust manifolds and

remove with washers.
Pull off exhaust manifolds towards rear.
Installing
note the following:
Note
. Volkswagen AG
gen AG does
swa
Renew seals, gaskets and y Vself-locking nuts.
olk not
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Install intake manifold
aut
h page 170 . ra
ss c
Specified torques
ce
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nl
pt
du
an
itte
Component Nm
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erm
ab
Exhaust manifold to cylinder head 23 3)
ility
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wit
, is n
Front exhaust pipe to exhaust manifold 40 3)
h re
hole
Heat shield for exhaust manifold to cylinder 20
spec
head
es, in part or in w
t to the co
3) Renew nuts.
rrectness of i
1.4 Removing and installing front exhaust
l purpos
pipe with catalytic converters

Remove Lambda probe -G39- and Lambda probe 2 -G108- nform
ercia
page 192 .
m
at
If fitted, unscrew bracket from front exhaust pipe -arrow-.

om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Unscrew nuts for front exhaust pipe - accessible from above -

from exhaust manifolds -arrows-.
Golf 2004
Remove middle noise insulation.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
Remove right wheel housing liner front part.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
Remove three screws of underbody cover on right -arrows-.

t
sd
iva
o
pr
Separate electrical connectors for Lambda probe after cata cum

r
fo
lytic converter -G130- -1- and Lambda probe 2 after catalytic

en
ng
t.
yi Co
converter -G131- -2- on vehicle underbody. . Cop py
rig
ht ht
rig
Remove push-fit coupling from bracket and place wiring for py by
o Vo
Lambda probe after catalytic converter -G130- and Lambda
by c lksw
cted agen
probe 2 after catalytic converter -G131- to one side.
Prote AG.
Unscrew nuts for front exhaust pipe (accessible from below)

from exhaust manifolds -arrows-.

Golf 2004
Remove front cross member for underbody. To do this, un

screw nuts -1- and -2-.
Note
The flexible joints in the front exhaust pipe must not be bent more
than 20 - risk of damage.
Separate exhaust system at clamp -3-.
Unbolt bracket for exhaust system -arrows-.

Remove front exhaust pipe with catalytic converters.
Installing
note the following:
Note
Renew seals, gaskets and self-locking nuts.
Align exhaust system free of tension page 200 .

Specified torques
Component Nm
n AG. Volkswagen AG
Front exhaust pipe to exhaust manifold lks wage 40 4)does no
o t gu
yV
Catalytic converter to front rexhaust
ise
d b
pipe 23 4) ara
nte
ho eo
Lambda probe in front exhaust
aut pipe 50 ra
ss c
Bracket for exhaust system to subframe 23
ce
le
un
pt
an
d
itte
4) Renew bolts and nuts.

y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
ksw
Golf 2004 by V ol not
gu
d ara
6-cylinderoinjection
ris
e engine VW Individual - Edition 10.2009 nte
h eo
aut ra
ss c
2 Silencer with mountings
ce
e
nl
pt
du
an
itte
y li
Assembly overview - silencers with mountings page 198
erm
ab
ility
ot p
Aligning exhaust system free of stress page 200 .
wit
, is n
h re
Checking exhaust flap page 199
hole
spec
2.1 Assembly overview - silencers with mountings
es, in part or in w
t to the co
1 - Mounting
rrectness of i
Renew if damaged.
l purpos
2 - 25 Nm
3 - Rubber mounting
nf
ercia
orm
Renew if damaged.
m
atio
om
4 - Centre silencer
n in
or c
thi
e
Assembly with rear si

t
sd
iva
lencer
o
r
rp
cu
o
m
f
5 - Mounting with rubber

en
ng
t.
yi Co
mounting t. Cop py
rig
Renew if damaged.
gh ht
pyri by
Vo
o
by c lksw
6 - Rear silencer cted agen
Prote AG.
Assembly with centre si
lencer
7 - To vacuum unit
Fitting location in rear
left wheel housing.
Individual parts
page 199
To remove, remove
wheel housing liner
8 - Vacuum unit
Checking page 199 .
9 - Clamp
Align exhaust system
before tightening
page 200
Tighten bolted connec
tions evenly.
Installation position of
clamp page 200 .
10 - 25 Nm
11 - From catalytic converter

Golf 2004
Individual parts of vacuum unit

1 - Separating point agen
AG. Volkswagen AG d
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2 - To intake manifold Item 10 (page 167) ed by
V gu
ara
ris nte
3 - Vacuum reservoir aut
ho eo
ra
ss c
4 - Tighten bracket to 25 Nm.
ce
le
un
pt
an
d
5 - Exhaust flap 1 valve -N321-
itte
y li
erm
ab
6 - To exhaust flap vacuum unit Item 8 (page 198)
ility
ot p
wit
is n
h re
ole,
spec
2.2 Checking exhaust flap
t to the co
rrectne
Hand vacuum pump -VAS 6213-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Test procedure Prote AG.
Vacuum pipes and hose connections free of leaks.

Vacuum hoses not blocked or porous.
Pull hose off exhaust flap vacuum element.
Connect hand vacuum pump -VAS 6213- to vacuum element
-A-.
2. Silencer with mountings 199

Golf 2004
AG. Volkswagen
6-cylinder injection lengine
ksw
agen VW IndividualAG- dEdition
oes
n 10.2009
o ot g
yV ua
edb ran
Move slide ring -1- ho
rison hand vacuum pump -VAS 6213- to potee
sition -A- for vacuum.
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Create a vacuum using the hand vacuum pump -VAS 6213-
l purpos
and observe the linkage.

The linkage must move to the left and the exhaust flap
nform
ercia
-arrow- must close.

m
at
Vent hand vacuum pump -VAS 6213- .
om
ion
c
in t
r
The linkage must move to the right and the exhaust flap
o
his
e
-arrow- must open.

at
do
priv
cum
If the linkage does not move:
for
en
ng
t.
yi Co
Check the linkage for ease of movement and/or check the Cop py
vacuum element is not leaking.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
2.3 Aligning exhaust system free of stress
Prote AG.
The exhaust system must be aligned when cold.

Procedure
Separate exhaust system at clamp -1-.
Align clamping sleeve on front exhaust pipe in consideration

of dimension -a-. -Arrow- points in direction of travel. Dimen
sion -a- = 5 mm.
Tighten front bolts on clamp to 25 Nm.

lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or Golf 2004
u
ss
a
6-cylinder injection engine VW Individual ac
- Edition 10.2009
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
The bolted connections on the clamp point to the right.
h re
Note the installation position of the clamp, the bolt ends must hole
spec
not protrude beyond the bottom of the clamp.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Taking dimension -a- into account, align silencers at mounting.

-Arrow- points in direction of travel. Dimension -a- = 7 9 mm.
m
at
om
io
Tighten rear bolts on clamp to 25 Nm.
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Silencer with mountings 201

Golf 2004
3 Secondary air system

Function page 202
Assembly overview - secondary air system page 203 .
Removing and installing secondary air pump page 204 .
Checking combination valve for secondary air system AG. Volkswagen AG d
agen oes
ksw
page 205 . byV
ol not
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ara
ed
is nte
Removing and installing combination valve for secondarythoair sys
r eo
tem page 205 . ss au ra
c
ce
le
3.1 Function
un
pt
an
d
itte
y li
Air is blown from the secondary air system behind the exhaust rm
ab
pe
ility
valves for 65 seconds during a cold start (+15 C+35 C coolant
ot
wit
temperature). This produces an oxygen rich exhaust gas, causing
, is n
h re
afterburning and reducing the heat-up phase of the catalytic con
hole
verter. The activation is initiated by the engine control unit via the
spec
es, in part or in w
secondary air pump relay -J299- to combination valve. The com
t to the co
bination valve is self-opening. Additionally, after each subsequent
engine start (up to max. 80 C engine temperature), the secondary
air system will, after a 20 second delay, switch in for 5 seconds
rrectness of i
during idling and will be checked by the self-diagnosis.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Golf 2004
3.2 Assembly overview - secondary
Vol
ksair
wagesystem es n
ot g
y ua
db ran
rise tee
tho
1 - To secondary air inlet valve s au
or
ac
-N112- s
ce
le
un
pt
Item 6 (page 169)
an
d
itte
y li
2 - Left combination valve
rm
ab
pe
ility
Checking page 205 .
ot
wit
, is n
To remove, remove
h re
hole
throttle valve module -
spec
J338-
es, in part or in w
t to the co
Item 17 (page 168)
3 - Gasket
rrectness of i
Renew.
l purpos
4 - Connection
For combination valve.
nform
ercia
5 - 10 Nm
m
a
6 - Front intake manifold sup
com
tion in
port
r
te o
thi
Removing intake mani
s
iva
do
fold page 170 .
r
rp
cum
fo
en
g
7 - 20 Nm
n
t.
yi Co
Cop py
8 - Connecting hose
t. rig
gh ht
pyri by
Vo
o
9 - 9 Nm
c by lksw
cted agen
Prote AG.
10 - Connection
11 - To secondary air inlet
valve 2 -N320-
Item 10 (page 169)
12 - Right combination valve
Checking page 205 .
To remove, remove in
take manifold
page 170
13 - Spring-type clip
14 - 2 Nm
15 - Sender 1 for secondary air pressure -G609-
16 - Connector
17 - O-ring
Renew if damaged.
18 - Pressure hose
19 - Connecting piece
20 - Air filter
Clean if soiled.
21 - Secondary air pump motor -V101-
22 - 10 Nm
23 - Bracket
For secondary air pump motor.
3. Secondary air system 203

Golf 2004
24 - 20 Nm
25 - Rubber bush
3.3 Removing and installing secondary air

pump motor -V101-
Removing
Detach secondary air hose at position marked by -arrow-.
Place air hose to secondary air pump motor -V101- to one
side.
Remove middle noise insulation.
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Place bottom coolant hose on fan shroud to one side.

ab
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Disconnect electrical connector -3- for secondary air pump

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, is n
motor -V101- and place electric cable to one side.

h re
hole
spec
Unscrew bracket -2- for coolant pipe to gear oil cooler on ve

es, in part or in w
hicles with DSG.

t to the co
Remove bolts -1-.

rrectness of i
Loosen bolt -4- and remove secondary air pump with bracket.
l purpos
Installing
Install in reverse order.
nform
ercia
Specified torques page 203 .

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3.4 Checking combination valve for secon
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ab
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Procedure:
h re
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spec
Separate hose for secondary air -arrow- and connect auxiliary
hose at hose to secondary air combination valve.
t to the co
Blow from mouth into auxiliary hose using light pressure. Do
not use compressed air.
rrectne
The combination valve for secondary air system must be
closed. Blowing through must not be possible.
ss o
cial p
f
Blow from mouth into auxiliary hose using greater pressure.
inform
Do not use compressed air.
mer
atio
Combination valve for secondary air system must open. Blow
om
n
ing through must be possible.
c
i
or
n thi
te
If switch point cannot be detected, renew secondary air com
sd
iva
o
r
bination valve page 205 .

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3.5 Removing and installing combination Cop py
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valve for secondary air system
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Removing
AG.
Remove throttle valve module -J338- page 170 .

Disconnect pressure hose -A- at secondary air combination
valve.
Unscrew 2 securing bolts -arrow- and remove combination
valve.
Installing
Note
Renew seals and gaskets.
Specified torques
Component Nm
Secondary air combination valve to bracket 10
Throttle valve module -J338- to intake manifold 10
3. Secondary air system 205

Golf 2004
AG. Volkswagen AG d
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1 Ignition system
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General notes on ignition system page 206 .
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Safety precautions page 206 .
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Assembly overview - parts of ignition system page 207
h re
hole
spec
Removing and installing ignition coils with output stage
es, in part or in w
page 208 .
t to the co
Test data, spark plugs page 210
rrectness of i
1.1 General notes on ignition system
l purpos
Only the components which specifically relate to the ignition

system are dealt with here. For other components of the in
jection and ignition system, page 166 .
nform
ercia
For trouble-free operation of electrical components, a voltage

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of at least 11.5 V is necessary.
ion in
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Certain tests may lead to a fault being detected by the control

thi
s
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unit and stored. Then after completing all checks and repairs,
do
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read fault memory and erase if necessary vehicle diagnosis

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tester Guided functions.

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If, after fault finding, repairs or component tests, the engine
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starts, runs for a short period and then stops, then the fault
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may be that the immobilizer is blocking the engine control unit.
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In this case, the control unit must be adapted using vehicle
Prote AG.
diagnosis tester under Guided functions.
1.2 Safety precautions

To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
Do not touch or pull off ignition coils with output stage when
engine is running or turning at starter speed.
Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
If the engine is to be turned at starter speed without starting:
Pull connectors off ignition coils 16 using assembly tool -
T10118- .
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.
206 Rep. Gr.28 - Ignition system

Golf 2004
1.3 Assembly overview - parts of ignition

system
Note
The engine speed sender -G28- can be found on the cylinder

block Item 29 (page 19) .
1 - Ignition coil 1 with output

stage -N70-
Ignition coil 2 with output
stage -N127-
stage -N291-
stage -N292-
stage -N323-
stage -N324-
Remove using puller -
T10095 A- page 208
2 - Connector
4-pin
3 - Bracket
For connector for knock
sensor 1 -G61- .
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Black, 3-pin.auth or
ac
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Gold-plated contacts on
ce
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sensor and connector.

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Gold-plated contacts on
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sensor and connector.

is n
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Location: cylinder block

spec
exhaust side
t to the co
7 - 20 Nm
The specified torque in
fluences the function of
rrectne
the knock sensor.

s

s o
cial p
With sender wheel for Hall sender 2 -G163-

inform
If the camshaft adjuster has been removed, adjust timing page 62

mer
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9 - Cover
o
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10 - Seal
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Renew.
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11 - Hall sender 2 -G163- t. C rig
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For exhaust camshaft. cop Vo
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Gold-plated contacts on sensor and connector. Prote AG.
1. Ignition system 207

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12 - 10 Nm au ra
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13 - Connector
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Black, 3-pin.
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Gold-plated contacts on sensor and connector.
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Mark connector before removing.
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es, in part or in w
For inlet camshaft.
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Fitting location: cylinder block intake side l purpos
16 - Connector
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Black, 2-pin.
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With sender wheel for Hall sender -G40-
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If the camshaft adjuster has been removed, adjust timing page 62
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18 - Spark plug C py
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If a spark plug is replaced, regrease ignition coil with final output stage page 208 . yri
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Remove and install with spark plug socket and extension -3122 B- . cted agen
Prote AG.
Type, specified torque and electrode gap page 210
For camshaft adjustment.
1.4 Removing and installing ignition coils

with output stage

Golf 2004
6-cylinder
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VW Individual - Edition 10.2009
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Puller -T10095 A- ed
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spec
t to the co
rrectne
Lubricating paste -G 052 141 A2-
s
Removing
s o
cial p
f
Unclip cover from connector rail.
inform
mer
Fit assembly tool -T10118- on to locking mechanism button
atio
m
-arrow- and carefully pull connector off each ignition coil with
o
n
c
output stage .
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-direction of arrow- and pull out ignition coil with output stage .
Installing
Note
When fitting new spark plugs, the ignition coil must be re

greased using lubricating paste -G 052 141 A2- This will stop
the ignition coil sealing hose from sticking to the spark plug.
The lubricating paste must be distributed on the spark plug
when inserting on the ignition coil.
New ignition coils with output stage are lubricated when de
livered.

Golf 2004
Apply a thin line of lubricating paste -G 052 141 A2- around

the ignition coil sealing hose -arrow-. The bead must be 12
mm thick.
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To install, insert ignition coil with output stage into respective
spark plug hole so that the flat sides of connectors fit with each
other -arrows-.
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ate
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-direction of arrow- and push ignition coil with output stage C py
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onto spark plug. gh ht
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1.5 Test data, spark plugs

Engine code CBRA6)
Firing order 1-5-3-6-2-4
Spark plugs5)
VW/Audi 101 905 606 A
Electrode gap 0.80.9 mm
Specified torque 18 Nm
Change interval Maintenance ; Booklet 23 ; Time or distance de
pendent additional work

Golf 2004
5) Remove and install spark plugs with spark plug socket and extension -3122
B- .
6) For removal of ignition coils with output stage, use only puller -T10095 A- .
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6-Cylinder Injection Engine VW Individual

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6-Cylinder Injection Engine VW Individual

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Service

Service Department. Technical Information

matter of course, be observed.

1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.2 Removing and installing crankshaft seal on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.4 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.5 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.2 Allocation of crankshaft bearing shells (classification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.3 Fitting sender wheel to crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1.3 Assembly overview - thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1.4 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

1.6 Removing and installing fan support with fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1.9 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 128

2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

3 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

3.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

3.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

4.3 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

1.6 Assembly overview - fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

1.3 Assembly overview - parts of ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Exhaust gas recirculation no

Electronic power control yes

Variable intake manifold yes

Variable valve timing yes 3) t to the co

VR = V-arrangement in compact in-line design.

2)In exceptional circumstances min. 95 RON, however with re

3) Two independently variable camshafts.

2 Rep. Gr.00 - Technical data

10 Removing and installing engine

Engine bracket -T40074-

Torque wrench -V.A.G

Engine and gearbox jack -

1. Removing and installing engine 3

Spring-type clip pliers -VAS

Container for removed parts -V.A.G 1698-

Engine bung set -VAS 6122-

High-temperature grease -G 052 133 A2-

1.1 Removing engine

The engine is removed downwards with gearbox.

4 Rep. Gr.10 - Removing and installing engine

vides the most ergonomic working position regarding acces

sibility of engine compartment components.

Some components cannot be removed, or removed only with

the container for removed parts -V.A.G 1698- .

When doing any repair work, especially in the engine compart

ment, pay attention to the following due to the cramped condi

ance to all moving or hot components.

Disconnect earth strap at battery with ignition switched off

1. Removing and installing engine 5

Release feed-through for engine wiring harness -arrow- and

body and lay engine wiring harness on engine.

Fuel supply line is pressurised. Wear eye protection and pro

Observe rules for cleanliness page 129 .

6 Rep. Gr.10 - Removing and installing engine