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Service
Workshop Manual
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Service Department. Technical Information

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00 - Technical data ss
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10 - Removing and installing engine
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13 - Crankshaft group
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15 - Cylinder head, valve gear
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17 - Lubrication
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19 - Cooling
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20 - Fuel supply system
21 - Turbocharging/supercharging
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23 - Mixture preparation - injection
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26 - Exhaust system
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28 - Glow plug system

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

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg D3E801CBF41

Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Removing engine (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Removing engine (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.5 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.6 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1 Assembly overview - sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .en. A. G
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3.1 Assembly overview - crankshaft . . . . .V.ol.ks.w. . . . . . . . . . . . . . . . . . e.s.n.ot.g. . . . . . . . . . . . . . . . 48
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4 Pistons and conrods . . . . . . . . .or.ise.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an.te. . . . . . . . . . . . 54
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4.1 Assembly overview - pistons and au conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.ac. . . . . . . . . 54
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4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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4.3 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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4.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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4.5 Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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

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1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.3 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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2.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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2.3 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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2.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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2.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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Contents
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1.1 Oil scapacities
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Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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1.3 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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2 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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2.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line . . . . . . . . . . . . . . . . . . 109
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3.1 Assembly overview - oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 109
3.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.3 Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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3.4 Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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1.1 Parts of cooling system, body side (radiator with two radiator fans) . . . . . . . . . . . . . . . . . . 115
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1.2 Assembly overview - parts of cooling system, body side (radiator with one radiator fan) . . 117
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1.3 Removing and installing fan support with fans (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . 117
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1.4 Removing and installing fan support with fans (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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1.5 Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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1.6 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

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1.7 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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1.8 Removing and installing radiator (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . . . . . . . . . . . 126
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1.9 Removing and installing radiator (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.10 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.11 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.12 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.13 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.1 Rules for cleanliness when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 137
3 Parts of fuel supply system (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.1 Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.2 Fuel tank, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.5 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.6 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3.7 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3.8 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4 Parts of fuel supply system (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.1 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.7 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5 Parts of fuel supply system (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.1 Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.2 Emptying fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
ii Contents

6 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
6.1 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7 Tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7.1 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7.2 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.3 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
1.4 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.5 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1.6 Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.7 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.8 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
23 - Mixture preparation e-ninjection

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1.1 Safety ris precautions . . . . . . . . . . . . . . . . . . . .n.te.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 Removing and installing pre-wired wiring harness for unit injectors and glow plugs . . . . . . 226
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1.4 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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1.5 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

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1.6 Adjusting non-contact gap of unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

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1.7 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

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1.8 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

hole
spec
1.9 Cleaning the intake manifold flap support, Engine code BLS and BXJ . . . . . . . . . . . . . . . . 237
es, in part or in w
t to the co
1.10 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
2.1 Reading and clearing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
rrectness of i
2.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

l purpos
2.3 Removing and installing engine control unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

2.4 Removing and installing anti-theft engine control unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . 241
nform
ercia
2.5 Removing and installing engine control unit (Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.6 Removing and installing anti-theft engine control unit (Golf Plus) . . . . . . . . . . . . . . . . . . . . 244
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2.7 Removing and installing engine control unit (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

n in
r
te o
2.8 Removing and installing anti-theft engine control unit (Touran) . . . . . . . . . . . . . . . . . . . . . . 247
thi
s
iva
do
3 Engine control unit (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

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3.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

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3.2 Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
p by
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by c lksw
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1 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Prote AG.
1.1 Assembly overview - front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . . . 255
1.2 Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . 256
1.3 Assembly overview - silencer with mountings (vehicles with front wheel drive) . . . . . . . . . . 258
1.4 Assembly overview - silencers (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1.5 Assembly overview - silencer with mountings (vehicles with four-wheel drive) . . . . . . . . . . 262
1.6 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.1 Assembly overview - parts of exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.2 Checking mechanical exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Contents iii
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.1 Removing, installing and checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.2 Characteristics of ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.3 Removing, installing and checking ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
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iv Contents
00 – Technical data
1 Technical data
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Engine number ⇒ page 1 agen oes
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1.1 Engine number s a c
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1.2 Engine data
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Edition 07.2010 Version 5.0

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AVQ BJB BKC BRU BLS BXE BXF BXJ
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Golf/Golf Plus produc‐ 10.03 ► 10.03 ► 04.04 ► 02.06 ► 03.06 03.06 11.07
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Passat 05.05► 03.06 12.04► C py
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Touran 02.03 ► 10.03 ► 10.04 02.06 ► 03.06 03.06 ► 10.06 ►
c by lksw
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production ►
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Emissions fulfil EU4 stan‐ EU3 EU4 EU4 EU4 EU4 EU4 EU4 stan‐
dard standard standard stan‐ stan‐ stan‐ stan‐ dard
dard dard dard dard
Capacity l 1.9 1.9 1.9 1.9 1.9 1.9 1.9 1.9
Output kW at rpm 74/4000 77/ 77/ 66/ 77/ 77/ 66/ 66/
4000 4000 4000 4000 4000 4000 4000
Torque Nm at 250/1900 250/ 250/ 210/ 250/ 250/ 210/ 210/
rpm 1900 1900 1800 ...2 1900 1900 1800 1800 ...25
500 00
Bore ∅ mm 79.5 79.5 79.5 79.5 79.5 79.5 79.5 79.5
Stroke mm 95.5 95.5 95.5 95.5 95.5 95.5 95.5 95.5
Valves per cylinder 2 2 2 2 2 2 2 2
Compression ratio 19.0 19.0 19.0 19.0 18.5 18.5 19.0 19.0
Fuel according DIN EN DIN EN DIN EN DIN EN DIN EN DIN DIN EN DIN EN
to 590 590 590 590 590 EN 590 590
590
Firing or‐ 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4- 1-3-4-2 1-3-4-2
der 2
Catalytic yes yes yes yes yes yes yes yes
converter
Exhaust yes yes yes yes yes yes yes yes
gas recir‐
culation
1. Technical data 1
AVQ BJB BKC BRU BLS BXE BXF BXJ

Tur‐ yes yes yes yes yes yes yes yes
bocharg‐
ing/super‐
charging
Charge air yes yes yes yes yes yes yes yes
cooler
Particulate no no no no yes no no yes
filter
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Prote AG.
Rep. gr.00 - Technical data
10 – Removing and installing engine

1 Removing and installing engine
Removing engine (Golf, Golf Plus) ⇒ page 3
Removing engine (Touran) ⇒wpage
agen 9
AG. Volkswagen AG d
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Removing engine (Passat)
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Securing engineauto
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Notes on installing ⇒ page 21 .
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Assembly mountings ⇒ page 22

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1.1 Removing engine (Golf, Golf Plus)
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Special tools and workshop
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♦ Lifting tackle -2024 A-
♦ Engine bracket -T10012-
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♦ Support clamp -VW 313-
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♦ Engine and gearbox sup‐

port -VW 540-
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♦ Workshop hoist -V.A.G

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♦ Drip tray -V.A.G 1306-

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1. Removing and installing engine 3

♦ Torque wrench -V.A.G

1331-
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Spring-type clip pliers -VAS
5024-
♦ Stepladder -VAS 5085-
♦ Guide rods -T10093-
♦ Cable ties
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♦ Before carrying out further work, disconnect battery earth

strap. First check whether a coded radio is fitted and obtain nf
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anti-theft coding if necessary.

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♦ The engine is removed downwards together with the gearbox.

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♦ All cable ties which are opened or cut through when engine is
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4 Rep. gr.10 - Removing and installing engine

WARNING
When doing any repair work, especially in the engine com‐

partment, pay attention to the following due to the cramped
conditions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
Procedure
– With ignition switched off, disconnect earth strap from battery.
One-piece engine cover
For one-piece engine cover, pull engine cover abruptly upwards
at front and right -arrows A-, then pull forwards out of rear fas‐
tening -arrow B-.
Two-piece engine cover

For two-piece engine cover, first pull outer engine cover abruptly
upwards at -arrows-, then pull inner engine cover abruptly up‐
wards at -arrows-. gen AG
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– Remove plenum chamber bulkhead. ⇒ General dbody by
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– Remove air filter housing with air mass meter
ss
a and connecting c
pipe.
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– Remove bolt -arrow A- and pull air filter housing upwards out
of mounting.
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– Remove battery and battery tray.

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– Disconnect fuel supply and return lines as well as coolant line

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WARNING
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Assembly overview - Body - front .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
– Drain coolant ⇒ page 123 .
Vehicles with air conditioner
AG. Volkswagen AG d
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To prevent damage to condenser
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To facilitate removing and installing engine without opening re‐

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– Remove poly V-belt ⇒ page 25 .

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– Remove air conditioner compressor ⇒ Heating, air condition‐

h re
hole
ing; Rep. gr. 87 ; Removing and installing compressor brack‐

spec
et .
es, in part or in w
t to the co
– Secure air conditioner compressor to lock carrier so that re‐

frigerant lines/hoses are free of stress.
rrectness of i
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐

ing and installing alternator and poly V-belt .
l purpos
Continuation for all vehicles

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– Remove connecting pipes between charge air cooler and en‐

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gine.
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– Unbolt left and right-hand drive shafts from gearbox ⇒ Run‐

or c
ning gear, axles, steering; Rep. gr. 40 ; Removing and in‐

thi
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a
stalling drive shaft .

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– Remove front exhaust pipe ⇒ page 255 .

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Golf 2004 ➤ , GolflksPlus
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– Open all cable guide fasteners -arrows-.
au ra
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– Remove wiring harness from cable guide on longitudinal mem‐
un
pt
ber and lay to side on engine.
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– Pull off or disconnect all other electrical connections from en‐
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gine and gearbox as necessary and lay to side.
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– Separate all connecting, coolant, vacuum and intake hoses
ole,
spec
from engine.
t to the co
Vehicles with manual gearbox
– Remove slave cylinder for hydraulic clutch. ⇒ 6-speed manual
gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism; As‐
rrectne
sembly overview - hydraulics .
s
– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
s o
gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .
cial p
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Vehicles with four-wheel drive:
mer
atio
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– Remove selector mechanism from gearbox ⇒ 6-speed man‐

o
n
c
ual gearbox 02Q, four-wheel drive; Rep. gr. 34 ; Repairing
i
or
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selector mechanism .
t
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– Separate pressure line for hydraulic clutch control.
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– Remove front propshaft ⇒ Final drive 02D, 0AV; Rep. gr. 39 ;
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Continuation for all vehicles:
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– Unbolt pendulum support -arrows-.

Vehicles with particulate filter
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Removing and installing drive shafts .
– Remove steering box ⇒ Running gear, axles, steering; Rep.
gr. 48 ; Removing and installing steering box .
– Insert engine bracket -T10012- in engine and gearbox jack -

V.A.G 1383 A- .
Note
Support pins must be secured to engine bracket -T10012- as

shown.
– Fit engine bracket -T10012- to cylinder block with M10 x 25/

8.8 bolt and tighten to approx. 40 Nm.
– Raise engine and gearbox slightly using engine and gearbox
jack -V.A.G 1383 A- .

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– Unbolt assembly mounting on engine side from engine bracket
au
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-arrows-. ss
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To remove securing bolts, use stepladder -VAS 5085- .
h re
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spec
t to the co
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– Unbolt assembly mounting on gearbox side from gearbox
ss
bracket -arrows-.
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– Carefully lower engine with gearbox.
form
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Engine with gearbox must be guided carefully when lowered to
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1.2 Removing engine (Touran)

equipment required
♦ Engine and gearbox sup‐
port -VW 540-
1202 A-
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1331-
1332-
V.A.G 1383 A-
5024-
♦ Guide rods -T10093-
♦ Cable ties
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WARNING

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– Remove air filter housing with air mass meter and connecting
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of mounting.
on cylinder head.

WARNING
– Remove noise insulation. ⇒ General body repairs, exterior;

Rep. gr. 50 ; Body - front; Assembly overview .
– Bring lock carrier into service position. ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier service
position .
– Drain coolant ⇒ page 123
Vehicles with air conditioner
Note
To prevent damage to condenser or to refrigerant lines/hoses,

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

frigerant circuit:
– Remove air conditioner compressor. ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Removing and installing compressor brack‐
et .
AG. Volkswagen AG d
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– Secure air conditioner compressor to lock carrier soolthat
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moving and installing alternator with poly
ss V-belt .
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– Remove connecting pipes between charge air cooler and en‐

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ab
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– Unbolt left and right-hand drive shafts from gearbox ⇒ Run‐

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ning gear, axles, steering; Rep. gr. 40 ; Removing and in‐

hole
spec
stalling drive shaft .

es, in part or in w
t to the co
– Remove front exhaust pipe.
– Remove securing nuts -arrows- for engine control unit.

rrectness of i
– Release connector from engine control unit, disconnect con‐

l purpos
nector.
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Prote AG.
Rep. gr.10 - Removing and installing engine

– Separate all connecting, coolant, vacuum and intake hoses
from engine.
– Remove slave cylinder for hydraulic clutch. ⇒ 6-speed manual
– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .

– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe .
Rep. gr. 40 ; Removing and installing drive shafts .
– Remove steering box ⇒ Running gear, axles, steering; Rep.
gr. 48 ; Removing and installing steering box .
Continuation for all avehicles:
gen AG
. Volkswagen AG
do
ksw es n
Vol ot g
d by ua
ran
e
ris tee
– Insert
utho engine bracket -T10012- in engine and gearbox or jack -
V.A.G
ss
a 1383 A- . ac
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
Support pins must be secured to engine bracket -T10012- as

wit
, is n
shown.
h re
hole
spec
es, in part or in w
– Fit engine bracket -T10012- to cylinder block with

t to the co
M10 × 25/ 8.8 bolt and tighten to approx. 40 Nm.

rrectness of i
jack -V.A.G 1383 A- .

l purpos

-arrows-.
nform
mercia
Note
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.


bracket -arrows-.
Note
Engine with gearbox must be guided carefully when lowered to

1.3 Removing engine (Passat)

equipment required
AG. Volkswagen AG d
♦ Engine and gearbox sup‐ agen oes
olksw not
port -VW 540- or engine d byV gu
ara
and gearbox support -VAS orise nte
eo
6095- aut
h
ra
ss c
ce
e
nl
pt
du
1202 A- or workshop crane
an
itte
-VAS 6100-
y li
erm
ab
ility
♦ Drip tray -V.A.G 1306- or
ot p
wit
drip tray -VAS 6208-
, 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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Torque wrench (5... 50 Nm)

-V.A.G 1331-
♦ Torque wrench (40... 200
Nm) -V.A.G 1332-
V.A.G 1383 A-
5024-
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
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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
Not illustrated:
l purpos
♦ Container for removed parts -V.A.G 1698-
nform
ercia
♦ Engine bung set -VAS 6122-

m
♦ Grease -G 000 100-

com
tion in
♦ Cable ties
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.

Procedure
AG. Volkswagen AG d
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olksw not
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Note ised b ara
nte
or eo
h
aut ra
♦ Before carrying
ss out further work, disconnect battery earth c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
♦ Leave ignition key in ignition lock to prevent steering lock from
wit
, is n
h re
engaging.
hole
spec
♦ It is advisable to remove the front wheels before beginning
es, in part or in w
engine removal. The vehicle can then be lowered on hoist until
t to the co
the brake disc splash plates are just above the floor. This pro‐
vides the most ergonomic working position regarding acces‐
sibility of engine compartment components.
rrectness of i
l purpos

is installed.
nform
ercia
♦ To prevent damage to removed components, place them in

m
the container for removed parts -V.A.G 1698- .
at
om
ion
c
♦ Some components cannot be removed, or removed only with

in t
or
his
e
difficulty, with the engine installed. Therefore, you should de‐

at
do
riv
termine all defective components before removing engine and

p
cum
or
renew them while engine is removed.

f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
WARNING py by
co Vo
by lksw
cted agen
Prote AG.
conditions:
sitions.
hot components.
– Read fault memories of all control units before removal ⇒ Di‐

agnosis tester VAS 5051; Guided fault finding; Vehicle system
test or VAS 5052; Vehicle self-diagnosis .
One-piece engine cover
For one-piece engine cover, pull engine cover abruptly upwards
at front and right -arrows A-, then pull forwards out of rear fas‐
tening -arrow B-.


wage es n
For two-piece engine yV
olk cover, first pull outer engine
s otcover
gu abruptly
upwards at -arrows-,
ised b then pull inner engine cover abruptly
ara
nte up‐
wards at -arrows-.
tho
r eo
s au ra
c
s
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
or
m
m
atio
of mounting.
om
n in
or c
– Remove air filter housing together with air mass meter and
thi
e
connecting pipe.
t
sd
iva
o
r
rp
cu

o
m
f
en
ng
t.
yi Co
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐ Cop py
screen wiper system; Removing and installing wiper arms . ht. rig
rig ht
py by
o Vo
– Remove plenum chamber cover ⇒ General body repairs, ex‐
by c lksw
cted agen
terior; Rep. gr. 64 ; Removing and installing plenum chamber
Prote AG.
cover.
Vehicles without anti-theft alarm system
– Release and disconnect connector from engine control unit ⇒
page 251 , Removing and installing engine control unit.
Vehicles with anti-theft alarm system
– Release and disconnect connector from engine control unit ⇒
page 240 , Removing and installing engine control unit with
theft protection.
– Remove feed-through for engine control unit wiring harness

-arrow-.


AG. Volkswagen AG d
agen oes
olksw not
yV g
– Pull off fuel supply hoses-2-, ed fuel return hose -1- and coolant uara
b
nte
hose -3-. ho
ri
eo
aut ra
ss c
ce
e
WARNING
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
– Remove wire from central electrics -arrow-. 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.
– Unscrew earth cable from longitudinal member.

– Separate all connecting, vacuum and intake hoses from en‐
gine.
ual gearbox 0A4; Rep. gr. 34 ; Repairing selector mechanism .
– Remove hydraulic clutch slave cylinder ⇒ 5-speed manual
gearbox 0A4; Rep. gr. 30 .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
– Pull connector off oil level and oil temperature sender -G266- .

AG. Volkswagen AG d
agen oes
olksw no
d by
V
Golf 2004 ➤ , Golf tPlusgu 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
ara
e nte
horis 4-cylinder diesele o engine (1.9 l engine) - Edition 08.2010
aut ra
ss c
– Pull retainer for oil level and oil temperature sender -G266-
ce
le
un
connector off subframe.
pt
an
d
itte
y li
rm
ab
pe
ility
– Completely remove exhaust pipes from auxiliary heater ⇒
ot
wit
, is n
Heating, air conditioning; Rep. gr. 82 .
h re
hole
spec
– Pull off coolant hoses on coolant pipes to supplementary
es, in part or in w
heater.
t to the co
– Separate all other coolant hoses from engine.
– Unbolt left and right drive shafts from gearbox ⇒ Running
rrectness of i
gear, axles, steering; Rep. gr. 40 ; Removing and installing
l purpos
drive shafts .
nform
mercia
a
com
ti
frigerant circuit:
on in
r
te o
thi
s
iva
do
r
rp
c
– Remove air conditioner compressor from ancillary bracket ⇒
um
fo
Heating, air conditioning; Rep. gr. 87 ; Removing and in‐
en
ng
t.
yi
stalling compressor bracket .
Co
Cop py
t. rig
gh
– Secure air conditioner compressor to lock carrier so that re‐
ht
pyri by
Vo
o
frigerant lines/hoses are free of stress. by c lksw
cted agen
Prote AG.
Note
To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or bent.
– On vehicles with particulate filter remove subframe ⇒ Running

gear, axles, steering; Rep. gr. 40
– Unscrew rear coolant pipe ⇒ page 120 .
– Tighten engine bracket -T10012- on cylinder block with se‐

curing nut and M10 × 25/ 8.8 bolt to approx. 40 Nm.
– Insert engine bracket -T10012- in engine and gearbox jack -
V.A.G 1383 A- .
jack -V.A.G 1383 A- .


-arrows-.
Note

bracket -arrows-.
Note
Note
Engine with gearbox must be guided carefully when lowering to

AG. Volkswagen AG d
agen oes
olksw not
1.4 Securing engine to assembly stand
ise
d by V gu
ara
nte
o r eo
h
When working on the engine,
s a secure it to support clamp -VW 540-
ut ra
c
of the assembly stand using
s engine and gearbox support -VW
ce
e
313- .
nl
pt
du
an
itte
y li
Procedure
erm
ab
ility
ot p
– Disconnect gearbox.
wit
, is n
h re
– Attach lifting tackle -2024 A- as shown and raise engine out of

hole
engine and gearbox jack -V.A.G 1202 A- using workshop

spec
crane -V.A.G 1383 A- .

es, in part or in w
t to the co
Belt pulley end: 2nd hole in hook rail at position 1

Flywheel end: 4th hole in hook rail at position 8
rrectness of i
l purpos
WARNING
nf
ercia
The hooks and locating pins must be secured with locking pins.
orm
m
atio
om
n in
or c
thi
te
Note
sd
iva
o
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cu
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m
f
♦ The holes marked with 1 … 4 of the support bar point to the

en
ng
t.
yi
belt pulley.
Co
Cop py
t. rig
gh
♦ The holes in the hook rails are counted up from the hook.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Secure engine on support clamp -VW 540- using engine and
gearbox jack -VW 313- .

1.5 Notes on installing

Installation is carried out in the reverse order. When installing,
note the following:
– Check clutch release bearing for wear and renew if necessary.
– Lubricate splines of input shaft lightly with G 000 100.
– Check whether dowel sleeves for centring engine and gearbox
are in cylinder block and install if necessary.
When installing engine, ensure correct position of assembly
mounting:
– On belt pulley side, ensure that there is a distance -a- of at
least 10 mm between engine support and right longitudinal
member.
– The side surface of the engine support -2- should be located
parallel to the support arm -1-. Dimension -x- must be identical
at top and bottom.
Note
Distance -a- = 10 mm can also be checked

agen
AG. Vwith
olkswaage
metal
n AG d rod of
suitable size, or similar. Volksw
oes
not
g y ua
db ran
rise tee
tho or
– Ensure that the edges
ss
of the support arm on the gearbox as‐ au ac
sembly mounting -2- and gearbox support -1- are parallel with ce
e
nl
one another. Dimension -x- must be identical at top and bot‐

pt
du
an
tom.
itte
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
♦ Specified torques for assembly mountings ⇒ page 22

es, in part or in w
t to the co
♦ Electrical connections and routing. ⇒ Electrical system; Rep.

gr. 97
rrectness of i
Procedure
l purpos
– Install pendulum support.

– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
nform
ercia
40 ; Removing and installing drive shafts .

m
at
om
– Install front exhaust pipe ⇒ page 255 .

on
c
in t
or
Vehicles with manual gearbox

his
ate
do
riv
– Install slave cylinder for hydraulic clutch ⇒ 6-speed manual

p
cum
or

f
en
ng
t.
yi
Co
Cop py
t. rig
gh
ht
pyri by
Vo
ual gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .
o
by c lksw
cted agen
Prote AG.
– Install selector mechanism on gearbox ⇒ 6-speed manual
gearbox 02Q, four-wheel drive; Rep. gr. 34 ; Repairing selec‐
tor mechanism .
– Install pressure line for hydraulic clutch mechanism.
– Install front propshaft ⇒ Final drive 02D, 0AV; Rep. gr. 39 ;
Assembly overview - repairing propshaft .

AG. Volkswagen AG d
agen oes
Continuation for all vehicles: olksw not
V gu
d by ara
e
– On vehicles with particulate filter install
horissubframe ⇒ Running nte
eo
gear, axles, steering; Rep. gr. 40 s aut ra
c
s
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Removing
ce
e
nl
pt
du
and installing alternator and poly V- belt .
an
itte
y li
erm
ab
– Install air conditioner compressor ⇒ Heating, air conditioning;
ility
Rep. gr. 87 ; Removing and installing compressor bracket. ot p
wit
, is n
h re
– Install poly V-belt ⇒ page 26 .
hole
spec
– Install noise insulation ⇒ General body repairs, exterior; Rep.
es, in part or in w
t to the co
gr. 50 ; Assembly overview - Body - front .
– Install engine control unit ⇒ page 239 .
rrectness of i
– Install plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulk‐
l purpos
head .
– Fill coolant system with coolant ⇒ page 123 .
nf
ercia
orm
– Carry out road test and then read fault memory ⇒ page
m
atio
m
239 .
o
n in
or c
Specified torques
thi
te
sd
iva
o
r
Threaded connection Specified torque

rp
cu
o
m
f
en
ng
Bolts, nuts M6 10 Nm
t.
yi Co
Cop py
M8 20 Nm
t. rig
gh ht
pyri by
M10 45 Nm
o Vo
by c lksw
cted agen
Prote
M12 60 Nm
AG.
1.6 Assembly mountings

Engine assembly mountings
A = 20 Nm + 90° further 1)
B = 40 Nm + 90° further 1)
C = 60 Nm + 90° further 1)
1) Renew.
Gearbox assembly mounting

A = 40 Nm + 90° further 1)
B = 60 Nm + 90° further 1)
1) Renew.

Pendulum support
Always note the size and strength rating of bolt. Different specified
torques are valid.
AG. Volkswagen AG d
agen oes
olksw not
V gu
Caution d by ara
ise nte
or eo
h
ut ra
From model year 08, in manual gearboxes 02Q
ss a
Heli Coil in‐ c
serts are installed in the threaded connections to pendulum
ce
e
nl
pt
du
support. Difference ⇒ Rep. gr. 34
an
itte
y li
erm
For these and all other gearboxes bolts with strength rating
ab
ility
10.9 must be used.
ot p
wit
, is n
If Heli Coil inserts are not fitted in manual gearboxes 02Q, use
h re
hole
bolts with strength rating 8.8 and the specified torques.
spec
es, in part or in w
t to the co
Bolt -A-
rrectness of i
M10 x 35 strength rating 8.8: turn 40 Nm + 90° further
l purpos
Always renew after removing
nf
ercia
o
Bolt -B-
rm
m
atio
m

o
n in
or c
thi
te
sd
iva
o
r

rp
cu
o
m
f
en
ng
Bolt -C-
t.
yi Co
Cop py
t.
M14 x 1.5 x 70
rig
gh ht
pyri by
Vo
o
by c
100 Nm + 90° turn
lksw
cted agen
Prote AG.
Do not tighten until pendulum support is bolted on gearbox

13 – Crankshaft group
1 Dismantling and assembling engine
Assembly overview - poly V-belt drive ⇒ page 24 .
Removing and installing poly V-belt ⇒ page 25 .
Assembly overview - toothed belt drive ⇒ page 28 .
Assembly overview - crankcase ⇒ page 32 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Note thor eo
au ra
ss c
If large quantities of swarf or metal particles (caused, for example,
ce
le
un
pt
by partial seizure of the crankshaft or conrod bearings) are found
an
d
itte
in the engine oil when performing repairs, clean the oil passages
y li
erm
ab
thoroughly and renew the engine oil cooler in order to prevent
ility
ot p
subsequent damage.
wit
is n
h re
ole,
1.1 Assembly overview - poly V-belt drive
spec
t to the co
1 - Belt pulley and vibration
damper
rrectne
❑ Can only be installed in
one position, holes are
ss
offset.
o
cial p
f in
2 - 25 Nm
form
mer
3 - Alternator
atio
om
n
c
i
4 - Bracket
or
n thi
te
sd
❑ For alternator and air
iva
o
r
conditioner compressor.
p
cum
r
fo
en
ng
5 - Poly V-belt tensioning ele‐

t.
yi Co
op
ment
C py
t. rig
gh ht
yri
❑ Swing with ring spanner p by
co Vo
lksw
to slacken poly V-belt.
by
cted agen
Prote AG.
6 - 25 Nm
7 - Air conditioner compressor
8 - 25 Nm
9 - Dowel sleeves
10 - Poly V-belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing and installing
⇒ page 25
24 Rep. gr.13 - Crankshaft group

GolfAG
2004
. Volks➤
wa,ge
Golf
n AG Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
agen does
olksw 4-cylinder diesel
not engine (1.9 l engine) - Edition 08.2010
yV gu
db ara
ise nte
1.1.1 Removing poly V-belt or eo
h
aut ra
ss c
Special tools and workshop equipment required
ce
e
nl
pt
du
an
♦ Locking pin -T10060 A- 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
♦ 16 mm open-end spanner -T 10241-
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
o
by c lksw
cted agen
Prote AG.

– Remove lower part of front right wheel housing liner ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Removing and in‐
stalling wheel housing liner .
WARNING
– Golf, Golf Plus, Touran: Pull fuel filter out of bracket and place
it with hoses to one side.
1. Dismantling and assembling engine 25

– Only Passat: Separate push-fit couplings of fuel lines

-arrows-.
Note
Do this by lifting catch of push-on connectors.
All other vehicles continued . Volkswagen AG

gen AG doe
swa
– Unbolt fuel filter from engine yV
olk assembly mounting and slay not to
gu
side (hoses remain connected).
ised b ara
nte
or eo
th
– Mark direction of s aurotation of poly V-belt. ra
c
s
ce
– Swing tensioning element in direction of arrow to remove ten‐
le
un
pt
sion from poly V-belt.
an
d
itte
y li
erm
ab
ility
The open-end spanner 16 mm -T 10241- is particularly well suited
ot p
wit
to relieve tension.
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Lock tensioning element using locking pin -T10060 A- .

o
n
c
i
or
n thi
– Remove poly V-belt.

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.
1.1.2 Installing poly V-belt

– Install in reverse order.
Note
♦ Ensure, before installing poly V-belt, that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
♦ When fitting poly V-belt, check direction of belt rotation and
ensure proper seating of belt in pulleys.
♦ Lastly, place poly V-belt over alternator.
– Only Passat: Install fuel filter. Specified torque: 10 Nm.

After completing repairs always:

n AG. Volkswagen4-cylinder
AG do diesel engine (1.9 l engine) - Edition 08.2010
lkswage es n
Vo ot g
– Start engine and by ua
edcheck belt running. ran
oris tee
h
Belt drive without
au air conditioner compressor
t 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
Belt drive with air conditioner compressor
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.

1.2 Assembly overview - toothed belt drive
1 - Toothed belt guard upper

part
2 - 100 Nm
3 - 25 Nm
4 - Camshaft pulley
5 - Hub
❑ With sender wheel
❑ Use counterhold tool - wage
es n
T10051- to loosen andy Vo lks ot g
ua
tighten. ir se
d b ran
o tee
❑ To remove, use au puller -
th or
ac
T10052- . ss
ce
e
nl
pt
du
an
⇒ page 97 , remov‐
itte
y li
ing and installing
erm
ab
ility
camshaft.
ot p
wit
, is n
6 - 10 Nm
h re
hole
spec
❑ Renew.
es, in part or in w
t to the co
7 - Stud
❑ 15 Nm
rrectness of i
8 - Rear toothed belt guard
l purpos
9 - 25 Nm
10 - Sealing grommet
nform
ercia
❑ Renew if damaged.
m
at
11 - 20 Nm + turn (45°)
om
ion
c
in t
or
12 - Tensioning roller
his
ate
do
riv
❑ Remove engine support

p
in order to remove and

um
for
en
g
install ⇒ page 29 .
n
t.
yi Co
Cop py
13 - 20 Nm
t. rig
gh ht
pyri by
Vo
o
14 - Idler roller
c by lksw
cted agen
Prote AG.
15 - Coolant pump
❑ Removing and installing ⇒ page 128
16 - Crankshaft toothed belt pulley
17 - 120 Nm + turn (90°)
❑ Renew.
❑ Use counterhold tool -3099- to loosen and tighten.
❑ Do not additionally oil or grease thread and shoulder.
❑ Turning further can be done in several stages.
18 - 15 Nm
19 - Toothed belt guard lower part
20 - Belt pulley and vibration damper
❑ Can only be installed in one position, holes are offset.
21 - 10 Nm + turn (90°)
❑ Renew.

22 - Cover
23 - Toothed belt
❑ Mark direction of rotation before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing and tensioning ⇒ page 66 .
24 - 40 Nm + turn (180°)
❑ Renew.
25 - Toothed belt guard centre part
26 - Engine bracket
1.3 Removing and installing engine support

♦ Support bracket -10 - 222 A- n AG. Volkswagen AG do
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♦ Torque wrench -V.A.G 1331- d byV
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– Remove engine cover.
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– To do this, pull engine cover upwards abruptly at front and right
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-arrows A- and then pull forwards out of rear fastening
pt
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-arrow B-.
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– Separate push-on connectors of fuel lines -arrows-.
Note
♦ Do this by pressing in catch of push-on connectors.

♦ Ensure that no fuel escapes (use a cloth).
– Lay fuel filter with hoses to side.

– Disconnect coolant hose from top of expansion tank.
– Remove expansion tank and lay it to side.
– Remove charge air pipe between charge air cooler and tur‐
bocharger.
– Carefully cover or seal open ends.
Golf, Golf Plus and Touran:
– Fit engine support bracket -10-222A- with adapters -10-222A/

13- and take up weight of engine in installation position.
AG. Volkswagen AG d
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– Remove securing bolts from assembly mounting/engine sup‐
ility
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port -arrows- and remove complete assembly mounting.
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Note
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♦ The assembly mounting may only be removed if the engine is
supported with support bracket 10-222A!
rrectne
♦ The engine support must only be loosened when the assembly
mounting has been removed. ss o
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mer
WARNING
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When raising and lowering engine using support bracket

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-10-222A- , ensure that no components or hoses are damaged,

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strained or torn off.

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– Remove noise insulation ⇒ General body repairs, exterior; C py
t. rig
gh
Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐
ht
pyri by
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– Remove front right wheel housing liner.

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

bolts of engine support can be loosened and removed.
– Lower engine with support bracket -10-222A- until lower bolt
can be loosened and removed.
– Remove engine support upwards.
Installing
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– Position engine support from aboveolks
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– Insert new bolts and tighten horis
by hand. tee
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The tightening sequence and specified torques for the engine
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support securing bolts must always be followed. Otherwise the
ot
engine support can be stressed and it can break.
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es, in part or in w
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– Tighten bolts for engine support in the sequence shown
-1…3- to 40 Nm + (180°) turn further. To do this, raise or lower
engine using support bracket -10 - 222 A- .
rrectness of i
I : Engine support with less clearance to engine
l purpos
II: Engine support with greater clearance to engine
nform
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Note
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Before installing assembly mounting, tighten all engine support
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bolts to prescribed torque.
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– Install assembly mounting between engine and body, renew

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securing bolts ⇒ page 22 .
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– Bolt engine assembly mounting to engine support -arrows- by

bringing contact surfaces together using support bracket
-10-222A- . Specified torque: 60 Nm + turn 90° further.
Further assembly is basically the reverse of the dismantling se‐
quence. In the process, note the following:
♦ Ensure that fuel hose connections are tight.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
♦ When installing charge air pipes, ensure that locking lugs en‐
gage correctly.
– Install wheel housing liner.
– Install noise insulation. ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body - front, assembly overview - noise insulation .

1.4 Assembly overview - crankcase
1 - Cylinder block
sealing flange and fly‐
wheel ⇒ page 33 .
crankshaft ⇒ page
48 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 48
2 - Seal
❑ Renew.
3 - Oil filter bracket
bling ⇒ page 109 .
4 - 15 Nm + turn (90°)
❑ Renew.
❑ First fit upper left and
lower right bolts and
then tighten all 4 bolts in AG. Volkswagen AG d
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5 - Bracket hor eo
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6 - 20 Nm ss
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7 - Connection
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❑ For thermostat.
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8 - 15 Nm
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9 - O-ring
hole
spec
❑ Renew.
es, in part or in w
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10 - Thermostat
rrectness of i
⇒ page 130
❑ Observe installation position ⇒ page 130 , removing and installing thermostat.
l purpos
❑ Checking: heat thermostat in water.

❑ Opening begins at approx. 85 °C.
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❑ Ends at approx. 105 °C

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❑ Opening lift at least 7 mm.

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11 - Hexagon bolt
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❑ Tightening sequence and torque specifications ⇒ Heating, air conditioning; Rep. gr. 87 ; Removing and
r
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installing compressor bracket .

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12 - Bracket C py
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13 - Poly V-belt tensioning element
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14 - 25 Nm
15 - Oil sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant -D 176 404 A2- .
16 - 15 Nm

2 Removing and installing sealing

flange and flywheel
Assembly overview - sealing flange and flywheel ⇒ page 33
Removing and installing engine speed sender ⇒ page 46
Renewing crankshaft oil seal - belt pulley end ⇒ page 36 .
Removing and installing sealing flange - pulley end ⇒ page
36 .
Removing and installing dual-mass flywheel ⇒ page 34 .
Renewing crankshaft sealing flange - flywheel end ⇒ page
40 .
AG. Volkswagen AG d
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Repairing clutch ⇒ 6-speed manual gearbox 02S; Rep. gr. 30 ; Repairing clutch .
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1 - Seal
h re
hole
❑ Do not additionally oil or
spec
grease the oil seal seal‐
es, in part or in w
t to the co
ing lip.
❑ Before installing, re‐
move deposits from
rrectness of i
crankshaft journal using
a clean cloth.
l purpos
❑ Renewing crankshaft oil

seal - belt pulley end ⇒
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page 36 .
m
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2 - Sealing flange
ion
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❑ Must seat on dowel
or
his
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sleeves.
at
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⇒ page 38
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❑ Install with silicone C py
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sealant -D 176 404 A2- rig ht
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⇒ page 38 .
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3 - Cylinder block
crankshaft ⇒ page
48 .
bling pistons and con‐
rods ⇒ page 48
4 - 60 Nm + turn (90°)
❑ Renew.
5 - Flywheel
❑ To remove and install
flywheel, counterhold
with 3067.
dual-mass flywheel ⇒
2. Removing and installing sealing flange and flywheel 33

page 34 .
6 - Intermediate plate
❑ Must sit on dowel sleeves
❑ Do not damage or bend when assembling.
7 - 15 Nm
❑ Renew.
8 - Sealing flange with oil seal
❑ Renew complete with oil seal and sender wheel only.
9 - Removing and installing engine speed sender -G28- ⇒ page 46 .
❑ Loosen and tighten using commercially available ball-ended hexagon key socket
❑ Specified torque: 5 Nm.
2.2 Removing and installing dual-mass fly‐

wheel
♦ Counterhold -3067-
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– Remove gearbox s⇒
s Power transmission; Rep. gr. 37 ; Re‐
a ra
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moving and installing gearbox .
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To prevent damage to the dual-mass flywheel when removing,

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the bolts -B- must not be removed with an impact wrench or

hole
spec
similar. The bolts may only be removed by hand.

es, in part or in w
t to the co
– Mark position of dual-mass flywheel in relation to engine.

rrectness of i
– Rotate the dual-mass flywheel -A- so that the bolts -B- align
centrally with the holes -arrows-.
l purpos
– When unscrewing bolts -B-, ensure that none of the bolt heads
come into contact with the dual-mass flywheel -arrows-. The
nf
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flywheel will otherwise be damaged when the bolts are un‐

rm
screwed further.
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Rep. gr.13 - Crankshaft group
– Insert counterhold -3067- in hole on cylinder block -B-.

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– Unscrew dual-mass flywheel. lksw
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Installation is carried out in the reverse sorder.
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• Specified torque ⇒ Item 4 (page 33) .
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– Use new bolts for securing.
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– Insert counterhold -3067- in hole on cylinder block -A-.
mer
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2.3 Renewing crankshaft oil seal - belt pulley end

AG. Volkswagen AG d
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Special tools and workshop ed b ara
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equipment required hor eo
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♦ Counterhold tool -3099- ss
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♦ Oil seal extractor -3203-
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♦ Assembly tool -T10053+3-
ility
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♦ Torque wrench -
wit
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V.A.G 1331-
ole,
spec
♦ Torque wrench -
V.A.G 1332-
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2.3.1 Removing
– Remove toothed belt. ⇒ page 66
– Remove crankshaft toothed belt pulley. To do this, lock
toothed belt pulley using counterhold -3099- .
Note
When bolting on counterhold, place two washers between

toothed belt pulley and counterhold.
– To guide oil seal extractor -3203- , screw central bolt by hand

into crankshaft to stop.
– Unscrew inner part of oil seal extractor two turns (approx. 3
mm) out of outer part and lock with knurled screw.
– Oil threaded head of oil seal extractor.

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– Using great pressure,
ss a screw oil seal extractor as far as possi‐ c
ble into seal.
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– Loosen knurled screw and turn inner part against crankshaft itte
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until oil seal is pulled out.
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2.3.2 Installing
ss o
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Note
atio
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The oil seal sealing lip must not be additionally oiled or greased.
thi
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– Remove oil residue from crankshaft journal using clean cloth.
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– Place guide sleeve -T10053/1- onto crankshaft journal.
Co
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– Slide oil seal over guide sleeve onto crankshaft journal.
rig ht
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– Press oil seal in to stop using assembly tool -T10053- and

centre bolt.
– Install and tighten toothed belt ⇒ page 66 .

2.4 Removing and installing sealing flange - pulley end

equipment required
♦ Counterhold tool -3099-
♦ Assembly tool -T10053-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Hand drill with plastic brush
attachment
♦ Silicone sealant -D 176 404
A- AG. Volkswagen AG d
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♦ Flat scraper byV
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2.4.1 Removing
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– Remove toothed belt. ⇒ page 66 . Cop py
rig
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rig
– Remove crankshaft toothed belt pulley. To do this, lock py by
co Vo
toothed belt pulley using counterhold -3099- .
by lksw
cted agen
Prote AG.
Note
When bolting on counterhold, place two washers between

toothed belt pulley and counterhold.
– Drain engine oil.

– Remove sump ⇒ page 105 .
– Pull off front sealing flange.
– Remove sealing flange; if necessary, loosen by applying light
blows with a rubber-headed hammer.
– Remove sealant residue from cylinder block with a flat scraper.

– Remove residual sealant from sealing flange using a plastic

rotary brush (wear eye protection).
– Clean sealing surfaces. They must be free of oil and grease.
2.4.2 Installing
AG. Volkswagen AG d
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♦ Observe expiry date
ss a
of sealing compound. c
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♦ The sealing flange must be installed within 5 minutes of ap‐
pt
an
d
plying the silicone sealant.

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– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3
wit
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mm).
h re
ole,
spec
t to the co
Note
♦ The sealant bead must not be thicker than 2… 3 mm, other‐
rrectne
wise excess sealant can enter sump and block the strainer in
oil pump suction pipe, as well as drip onto the sealing surface
of crankshaft oil seal.
ss o
cial p
♦ Before applying sealant bead, cover sealing surface of oil seal

inform
with a clean cloth.

mer
atio
om
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– Apply silicone sealant bead as shown to the clean sealing sur‐

or
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face of sealing flange.

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– Install sealing flange immediately and tighten all bolts lightly.

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Cop py
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When fitting sealing flange with oil seal installed use guide sleeve Prote AG.
-T10053/1- .
– Tighten securing bolts for sealing flange to 15 Nm using alter‐

nate and diagonal sequence.
– Install sump ⇒ page 105 .
Note
Sealing compound must dry for approx. 30 minutes after instal‐

lation. Only then fill with engine oil.
Installing toothed belt and adjusting valve timing. ⇒ page 66

2.5 Renewing crankshaft sealing flange -

flywheel end
♦ Assembly tool -T10134-
♦ Torque wrench -V.A.G 1331-

♦ Socket -V.A.G 1332/11-
♦ Vernier gauge
♦ Three hexagon bolts M 6 x 35 mm
♦ Two hexagon bolts M 7 x 35 mm
2.5.1 Pressing out sealing flange with sender

wheel
Note
♦ For the sake of clarity, the work is performed with the engineagen AG. Volkswagen AG do
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– Remove flywheel.
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– Remove intermediate plate.

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– Set engine to TDC No. 1 cylinder ⇒ page 66 , Removing

wit
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and installing toothed belt.

h re
hole
spec
– Remove sump ⇒ page 105 .

es, in part or in w
t to the co
– Remove engine speed sender -G28- -arrow- using a commer‐

cially available ball-ended hex key socket ⇒ page 46 .
– Unscrew sealing flange securing bolts.
rrectness of i
l purpos
Note
nform
ercia
Sealing flange and sender wheel are pressed off the crankshaft
m
at
together using three M 6 x 35 mm bolts.

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– Screw three M 6 x 35 mm bolts into threaded holes -arrows-

of sealing flange.
– Screw bolts alternately (max. 1/2 turn 180° for each bolt) into
sealing flange and press sealing flange together with sender
wheel off crankshaft.
2.5.2 Pressing in sealing flange with sender

wheel
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing

lip support ring. This support ring serves as a fitting sleeve and
must not be removed prior to installation.
♦ Sealing flange and sender wheel must not be separated or
turned after removal from packaging.
♦ The sender wheel is held in its installation position on the as‐
sembly device -T10134- by a locating pin.
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
♦ The assembly device -T10134- is held in its position .relative
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Assembly tool -T10134- au
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A - Clamping surface
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B - Hexagon nut
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C - Assembly housing
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D - Locating pin
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E - Hexagon socket head bolt

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F - Guide pin for diesel engines (black knob)

G - Guide pin for petrol engines (red knob)
rrectness o
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2.5.3 A - Assembling seal with sender wheel

on assembly tool -T10134-
– Screw in hexagon nut -B- to just before clamping surface -A-
of threaded spindle.
– Clamp assembly device -T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
– Press assembly housing -C- downwards until it lies on
hexagon nut -B- -arrow-.
Note
Inner part of assembly tool and assembly housing must be at

same height.
– Remove securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
twisted. olks
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– Locating hole -A- on sender wheel -C- must align with marking
wit
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-B- on sealing flange.

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spec
– Place sealing flange with front side downwards on a clean flat

surface.
t to the co
rrectness o
cial p
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mer
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– Push sealing lip support ring -A- downwards in direction of ar‐

row until it lies on flat surface.
AG. Volkswagen AG d
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– Upper edge of sender wheel and front edge of sealing flange
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must align -arrows-.
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mer
atio
– Place sealing flange with front side on assembly tool -T10134-
om
n
so that locating pin -B- can be inserted in sender wheel hole
c
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or
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-A-.
thi
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Cop py
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Ensure sealing flange lies flat on assembly tool.
gh ht
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Prote AG.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool -T10134- whilst tightening the three
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains

fixed in assembly device.
2.5.4 B - Attaching assembling tool -T10134-

with sealing flange on crankshaft flange
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder.

– Screw hexagon nut -B- to end of threaded spindle.

Volkswagen AG
– Press threaded spindle of assembly tool -T10134- in sdirection
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– Align flat side of assembly housing on sump
ss
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sealing surface.
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hole
spec
es, in part or in w
– Secure assembly tool -T10134- to crankshaft flange using
t to the co
hexagon socket head bolts -A-.
rrectness of i
Note
l purpos
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
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– To guide sealing flange, screw two M 7 × 35 mm bolts -A- into

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2.5.5 C - Bolting assembly tool -T10134- onto

crankshaft flange
– Push assembly housing -C- by hand in direction of arrow until
sealing lip support ring -B- contacts crankshaft flange -A-.
– Push guide pin for diesel engines (black knob) -D- into hole in
crankshaft. This ensures that the sender wheel reaches its fi‐
nal installation position.
Note
The guide pin for petrol engines (red knob) -F- must not be in‐
serted in threaded hole of crankshaft.
– Hand-tighten both hexagon socket head bolts of assembly

tool.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies on assembly housing -C-.

AG. Volkswagen AG d
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2.5.6 D - Pressing sender wheel onto d byV
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crankshaft flange using assembly tool - ise nte
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ut
T10134- a ra
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– Tighten hexagon nut of assembly tool -T10134- to 35 Nm us‐
du
an
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ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G
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erm
ab
1332/11- .
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spec
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After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and sealing flange.
rrectness of i
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nform
ercia
2.5.7 E - Checking sender wheel installation

position on crankshaft
m
at
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ion
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– Screw hexagon nut -E- to end of threaded spindle.

o
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ate
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– Remove the two bolts -A- from cylinder block.

p
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– Screw the three knurled screws -B- out of sealing flange.
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op py
– Remove assembly tool -T10134- .
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rig by
py
– Remove sealing lip support ring.
co Vo
by lksw
cted agen
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– The sender wheel is in the correct installation position on the

crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.
– Set vernier gauge on crankshaft flange.

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

– Install engine speed sender -G28- -arrow- and tighten secur‐

ing bolt to 5 Nm.
– Install sump ⇒ page 105 .
– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to
60 Nm + turn 90° further.
2.5.8 F - Re-pressing sender wheel

– Secure assembly tool -T10134- to crankshaft flange using
hexagon socket head bolts -A-.
– Hand tighten both hexagon socket head bolts.agen AG. Volkswagen AG do
w es n
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– Push assembly tool -T10134- by hand
ed
bto
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– Screw hexagon nut -E- onto threaded spindle by hand until it
es, in part or in w
lies on assembly housing -C-.
t to the co
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at
om
ion
c
in t
or
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ate
do
priv
– Tighten hexagon nut of assembly tool -T10134- to 40 Nm us‐

um
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ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G

en
ng
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1332/11- . . Cop py
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rig
– Check installation position of sender wheel on crankshaft py by
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again. ⇒ page 45
by c lksw
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Prote AG.
If dimension -a- is too small again:
– Tighten hexagon nut for assembly tool -T10134- to 45 Nm.
– Check installation position of sender wheel on crankshaft
again. ⇒ page 45
2.6 Removing and installing engine speed

sender -G28-

♦ Hexagon key extension, 4 mm -T10370-
♦ Or commercially available ball-ended hexagon key socket, 5

mm . Volkswag n AG en AG
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Two different bolts are installed, check which
s tool is to be used.
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– Clamp off coolant hoses at engine oil cooler using hose clip
hole
and pull off hoses.
spec
es, in part or in w
t to the co
– Remove oil filter bracket.
– Remove securing bolt -arrow- and pull out engine speed
sender -G28- . rrectness of i
Installation is performed in the reverse order, observing the fol‐

l purpos
lowing: specified torque for engine speed sender -G28- securing

bolt: 5 Nm.
nform
mercia
at
om
ion
c
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or
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ate
do
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for
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t.
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3 Crankshaft
Assembly overview - crankshaft ⇒ page 48 .
Renewing needle bearing in crankshaft - vehicles with dual clutch
gearbox ⇒ page 49
Crankshaft dimensions ⇒ page 48 .
3.1 Assembly overview - crankshaft
1 - Bearing shells 1, 2, 4 and 5

❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange
used bearing shells
(mark).
2 - 65 Nm + turn (90°)
❑ Renew.
❑ To measure radial clear‐
ance, tighten to 65 Nm agen
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3 - Bearing cap horis nte
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❑ Bearing cap 1: pulley ss a ra
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end.
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❑ Bearing cap 3 with re‐

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❑ Bearing shell retaining
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lugs in cylinder block h re

hole
and bearing caps must spec

es, in part or in w
align.
t to the co
4 - Bearing shell 3
❑ For bearing cap without
rrectness of i
oil groove.
l purpos
❑ For cylinder block with

oil groove.
nform
ercia
5 - Thrust washer
❑ For bearing cap 3.
m
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❑ Note fixing arrange‐

n
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ment.
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6 - Crankshaft
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❑ Axial clearance new: 0.07 … 0.17 mm wear limit: 0.37 mm

f
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t.
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❑ Check radial clearance with Plastigage new: 0.03…0.08 mm, wear limit: 0.17 mm Cop py
ht. rig
❑ Do not rotate crankshaft when checking radial clearance.
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❑ Crankshaft dimensions ⇒ page 48 . Prote
cted AG.
agen
7 - Thrust washer
❑ For cylinder block, bearing 3
3.1.1 Crankshaft dimensions

(Dimensions in mm)

Honing dimen‐ Main Conrod

sion journal ∅ journal ∅
Basic dimension 54.00 -0.022 47.80 -0.022
-0.042 -0.042
3.1.2 Renewing needle bearing in crankshaft

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

removing engine or gearbox.
6-speed dual clutch gearbox
AG. Volkswagen AG d
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- This gearbox can be identified by the gearbox oil cooler.

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Special tools, testers, measuring instruments and auxiliary items

ab
pe
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required
ot
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3. Crankshaft 49
1 - -1- Kukko 21/2

2 - Centring mandrel -3176-
3 - Drift -VW 207 C-
AG. Volkswagen AG d
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Puller -T10055- with adapter -T10055/3- s
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Procedure
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• Gearbox is separated from engine

pe
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Pulling needle bearing out:

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spec
es, in part or in w
t to the co
rrectness of i
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tion in
r
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50
AG.
– Pull out needle roller bearing using Kukko 21/2, adapter -

T10055/3- and puller -T10055- .
7-speed dual clutch gearbox n AG. Volkswagen AG do

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No gearbox oil cooler is installed. d byV ua
ran
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Always renew needle bearing when removing engine
utho or gearbox. or
a ac
ss
Special tools, testers, measuring instruments and auxiliary items
ce
le
required
un
pt
an
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spec
t to the co
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3. Crankshaft 51
1 - -1- Kukko 21/2 and -4-

Kukko 22/1
2 - Centring mandrel -3176-
3 - Drift -VW 207 C-
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c
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ate
do
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for
en
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t.
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Cop py
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Procedure
co lksw
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Prote AG.
• Gearbox is separated from engine
Pulling needle bearing out:
– Pull out using commercially available puller -A-, e.g. Kukko
21/2 and Kukko 22/1.
Installing

– Drive needle bearing in with drift -VW 207 C- or with centring

mandrel -3176- .
– Carefully drive needle bearing in.
– Always measure the driving depth when driving in.
Renew bearing, if driving depth is too deep.
• Driving depth: Dimension -a- = 1.5 to 1.8 mm.
AG. Volkswagen AG d
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3. Crankshaft 53
4 Pistons and conrodsolkswagen AG

. Volkswagen AG
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Assembly overview - pistons and conrods
rise ⇒ page 54 . nte
tho eo
Separating new conrod ⇒ page s au55 . ra
c
s
ce
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Checking piston projection at TDC ⇒ page 56 .
nl
pt
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Piston and cylinder dimensions ⇒ page 57 .
erm
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Piston rings, cylinder bore and piston installation position ⇒ page
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57
h re
hole
spec
4.1 Assembly overview - pistons and conrods
es, in part or in w
t to the co
1 - Piston rings
rrectness of i
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
l purpos
remove and install.

❑ „TOP“ faces towards
nform
ercia
piston crown.
m
❑ Checking ring gap ⇒
at
om
io
page 57 .
n
c
in t
or
❑ Checking ring-to-groove
his
ate
clearance ⇒ page
do
priv
c
58 .
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2 - Piston
Co
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❑ With combustion cham‐
ht ht
rig by
py
ber. co Vo
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❑ Mark installation posi‐ Prote AG.
tion and cylinder num‐
ber.
❑ Installation position and
allocation of piston to
cylinder ⇒ page 58 .
❑ Arrow on piston crown
points to belt pulley end.
❑ Install using piston ring
clamp.
❑ If piston skirt is cracked,
renew piston.
❑ Checking piston projec‐
tion at TDC ⇒ page
56 .
3 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C.
❑ Remove and install us‐
ing drift -VW 222- .
4 - Circlip
5 - Conrod
❑ Mark cylinder allocation -A- with coloured pen.
❑ Installation position: Marking -B- faces towards pulley end.
❑ With industrially cracked conrod cap.
6 - Bearing shell
❑ Note installation position.

❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
cation: Black line on bearing surface in area of joint.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Check for secure seating.
❑ Axial clearance, wear limit: 0.37 mm.
❑ Check radial clearance with Plastigage: Wear limit: 0.08 mm, do not rotate crankshaft when checking
radial clearance
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 58 .
❑ Piston and cylinder dimensions ⇒ page 57 .
8 - Conrod bearing cap AG. Volkswagen AG d
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❑ Note installation position. olksw not
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❑ The caps only fit in one position and onlyoron
ise the appropriate conrod due to the breaking nte procedure
(cracking) separating the cap from theauconrod.
th eo
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9 - Oil spray jet
ce
le
un
pt
❑ For piston cooling.
an
d
itte
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rm
ab
pe
ility
Note
ot
wit
, is n
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hole
10 - 25 Nm
spec
es, in part or in w
❑ Insert without sealant.
t to the co
11 - Conrod bolt, 30 Nm + turn (90°)
❑ Renew.
rrectness of i
❑ Oil threads and contact surface.
l purpos
❑ Use old bolt for measuring radial clearance.
nform
ercia
4.2 Separating new conrod

m
a
com
tion in
– Mark cylinder allocation of conrod ⇒ Item 5 (page 54)
r
te o
thi
s
iva
– Lightly clamp the conrod in a vice using aluminium vice do

r
rp
c
clamps, as shown in the illustration.
um
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Cop py
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Note
gh ht
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♦ To prevent damage to the conrod, only clamp conrod in lightly. Prote AG.
♦ Clamp conrod in below the marked line.
– Unscrew the two bolts -arrows- approx. 5 turns.
4. Pistons and conrods 55

– Using a plastic hammer, carefully knock against conrod bear‐

ing cap -arrow- until it is loose.
4.3 Checking piston projection at TDC

♦ Measuring bridge -VW 382/7-
AG. Volkswagen AG d
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♦ End dimension plate -VW 385/17- olksw
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♦ Dial gauge
rrectness of i
Test procedure
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nf
Note
ercia
orm
m
atio
If different values are determined during the projection measure‐

om
n in
ment, use the largest dimension for selecting the gasket.

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rig ht
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Prote AG.

Piston projection at TDC must be measured when installing new

pistons or a short engine. Install the appropriate cylinder head
gasket depending upon piston projection, according to following
table:
Note
Turn engine clockwise to measure piston projection at TDC.
Piston projection Identification

Holes/notches
0.91 mm … 1.00 mm 1
1.01 mm … 1.10 mm 2
1.11 mm … 1.20 mm 3
Cylinder head gasket identification

♦ Part No. = arrow 1
♦ Production control code = arrow 2 (can be disregarded)
♦ Holes = arrow 3
4.4 Piston and cylinder dimensions

wage es n
Honing dimension Piston Ø
yV
olks Cylinder bore ∅ ot g
ua
b
ed ran
Basic dimen‐ mm h
79.47
oris 79.51 tee
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t or
ac
ss
Stage I mm 79.72 79.76
ce
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an
Stage II mm 79.97 80.01

d
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4.5 Piston rings, cylinder bore and piston in‐

pe
ility
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wit
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stallation position
h re
hole
spec
Checking piston ring gap

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com

ion in
r
te o
♦ Feeler gauges
thi
s
iva
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Cop py
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by
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Prote AG.

– Push piston ring squarely from above down to approx. 15 mm

from bottom end of cylinder.
Piston ring New Wear limit
dimensions in mm
1. compression ring 0.20 ... 0.40 1.0
2. compression ring 0.20 ... 0.40 1.0
Oil scraper ring 0.25 ... 0.50 1.0
Checking ring-to-groove clearance

♦ Feeler gauges
– Clean ring groove before checking.
Piston ring New Wear limit
dimensions in mm
1. compression ring 0.06 ...0.09
AG. Volkswage0.25
n AG d
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2. compression ring by Vo0.05
l ...0.08 0.25 not
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Oil scraper ring horis 0.03...0.06 0.15 nte
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Checking cylinder bores ss ce
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spec
es, in part or in w
t to the co
rrectness of i

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♦ Inside caliper 50 … 100 mm

nform
ercia
– Take measurements at 3 positions in both transverse -A- and

longitudinal -B- directions, as illustrated. Difference between
m
at
om
actual and nominal diameter max. 0.10 mm.

ion
c
in t
or
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ate
do
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Note
p
cum
for
en
ng
t.
Cylinder bores must not be measured when cylinder block is op
yi Co
mounted on a repair stand with engine support bracket -VW 540- ,
C py
ht. rig
as measurements may then be incorrect.
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Piston installation position and allocation of piston to cylinder
Piston in cylinders 1 and 2:
Larger inlet valve recess -arrows- towards flywheel.
Piston in cylinders 3 and 4:
Larger inlet valve recess -arrows- towards belt pulley end.

Note
♦ New piston allocation to cylinders is shown by a coloured

marking on piston crown.
♦ Piston for cylinders 1 and 2: marked 1/2
♦ Piston for cylinders 3 and 4: marked 3/4
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orm
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15 – Cylinder head, valve gear

1 Cylinder head
Note AG. Volkswagen AG d

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♦ When installing an exchange
ise
d b
cylinder head with fitted ara
nte
camshaft, the contactuthsurfaces
or
between the bucket tappets eo
and the cam must sbe
s a oiled before installing the cylinder head
ra
c
cover.
ce
le
un
pt
an
d
♦ The plastic packing pieces for protecting the open valves must
itte
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not be removed until immediately before fitting cylinder head.
erm
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ility
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♦ If the cylinder head is replaced, all the coolant in the system
wit
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must also be renewed.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
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or
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Prote AG.
60 Rep. gr.15 - Cylinder head, valve gear

Assembly overview - cylinder head ⇒ page 61 .

Removing and installing cylinder head cover ⇒ page 64 .
Removing, installing and tensioning toothed belt ⇒ page 66 .
Removing and installing cylinder head ⇒ page 83 .
Checking compression ⇒ page 89 .
1.1 Assembly overview - cylinder head
1 - Toothed belt guard upper

part
2 - Toothed belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning ⇒ page
66 .
3 - 10 Nm
❑ Renew.
4 - 25 Nm
5 - 100 Nm
6 - Camshaft pulley
7 - Hub
❑ With sender wheel
❑ Use counterhold tool -
T10051- to loosen and
tighten.
❑ To remove, use puller - AG. Volkswagen AG d
T10052- . lksw
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❑ Removing and in‐ byV gu
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8 - Rear toothed belt guard ss c
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9 - Sealing grommet
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10 - Hall sender -G40-

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❑ For camshaft position

hole
spec
❑ To remove, unbutton
es, in part or in w
sealing grommet ⇒ Item 9 (page 61) from rear toothed belt guard.
t to the co
11 - Stud
❑ 15 Nm
rrectness of i
12 - Cylinder head bolt

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❑ Observe sequence when loosening and tightening ⇒ page 83 .

❑ Before installing, place washers in cylinder head ⇒ Item 4 (page 92) .
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copy Vo
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cted agen 1. Cylinder head
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13 - Fuel return line

14 - Fuel supply line
15 - Coolant line
16 - Cylinder head cover
❑ Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth.
17 - Pressure regulating valve
❑ For crankcase ventilation.
18 - To turbocharger.
19 - Cap
❑ Renew seal if damaged.
20 - Seal
21 - 10 Nm
❑ Observe tightening sequence ⇒ page 64 .
22 - Gasket for cylinder head cover
❑ Renew together with cylinder head cover only.
❑ Before fitting, seal transitions with „AMV 174 004g01“ ⇒. Vpage
en AG
olkswa64
gen AG
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23 - 20 Nm y Vol gu
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24 - Lifting eye tho eo
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25 - Unit injector
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26 - 10 Nm
ility
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27 - Central connector
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❑ For unit injector
hole
spec
es, in part or in w
28 - From brake servo

29 - Tandem pump t to the co
❑ For fuel and vacuum supply
rrectness of i
❑ Check ⇒ page 195 .

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❑ Must not be dismantled.
nform
ercia
30 - Supply hose
m
at
❑ From fuel filter.

om
ion
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❑ White or with white marking.

or
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ate

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❑ Secure with spring-type clips.

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31 - Return hose t. Cop py
rig
❑ To fuel filter
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co
❑ Blue or with blue marking.
by lksw
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Prote AG.
❑ Secure with spring-type clips.
32 - Seal
❑ Renew.

33 - Bracket
34 - 20 Nm
35 - Cylinder head
❑ After renewing, renew entire coolant.
36 - Cylinder head gasket
❑ Renew.
❑ Note marking ⇒ page 63 .
37 - Glow plug olkswagen AG
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❑ 15 Nm olkswag does
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❑ Check ised b⇒ page 269 . ara
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38 - Tensioning
au
t
roller or
ac
ss
❑ Remove engine support in order to remove and install ⇒ page 29 .
ce
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un
pt
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39 - 20 Nm + turn (45°)
itte
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Checking cylinder head for distortion

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
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thi

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♦ Straight edge
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♦ Feeler gauges Cop
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Max. permissible distortion: 0.1 mm.
gh ht
pyri by
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cted agen
Prote AG.
Note
Reworking diesel cylinder heads is not permissible.
Cylinder head gasket identification

♦ Part No. = arrow 1
♦ Production control code = arrow 2 (can be disregarded)
♦ Holes = arrow 3
1. Cylinder head 63
olkswagen AG
wag en AG. V
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ ol,ksTouran 2003 ➤
does
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4-cylinder diesel engine (1.9 l engine) - Edition
se
d 08.2010
b ara
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Note
un
pt
an
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itte
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♦ Different thicknesses of cylinder head gasket are fitted de‐
erm
ab
ility
pending on the piston projection. When renewing gasket,
ot p
install new gasket with same identification.
wit
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ole,
♦ Piston projection at TDC must be determined when installing
spec
new pistons or a short engine. ⇒ page 56
t to the co
1.2 Removing and installing cylinder head
rrectne
cover
ss o
cial p
f inform
mer
atio
om
n
c
i
or
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te
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t.
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Cop py
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Special tools and workshop equipment required rig ht
py by
co Vo
by lksw
♦ Torque wrench -V.A.G 1331- cted agen
Prote AG.
♦ Sealant -AMV 174 004 01-

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


wards at -arrows-.
– Remove upper toothed belt guard.
– Disconnect crankcase breather hose at union on rear of
charge air pipe.
– Unbolt bracket from exhaust gas recirculation valve.
Engine codes BLS, BXJ: to remove cylinder head cover, addi‐

tionally remove:
♦ -1- upper toothed belt guard
♦ -2- intake hose
♦ -3- intake manifold flap Renew seal.
♦ -4- bolt, 8 Nm
– Remove cylinder head cover.
Cylinder head cover, engine codes: AVQ, BJB, BKC, BRU, BXE,
BXF wage
e
olks s no
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Cylinder head cover, engine codes: BLS, BXJ

Installing for all engine codes
rrectne
Install in reverse order. In the process, note the following:

ss o
cial p
Note
inform
mer
♦ Renew cylinder head cover gasket and seal for bolts if dam‐
atio
m
aged.
o
n
c
i
or
n thi
e
♦ Renew seal for intake manifold flap. Engine codes BLS, BXJ
t
sd
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fo
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
65
cted agen
Prote AG.
1. Cylinder head
– Place a drop of sealant -AMV 174 004 01- (∅ approx. 5

mm) -arrows- on edges of both sealing surfaces of bearing cap
and cylinder head at front of engine.
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byV ua
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Cylinder head cover, engine codes: BJB, BKC, BRU, BXE, BXF
hole
spec
– Screw on cylinder head cover by hand in sequence -1 … 13-.
es, in part or in w
t to the co
– Tighten bolts in sequence -1 … 13- to 10 Nm.
rrectness of i
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nf
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orm
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atio
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Cylinder head cover, engine codes: BLS, BXJ
sd
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– Screw on cylinder head cover by hand in sequence -1 … 13-.
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– Tighten bolts in sequence -1 … 13- to 10 Nm. t. Cop py
rig
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cted agen
Prote AG.
1.3 Removing, installing and tensioning

toothed belts
Note
♦ A revised engine support has been introduced gradually and

it is no longer necessary to remove the engine support and to
support the engine for the procedure „removing, installing and
tensioning toothed belt“.
♦ To change the tensioning roller, for both versions the engine
support must be removed.
– Determine which type of engine support is installed in the ve‐

hicle.
-1-: Engine support bolted close to engine (removal necessary)
⇒ page 67 .

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a gen AG does
-2-: Engine support bolted further away from engine ► (removal
Vol
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gu
not necessary) ⇒ page 77 . ed
by ara
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es, in part or in w
t to the co
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nform
mercia
at
om
i
1.3.1 Removing and installing toothed belt (vehicles with engine support bolted
on
c
in t
or
close to engine)
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ate
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op
equipment required C py
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♦ Locking pin -3359-
p by
co Vo
by lksw
cted agen
♦ Pin wrench -T10020- or
Prote AG.
hexagon wrench
♦ Locking pin -T10115-
♦ Crankshaft stop -T10050-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
1. Cylinder head 67
♦ Support bracket -10-222A-

with adapters -10-222A/1- agen
AG. Volkswagen AG d
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♦ Counterhold tool -T10172- ed by
V gu
ara
with pins -T10172/4- horis nte
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♦ Crankshaft stop -T10100- ss c
(on vehicles with oval
ce
le
un
pt
crankshaft belt pulley)
an
d
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ility
ot
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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com
tion in
r
te o
thi
s
iva
do
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rp
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fo
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t.
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Cop py
t. rig
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pyri by
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by c lksw
cted agen
Prote AG.
Note
From model year 2004, a new toothed belt tensioner is installed.

The tensioner has an additional hexagon hole -arrow-. To tension
and release toothed belt, use Allen key instead of pin wrench -
T10020- . This does not alter the procedure.
Removing
Note
Adjustment work on toothed belts must be performed only on cold

engines, as the indicator position on the tensioning element varies
depending on the engine temperature.
– Remove engine cover. ⇒ page 5

– Remove coolant expansion tank, coolant hoses remain con‐
nected.
– Remove tensioning element for poly V-belt.

– Remove front right wheel housing liner.

– Remove charge air pipe between charge air cooler and tur‐
bocharger. ⇒ page 218
– Carefully cover or seal open ends.
– Remove belt pulley with vibration damper.
– Remove lower and centre parts of toothed belt guard.
Golf, Golf Plus, Touran
– Set up support bracket -10-222A- with adapters -10-222A/22-

and support enginen AinGinstallation
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Note
horis tee
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au ac
ss
If toothed belt is to be removed in order to remove cylinder head,
ce
le
set up support bracket -10-222A- with higher adapters -10-222A/

un
pt
an
d
13- . This will provide the space necessary for removing the cylin‐
itte
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erm
der head.
ab
ility
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Passat:
h re
ole,
spec
– Set up support bracket -10-222A- with adapters -10-222A/1- t to the co

and support engine in installation position.
Passat: If the toothed belt has to be taken off for removal of the
rrectne
cylinder head.
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
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t.
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op
Note
C py
t. rig
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pyri by
Vo
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by c
Both lifting eyes for the support are located on the cylinder head,
lksw
cted agen
Prote
so an additional spindle -A- with bracket to support the engine
AG.
must be secured on the cylinder block.
– Set up support bracket -10-222A- with adapters -10-222A/1-

and support engine in installation position with spindles -B-
and -C-.
Note
♦ Spindle -A- hangs loose.

♦ Unscrew filler neck for window wash system.
♦ Unbolt coolant expansion tank and lay to side (hoses remain
connected).
– Pull fuel filter out of bracket.

– Unscrew filler neck for window wash system.
1. Cylinder head 69
– Unbolt fuel filter bracket from engine mounting -arrows-.

– Unbolt coolant expansion tank and lay to side (hoses remain
connected).
– Remove securing bolts between assembly mounting and en‐

gine bracket and between assembly mounting and body
-arrows- and remove complete assembly mountings.
Note
♦ The assembly mounting may only be removed if the engine is

supported with support bracket -10-222A- !
♦ The engine bracket must be loosened only when the assembly
mounting has been removed.
WARNING
lkswage es n
Vo ot g
When raising and lowering engine using support bracket ed
by ua
ran
-10-222A- , ensure that no components or hoses are damaged,
thoris tee
strained or torn off. au or
ac
ss
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e
nl
pt
du
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itte
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– Raise engine with support bracket -10-222A- until both upper
erm
ab
bolts of engine bracket can be loosened.
ility
ot p
wit
, is n
– Lower engine with support bracket -10-222A- until both lower
h re
hole
bolts of engine bracket can be loosened.
spec
es, in part or in w
– Remove refrigerant line securing clamp from longitudinal

t to the co
member.
– Remove engine support. rrectness of i
– Turn crankshaft to TDC No. 1 cylinder.

l purpos
Note
nf
ercia
orm
m
atio
Gradual introduction of oval crankshaft toothed belt pulleys.

om
When installing this toothed belt pulley, the crankshaft stop -

n in
or c
T10100- must be installed to determine the TDC position instead

thi
te
of crankshaft stop -T10050- . Observe identification characteris‐

sd
iva
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r
tics -arrows-.
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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.

Characteristics of crankshaft toothed belt pulley

A = round belt pulley, lock using crankshaft stop -T10050- , TDC
marking at 12 o'clock
B = oval belt pulley, lock using crankshaft stop -T10100- . TDC
marking at 1 o'clock
Vehicles with round crankshaft pulley
Note
Turn crankshaft until marking on crankshaft pulley and tooth seg‐

ment of camshaft pulley is on top. The marking on the rear toothed
belt guard must align with the marking on the camshaft sender
wheel -arrow-.
– Lock hub using locking pin -3359- . To do this, slide locking

pin through the free elongated hole on left into hole in cylinder
head.
– Lock crankshaft toothed belt pulley with crankshaft stop -
T10050 - . To do this, push crankshaft stop into teeth of belt
pulley from face side.
AG. Volkswagen AG d
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Note by
Vol not
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ara
ed
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The marks on aut the crankshaft toothed belt pulley and the
h
ra
crankshaftsstop must align. When doing this, the pin of the
s c
ce
e
crankshaft stop must engage in the drilling of sealing flange.

nl
pt
du
an
itte
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erm
Vehicles with oval crankshaft pulley

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
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
71
by c lksw
cted
1. Cylinder head
agen
Prote AG.
Note

wheel -arrow-.

head.
T10100- . To do this, push crankshaft stop into teeth of belt
Note
The marks on the crankshaft toothed belt pulley and the

crankshaft stop must align. When doing this, the pin of the

olkswagen AG
en AG. V
– Mark direction of rotation of toothed
olksbelt.
wag does
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– Loosen securing bolts -1-utof
ho camshaft pulley until the camshaft
r eo
pulley can be moved within
ss a the elongated holes. ra
c
ce
e
– Loosen tensioning roller securing nut.

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
– Turn pin wrench -T10020- anti-clockwise until toothed belt

l purpos
tensioning roller can be locked with locking pin -T10115- .

nf
ercia
or
Note
m
m
atio
om
n in
c
A hexagon key can be used to tension or relieve tension on the

or
thi
tensioner.
te
sd
iva
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f
en
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t.
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Cop py
t. rig
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co lksw
by
cted agen
Prote AG.

– Now turn pin wrench -T10020- clockwise to stop and tighten

securing nut -1- hand tight.
– Remove toothed belt first from coolant pump and then from
remaining pulleys.
AG. Volkswagen AG d
Installing ksw
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not
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• Camshaftislocked
ed
b with locking pin -3359- . ara
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th
• The scrankshaft
au is locked with crankshaft stop -T10050- r a or
c
crankshaft
s stop -T10100- .
ce
le
un
pt
• Tensioning roller locked with locking pin -T10115- and se‐
an
d
itte
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cured to right stop.
erm
ab
ility
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is n
Note
h re
ole,
spec
t to the co
rrectne
– Turn camshaft pulley in its elongated holes to centre
position -arrows-.
ss o
cial p
f
– Fit toothed belt onto crankshaft toothed belt pulley, tensioning
inform
roller, camshaft toothed belt pulley and idler roller.
mer
atio
m
– Then fit toothed belt on coolant pump toothed belt pulley.

o
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Ensure that tensioning roller seats correctly in rear toothed belt

guard -arrow-.
– Loosen tensioning roller securing nut and pull out locking pin
-T10115- .
– Now carefully turn tensioning roller clockwise using pin wrench

-T10020- until indicator is in middle of gap in the base plate
-arrow-.
Ensure that securing nut does not turn as well.
– Hold tensioning roller in this position and tighten tensioning
roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.
1. Cylinder head 73
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 AG. Volkswagen A
n G do
wage es n
Volks ot g
– Fit counterhold -T10172- with pins -T10172/4- as shown. ed
by ua
ran
Press counterhold -T10172- in direction of arrow, keeping
oris tee
th
camshaft toothed belt pulley under tension. au
or
ac
ss
– In this position, tighten camshaft toothed belt pulley securing
ce
e
nl
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du
bolts -1- to 25 Nm.
an
itte
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erm
ab
– Remove locking pin -3359- and crankshaft stop -T10050- .
ility
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wit
– Turn crankshaft two rotations in engine direction of rotation
, is n
h re
until crankshaft is just before TDC No. 1 cylinder.
hole
spec
Vehicles with round crankshaft pulley
es, in part or in w
t to the co
rrectness of i
– Lock hub with locking pin -3359- whilst turning engine in di‐
rection of rotation.
l purpos
– Check whether crankshaft can be locked with crankshaft stop

-T10050- .
nf
ercia
or
If crankshaft cannot be locked:
m
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
o
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f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Loosen securing bolts -1- for camshaft toothed belt pulley.
– Turn crankshaft slightly against engine direction of rotation

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

– Lock hub with locking pin -3359- whilst turning engine in di‐
rection of rotation.
-T10100- .
AG. Volkswagen AG d
agen oes
olksw not
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un
pt
an
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ab
ility
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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
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p
cum
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fo

en
ng
t.
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op
– Now turn crankshaft in engine direction of rotation until C py
t. rig
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pyri by
Vo
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by
Continuation for all vehicles cted agen
Prote AG.
– Fit counterhold -T10172- with pins -T10172/4- as shown.

camshaft toothed belt pulley under tension.
bolts -1- to 25 Nm.
– Repeat check.
1. Cylinder head 75
– Set engine bracket against cylinder block and tighten securing

bolts -A- to 40 Nm + (180°) turn further.
Note
Before installing assembly mounting, tighten all engine bracket

bolts to specified torque.
– Install assembly mounting between engine and body (renew

securing bolts).
Tightening torque of M 8 bolts: 20 Nm + (90°) turn further
Tightening torque of M 10 bolts: 40 Nm + (90°) turn further
– Bolt engine assembly mounting to engine bracket by bringing
contact surfaces together using support bracket -10-222A- .
Specified torque: 60 Nm + turn (90°) further
– Install centre and lower parts of toothed belt guard.
– Install belt pulley vibration damper (renew securing bolts).
Tightening torque: 10 Nm + (90°) turn further
– Install upper toothed belt guard.
– Install front right wheel housing liner.
– Install coolant expansion tank.
AG. Volkswagen AG d
agen oes
olksw not
– Bolt fuel filter bracket to engine mountingd by V
to 8 Nm torque gu
ara
-arrows-. rise nte
tho eo
au ra
– Engage fuel filter in bracket. ss c
ce
le
un
pt
– Bolt on filler neck for window wash system.

an
d
itte
y li
– Fit engine cover.

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

1.3.2 Removing and installing toothed belt (vehicles with engine support bolted
further away from engine)
Note
♦ A revised engine support has been introduced gradually and it is no longer necessary to remove the engine
support and to support the engine for the procedure „removing, installing and tensioning toothed belt“.
♦ To change the tensioning roller, for both versions the engine support must be removed.

equipment required
♦ Diesel injection pump lock‐
ing pin -3359-
♦ Locking pin -T10060 A-
♦ Crankshaft stop -T10100-
♦ Counterhold tool -T10172-
♦ Special wrench, long reach
-T10264-
♦ Locking tool -T10265-
wage
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Removing C py
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– Remove engine cover. ⇒ page 5 To do this, pull engine cover
cop Vo
by lksw
upwards abruptly at front -arrows A- and then pull forwards out
cted agen
Prote AG.
of rear fastening -arrow B-.
1. Cylinder head 77
– Remove two-piece engine cover panel ⇒ page 5 .
WARNING
♦ In extreme cases the fuel lines and the fuel can reach a
temperature of 100 °C on vehicles with unit injector en‐
gine. Allow the fuel to cool down before disconnecting the
lines - danger of scalding.
♦ Wear protective gloves.
♦ Wear eye protection.
– Pull fuel supply hose -1- and fuel return hose -2- off fuel lines.
– Pull off coolant line -3-.
– Remove bolt -1-.
– Remove connecting pipe between charge air cooler and intake

connecting pipe, to do this, lightly lift retaining clips -arrows-.
AG. Volkswagen AG d
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– Disconnect fuel supply line -3- and return line -2- by pulling
l purpos
release tabs.
– Remove fuel filter »screwed filter« and lay it with hoses to side
nf
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-arrow-.
orm
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Cop py
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– Pull fuel filter »inserted filter« out of bracket -arrow-.

– Unscrew bolt at filler neck -2- for windscreen washer system
reservoir.
– Unscrew bracket -3- for fuel filter.
– Disconnect electrical connector on coolant expansion tank

-1-.
– Remove coolant expansion tank, coolant hoses remain con‐
nected. Place it on engine.
– Remove tensioning element for poly V-belt.
– Remove upper toothed belt guard, to do this, loosen retaining

clips -arrows-.
– Remove front right wheel housing liner. AG. Volkswagen AG d
agen oes
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– Remove belt pulley with vibration damper. by
Vol not
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– Remove lower and centre parts of toothed belthor guard. eo
aut ra
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– Turn crankshaft to TDC No. 1 cylinder. ss
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t to the co

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wheel -arrow-.

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c

or
thi
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T10100- . To do this, push crankshaft stop into teeth of belt

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Note
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The marks on the crankshaft toothed belt pulley and the
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crankshaft stop must align. When doing this, the pin of the
AG.
1. Cylinder head 79
– Mark direction of rotation of toothed belt.
– Loosen securing bolts -1- of camshaft pulley until the camshaft

pulley can be moved within the elongated holes.
AG. Volkswagen AG d
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– Loosen tensioning roller securing nut -1-.
spec
– Turn eccentric of tensioning roller anti-clockwise -arrow- using
t to the co
socket -T10264- , until the tensioning roller can be locked with
locking tool -T10265- .
rrectness o
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f inform
mer
atio
om
n
c
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sd
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– Now turn tensioning roller eccentric clockwise -arrow- onto

i
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stop and tighten securing nut -1- hand-tight.

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– Remove toothed belt first from coolant pump and then from Cop py
remaining toothed belt pulleys.
t. rig
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Installing
lksw
cted agen
Prote AG.
• Camshaft locked with locking pin -3359- .
• Crankshaft locked with crankshaft stop -T10100- .
• Tensioning roller locked with locking pin -T10265- and se‐
cured to right stop with securing nut.
Note

– Turn camshaft pulley in its elongated holes to centre

position -arrows-.
– Guide toothed belt through gap between engine support and
engine.
– Fit toothed belt onto crankshaft toothed belt pulley, tensioning
roller, camshaft toothed belt pulley and idler roller.
– Then fit toothed belt on coolant pump toothed belt pulley.

Note
Ensure that tensioning roller seats correctly in rear toothed belt

guard -arrow-.
– Remove locking pin -T10265- from tensioning roller.

– Loosen tensioning roller securing nut -1-.
– Turn eccentric of tensioning roller clockwise -arrow- using

special wrench, long reach -T10264- until indicator -2- is in
middle of gap in base plate.
Note
Ensure that securing nut does not turn as well.
– Hold tensioning roller in this position and tighten tensioning

roller nut to 20 Nm + turn 45° further.
AG. Volkswagen AG d
agen oes
o lksw not
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by
– Fit counterhold -T10172- with pin -T10172/4-
ised as shown in il‐ ara
nte
lustration, and keep the toothed beltut
hor
under tension on pulling eo
side, by pressing in -direction ofssarrow-.
a ra
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– Tighten bolts -1- of camshaft toothed belt pulley to 25 Nm.

nl
pt
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ility
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until the crankshaft is just before TDC again.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Lock hub of camshaft with locking pin -3359- whilst turning

engine in direction of rotation.
l purpos
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Cop py
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Prote AG.
1. Cylinder head 81

-T10100- .
AG. Volkswagen AG d
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es, in part or in w
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m
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ion in
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– Now turn crankshaft in engine direction of rotation until

thi
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Cop py
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– Fit counterhold -T10172- with pins -T10172/4- as shown.

camshaft toothed belt pulley under tension.
bolts -1- to 25 Nm.
– Repeat check and adjustment if necessary.
– Install centre and lower parts of toothed belt guard.
– Install belt pulley vibration damper (renew securing bolts).

Tightening torque: 10 Nm + (90°) turn further

– Install upper toothed belt guard.
– Install connecting pipe between charge air cooler and intake
connecting pipe.
– Install front right wheel housing liner.
– Install coolant expansion tank. AG. Volkswagen AG d
agen oes
olksw not
V gu
by
– Bolt fuel filter bracket to riseengine
d mounting to 8 Nm torque ara
nte
-arrows-. ut
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s a c
– Engage fuel filter in bracket. s
ce
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un
pt
– Bolt on filler neck for window wash system.
an
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1.4 Removing and installing cylinder head
ss o
cial p
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Note
inform
mer
atio
♦ From 05.05 a modified engine support has been introduced, it
om
is no longer necessary to support the engine for the procedure n

c
i
or
„removing and installing the cylinder head“.

thi
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sd
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♦ -1-: Engine support ► 05.05 (support necessary)

pr
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♦ -2-: Engine support 06.05 ► ( (support not necessary)

t.
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Cop py
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1. Cylinder head 83

equipment required
♦ Drip tray -V.A.G 1306- or
drip tray -VAS 6208-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Hand vacuum pump with
accessories -V.A.G 1390-
♦ Water drainage container -
V.A.G 1390/1-
♦ Retainer -T10014- (only ve‐
hicles ► 05.05)
AG. Volkswagen AG d
agen oes
olksw not
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pt
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♦ Support bracket -10-222A- with adapters -10-222A/13- (only y li

erm
ab
vehicles ► 05.05) ility
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es, in part or in w
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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Note
♦ From 05.05 a modified engine support has been introduced, it

is no longer necessary to support the engine for the procedure
„removing and installing the cylinder head“.
♦ -1-: Engine support ► 05.05 (support necessary) AG. Volkswagen AG d
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♦ -2-: Engine support 06.05 ► ( (support not necessary) by
Vol
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♦ All cable ties which are opened or cut through ut
howhen
r
cylinder eo
head is removed must be replaced in the same
ss a position when ra
c
cylinder head is installed.
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ab
WARNING
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conditions:
es, in part or in w
t to the co
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sitions.
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hot components.
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1.4.1 Removing
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Note
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op py
Before removing cylinder head, extract fuel using hand-operated t. C rig
gh ht
vacuum pump with accessories -V.A.G 1390- and water drainage pyri by
Vo
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container -V.A.G 1390/1- .
lksw
cted agen
Prote AG.
– Remove engine cover panel ⇒ page 5 .

Golf, Golf Plus, Touran
– Remove plenum chamber bulkhead. ⇒ General body repairs,
All other vehicles continued
pipe.
of mounting.
on cylinder head.
– Before removing cylinder head, extract fuel from tandem pump
using hand-operated vacuum pump with accessories -V.A.G
1390- and water drainage container -V.A.G 1390/1- ⇒ page
195 .
– Pull fuel filter module upwards out of bracket and lay it with
hoses to side.
1. Cylinder head 85

– Remove turbocharger support and oil return from turbocharg‐
er.
– Remove oil supply line and lay it to side ⇒ page 112 .
Note
From 05.05 a modified engine support has been introduced, it is

no longer necessary to remove the engine support and supporting
the engine for the procedure „removing, installing and tensioning
toothed belt“ ⇒ page 66
– Remove toothed belt. ⇒ page 66 lkswage es n
o ot g
byV ua
d ran
– Remove toothed belt tensioning roller. o
ir se tee
th or
u
– Install hub for camshaft pulley ⇒ page 97 , Removing and
ss
a ac
installing camshaft.
ce
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nl
pt
du
an
itte
y li
– Remove rear toothed belt guard securing bolts -2- and -4-.
erm
ab
ility
ot p
– Unscrew Hall sender -G40- -3-.
wit
, is n
h re
– Remove exhaust gas recirculation connecting pipe.
hole
spec
– Pull off or disconnect all other electrical connections as nec‐
es, in part or in w
t to the co
essary from cylinder head and lay to one side.
– Separate all connection, coolant, vacuum and intake hoses
from cylinder head.
rrectness of i
Golf, Golf Plus Touran: Vehicles ► 05.05
l purpos
nform
ercia
Note
m
at
om
i
Both lifting eyes for the support are located on the cylinder head,
on
c
so an additional bracket for supporting the engine must be se‐
in t
or
his
e
cured on the cylinder block.

at
do
priv
cum
for
en
ng
t.
– Screw retainer -T10014- into threaded hole above coolant op
yi Co
pump and tighten to 20 Nm.
C py
t. rig
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yri by
– Lift engine slightly using spindle -A- until spindle -B- is relieved. cop Vo
by lksw
cted agen
Prote AG.
– Unhook spindle -B- and push it to side.
Passat: Vehicles ► 05.05
Note
Both lifting eyes for the support bracket are located on the cylinder
head. Therefore, an additional spindle with bracket must be se‐
cured on the cylinder block to support the engine.

– Screw retainer -T10014- into threaded hole above coolant

pump and tighten to 20 Nm.
– Lift up engine slightly via spindle -A-.
– Once spindles -B- and -C- are no longer under tension, unhook
them and slide them to one side.
For vehicles 06.05 ►
– Remove tensioning roller securing nut for toothed belt
– Remove cylinder head cover. ⇒ page 64
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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– Maintain sequenceaut when loosening cylinder head bolts.
h eo
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– Lift cylinder head slightly and remove from engine laterally
ce
le
un
pt
past toothed belt guard.

an
d
itte
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ility
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Note
wit
is n
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ole,
The cylinder head must be guided carefully to prevent damage.

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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fo
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Cop py
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rig ht
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Prote AG.
1. Cylinder head 87
1.4.2 Installing
Note
♦ Always renew cylinder head bolts.

♦ In cases of repair carefully remove gasket remains from cylin‐
der head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces. When using abrasive
paper do not use a grade less than 100.
♦ Carefully remove remains of emery and abrasives.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
– Turn crankshaft to TDC marking before fitting cylinder head.

– Turn crankshaft opposite engine direction of rotation until all
pistons are approximately equally placed below TDC.
– Fit cylinder head gasket.
Note
Note identification on cylinder head gasket ⇒ page 63 .
– Fit cylinder head and tighten all cylinder head bolts hand-tight.
– Tighten cylinder head in four stages in sequence as shown as
follows: Volkswa AG. gen AG
agen does
1- Tighten initially with torque wrench:y Volksw not
gu
b ara
ed
Stage I = 35 Nm horis nte
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t
au ra
Stage II = 60 Nm ss c
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2- Turn further with rigid spanner:

an
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itte
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Stage III = + (90°) turn further

erm
ab
ility
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Stage IV = + (90°) turn further

wit
is n
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ole,
spec
Note
t to the co
After repair work it is not necessary to retighten the cylinder head

bolts.
rrectne
Further installation is carried out in the reverse order. In the pro‐

s
cess, note the following:

s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
hoGolf
ris
2004 ➤ , Golf Plus 2005 ➤ , Passat 2006
e o ➤ , Touran 2003 ➤
ut
ss a 4-cylinder diesel engine (1.9 l engine)
ra
c - Edition 08.2010
ce
e
nl
pt
– After tightening cylinder head, turn camshaft so that cams for
du
an
itte
No. 1 cylinder point equally upwards. Before fitting toothed
y li
erm
ab
belt, turn crankshaft in engine direction of rotation ⇒ page
ility
ot p
66 , removing, installing and tightening toothed belt.
wit
, is n
h re
– Install hub for camshaft toothed belt pulley ⇒ page 97 ,
hole
spec
Removing and installing camshaft. es, in part or in w
t to the co
– Install toothed belt ⇒ page 66 .
rrectness of i
– Install oil supply line ⇒ page 112 .
l purpos
– Install noise insulation ⇒ General body repairs, exterior; Rep.

gr. 50 ; Assembly overview - Body - front .
nf
ercia
orm
exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulk‐
m
atio
m
head .
o
n in
or c
thi
te
sd
iva
o
r
– Carry out road test and then read fault memory ⇒ page
rp
cu
o
m
239 .
f
en
ng
t.
yi Co
Cop py
t. rig
1.5 Checking compression
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Note
If ceramic glow plugs are fitted, before removing check idling

speed smooth running control using vehicle diagnosis, testing
and information system -VAS 5051B- . The compression test is
only justified if one or more cylinders are conspicuous.
1. Cylinder head 89

equipment required
♦ Jointed spanner -3220-
♦ Torque wrench -
V.A.G 1331-
♦ Adapter -V.A.G 1381/12-
♦ Compression tester -
V.A.G 1763-
lkswage es n
o ot g
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ir se tee
tho
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a ac
ss
ce
e
nl
pt
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itte
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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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nf
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m
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c
Test prerequisite
or
thi
te
sd
iva
• Engine oil temperature min. 30 °C.

o
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Test procedure
en
ng
t.
yi Co
op
– Pull off central connector for unit injectors.
C py
t. rig
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pyri by
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by
cted agen
Prote
Note
AG.
If ceramic glow plugs are fitted, always observe notes on remov‐

ing and installing ceramic glow plugs ⇒ page 269 .
– Remove all glow plugs or ceramic glow plugs using jointed

extension and socket -3220- .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
Golf 2004 ➤ ri,seGolf Plus 2005 ➤ , Passat 2006 ➤ , Touran
d b ara
nte 2003 ➤
ut 4-cylinder diesel engine (1.9 l engine) - Edition
ho e o 08.2010
r
a ac
ss
ce
e
– Screw in adapter -V.A.G 1381/12- in place of glow plugs or
nl
pt
du
ceramic glow plugs.
an
itte
y li
erm
ab
– Check compression using compression tester -V.A.G 1763- .
ility
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wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
Using the compression tester ⇒ Operating instructions.
– Operate starter until tester shows no further pressure in‐
rrectness of i
crease. l purpos
Compression pressures:
New: 25 … 31 bar, wear limit: 19 bar
nform
ercia
Maximum permissible difference between all cylinders: 5 bar

m
at
om
ion
c
in t
or
Note
his
ate
do
priv
cum
or
If ceramic glow plugs are fitted, always observe notes on remov‐

f
en
g
ing and installing ceramic glow plugs ⇒ page 269 .

n
t.
yi Co
Cop py
t. rig
gh ht
yri
– Remove glow plugs or ceramic glow plugs using jointed ex‐ p by
co Vo
tension and socket -3220- .
by lksw
cted agen
Prote AG.
Specified torque: 15 Nm.
– Read fault memory of engine control unit ⇒ page 239 .
Note
Disconnecting the central connector for unit injectors causes

faults to be stored. Therefore, read fault memory and clear if nec‐
essary.
1. Cylinder head 91
2 Valve gear
AG. Volkswagen AG d
agen oes
Note olksw not
V gu
d by ara
ise nte
r
Cylinder heads with cracks
aut between the valve seats may be used
ho eo
ra
without reducing engine
s life, provided the cracks are small and
s c
not more than 0.5 mm wide.
ce
le
un
pt
an
d
itte
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Assembly overview - valve gear ⇒ page 92 .
rm
ab
pe
ility
Checking valve guides ⇒ page 94 .
ot
wit
, is n
h re
Renewing valve stem seals ⇒ page 95 .
hole
spec
es, in part or in w
Removing and installing camshaft ⇒ page 97 .
t to the co
Removing and installing camshaft seal ⇒ page 101 .
2.1 Assembly overview - valve gear
rrectness of i
l purpos
1 - 20 Nm + turn (90°)
nform
ercia
❑ Renew.
❑ Note sequence when
m
a
com
t
loosening and tighten‐
ion in
ing ⇒ page 97 , Re‐
r
te o
thi
moving and installing
s
iva
camshaft. do
r
rp
cum
fo
2 - Rocker arm shaft

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ng
t.
yi Co
op
❑ Do not interchange. C py
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3 - Cylinder head bolt op Vo
by c lksw
cted agen
❑ Renew. Prote AG.
❑ Note sequence when

loosening and tighten‐
ing ⇒ page 83 , Remov‐
ing and installing cylin‐
der head.
❑ Before installing, insert
washers ⇒ Item 4 (page
92) in cylinder head.
4 - Washer
❑ For cylinder head bolts.
❑ Insert in cylinder head
before installing bearing
caps
5 - Bucket tappet
❑ Do not interchange.
❑ With hydraulic valve
clearance compensa‐
tion.
❑ Store with cam contact
surface downwards.
❑ Before installing, check
camshaft axial clear‐
ance ⇒ page 93 .
❑ Oil contact surfaces.
❑ Before removing, remove camshaft bearing caps

6 - Valve cotter AG. Volkswagen AG d

agen oes
olksw not
yV gu
7 - Valve spring platese d b ara
nte
ri
ho eo
8 - Outer valve spring
aut ra
c
ss
❑ Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder
ce
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nl
head installed ⇒ page 95 , Renewing valve stem seals.
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9 - Inner valve spring
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head installed ⇒ page 95 , Renewing valve stem seals.
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10 - Valve stem seal
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❑ Renewing ⇒ page 95 .
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11 - Valve guide
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12 - Unit injector
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13 - Cylinder head
❑ See note ⇒ page 92 .
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14 - Seal
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❑ Do not additionally oil or grease the oil seal sealing lip.

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❑ To install, tape over groove in taper of camshaft (e.g. using Sellotape).

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❑ Valve dimensions ⇒ page 94 .
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16 - Bearing shell
❑ Do not interchange used bearing shells (mark).
❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head
17 - Camshaft
❑ Checking axial clearance ⇒ page 93 .
❑ Check radial clearance with Plastigage, wear limit: 0.11 mm.
❑ Runout: max. 0.01 mm.
18 - Bearing cap
❑ Installation sequence ⇒ page 97 , removing and installing camshaft
❑ To install, seal parting surfaces of bearing caps 1 and 5 with sealant -AMV 174 004 01- ⇒ page 94
19 - 8 Nm + turn (90°)
❑ Renew.
Checking camshaft axial clearance
2. Valve gear 93

♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge
Check with bucket tappets removed and with first, third and last
bearing caps fitted. wage
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Wear limit: max. 0.15 mm ed by ara
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Seal parting surfaces of bearing caps 1 tho sealant
and 5auwith -AMV
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– Apply sealant -AMV 174 004 01- thinly and evenly on the sur‐
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Note
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Be careful that no sealant gets into grooves -arrows-.
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Valve dimensions
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Valves must not be reworked. Only lapping-in is permitted.
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Dimension Inlet valve Exhaust valve
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∅a mm 35.95 31.45
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∅b mm 6.980 6.956
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2.2 Checking valve guides

♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge

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Test procedure
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– Insert new valve into guide. The end of the valve stem must
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be flush with the guide. On account of differing stem diame‐
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ters, only use inlet valve in inlet guide and exhaust valve in
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– Determine rock. Wear limit: max. 1.3 mm
spec
es, in part or in w
– Cylinder head must be renewed if rock exceeds wear limit.
t to the co
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2.3 Renewing valve stem seals

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♦ Assembly tool -2036-
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♦ Puller -3047 A- C py
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♦ Valve lever -VW 541/1A-
AG.
♦ Thrust piece -VW 541/5-
2.3.1 Removing
(With cylinder head installed)
– Remove camshaft. ⇒ page 97
2. Valve gear 95
– Remove bucket tappets and place them with the contact sur‐
face downwards. When doing this, ensure that the tappets are
not interchanged.
– Set piston of respective cylinder to top dead centre (TDC).
– Insert valve assembly device -2036- and adjust mounting to
height of studs.
– Remove valve springs using valve lever -VW 541/1A- and
press tool -VW 541/5- .
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– Pull off valve stem seals using puller -3047 A- .
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2.3.2 Installing
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– Place the plastic sleeve -A- supplied on the respective valve
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stem. This will prevent the new valve stem seal -B- being
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– Insert new valve stem seal in fitting tool -3129- .
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– Lubricate sealing lip of valve stem seal and carefully push on
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valve guide.
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2.4 Removing and installing camshaft

equipment required
♦ Counterhold tool -T10051-
♦ Puller -T10052-
-V.A.G 1331-
♦ Torque wrench (40... 200
Nm) -V.A.G 1332-
♦ Sealant -AMV 174 004 01-
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hole
Removing
spec
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– Remove securing bolts for camshaft toothed belt pulley -1-.
rrectness of i
– Pull camshaft toothed belt pulley off hub.

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2. Valve gear 97
– Loosen hub securing bolt -1-.

– To do this, use counterhold -T10051- .
– Loosen hub securing bolt about 2 turns.
AG. Volkswagen AG d
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– Apply puller -T10052-
horis and screw securing bolts -1- into hub.
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– Apply tension
s to hub by evenly tightening puller until hub sep‐ c
s
arates from taper of camshaft.
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When doing this, hold puller with 30 mm spanner.
hole
spec
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– Remove hub from taper of camshaft.
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– Remove cylinder head cover.
– Mark rocker arm shafts using a permanent felt tip marker to rrectness of i
l purpos
prevent interchanging. This will prevent having to perform ba‐

sic settings of unit injectors -arrows-.
nform
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– Remove rocker arm shafts.

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

2.4.2 Installing
Note
♦ When camshaft is installed, No. 1 cylinder cams must point

upwards.
♦ Do not interchange used bearing shells (mark).
♦ When installing the camshaft, ensure proper seating of retain‐
ing lugs in bearing caps and cylinder head.
♦ Before installing bearing caps, ensure that cylinder head bolt
washers are inserted in the cylinder head.
– Oil bearing shell running surfaces.

– Install bearing caps 2 and 4 using new bolts.
– Tighten bearing caps 2 and 4 in diagonal sequence alternately
to 8 Nm + (90°) turn further.
– Install bearing caps 5, 1 and 3 using new bolts. AG. Volkswagen AG d
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♦ Seal parting surfaces of bearing caps 1 and 5 with sealant - s
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AMV 174 004 01- ⇒ page 94 .
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♦ Bearing cap 5 must be flush with outer edge of cylinder head,
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otherwise leaks can occur at the tandem pump.
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– Tighten bearing caps 5, 1 and 3 likewise to 8 Nm + (90°) turn
hole
spec
further.
es, in part or in w
t to the co
– Install camshaft oil seal. ⇒ page 101
– Install injector rocker arm shafts with new securing bolts and
rrectness of i
tighten, first the inner -2- and then the outer -1-, evenly and in
diagonal sequence to 20 Nm + (90°) turn further.
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– Fit hub onto camshaft. nf

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– Tighten hub securing bolt -1- to 100 Nm. py by
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– To do this, use counterhold -T10051- . Prote AG.
2. Valve gear 99
– Push camshaft toothed belt pulley onto hub.
Note
The toothed segment -arrow- of the camshaft belt pulley must be

on top.
– Align camshaft toothed belt pulley at centre of elongated

holes.
– Hand tighten securing bolts -1- to camshaft toothed belt pulley
so that there is no play.
– Lock hub using locking pin -3359- .
– Screw new adjustment screws into rocker arms hand-tight and
fit lock nut.
– Fit dial gauge onto adjustment screw of unit injector as shown.

– Turn crankshaft in direction of engine rotation until roller of
rocker arm is located at tip of drive cam. Roller side
-arrow A- positioned at highest point, dial gauge -arrow B- po‐
sitioned at lowest point.
– Remove dial gauge.
– Now turn the adjuster screw into rocker arm until significant
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– Turn adjustment screw 180° back off stop.
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– Hold adjuster screw in this position and tighten lock nut to 30
erm
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Nm.
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– Install tandem pump ⇒ page 195 .
h re
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spec
– Install cylinder head cover.
Note t to the co
rrectne
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. The hydraulic compensation
ss
elements must settle (otherwise valves will strike pistons).

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mer
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2.5 Removing and installing camshaft oil seal

equipment required
♦ Fitting sleeves -10-203-
♦ Oil seal extractor -3240-
1331-
1332-
♦ Bolt M12×1.5 × 65
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2.5.1 Removing
on
c
in t
or
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at
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or
– Remove camshaft toothed belt pulley and hub ⇒ page 97 ,

f
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Removing and installing camshaft.

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– Unscrew inner part of oil seal extractor -3240- two turns (ap‐
t. rig
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prox. 3 mm) out of outer part and lock with knurled screw.
p by
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– Lubricate threaded head of oil seal extractor -3240- , place it
Prote AG.
in position and exerting firm pressure, screw it as far as pos‐

sible into oil seal.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
2. Valve gear 101

2.5.2 Installing
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residue from camshaft journal using a clean cloth.

– Tape over groove in taper of camshaft (e.g. with Sellotape).
– Fit oil seal carefully on camshaft.
– Press in oil seal with press piece of fitting tool -10-203- and
bolt M12 -5 x 65 onto stop.
AG. Volkswagen AG d
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17 – Lubrication
1 Engine oil
Note
The oil level must not be above the max. mark - danger of damage
to catalytic converter! Markings.
Engine oil specification ⇒ Maintenance ; Booklet 38

Oil capacities ⇒ page 103 agen
AG. Volkswagen AG d
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Checking engine oil level ⇒ page 103 ed b ara
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1.1 Oil capacities
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Engine codes AVQ BJB, BKC, BRU, BXE and BXF

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With oil filter change: 3.8 l
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Engine codes BLS and BXJ
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spec
With oil filter change: 4.3 l
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Without oil filter change: 3.8 l
1.2 Checking engine oil level
rrectne
Check which dipstick is installed.
ss
1 - Max. mark
o
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2 - Min. mark
mer
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a - Area above hatched field up to max. mark: Do not top up with

o
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engine oil!
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b - Oil level within hatched field: Can be topped up with engine

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oil.
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c - Area from min. mark up to hatched field: Must be topped up,

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max. 0.5 l of engine oil!
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1.3 Checking engine oil level
AG.
1 - Min. mark
2 - Max. mark
a - Area of min. mark: top-up with max. 0.5 l of engine oil!
b - Oil level in middle range: can be topped-up with engine oil.
c - Area of max. mark: do not add engine oil!
1. Engine oil 103

2 Parts of lubrication system
Caution
Finding metal shavings or a large quantity of small metal par‐

ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs: en AG. Volkswagen AG
wag does
Thoroughly clean oil channels. olks not
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Renew engine oil cooler tho eo
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Renew oil filter element ss
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Assembly overview - oil pump, sump ⇒ page 104
ility
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Removing and installing sump ⇒ page 105 .
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2.1 Assembly overview - oil pump, sump
spec
t to the co
1 - 15 Nm
2 - Sealing flange
rrectne
❑ With seal.
s
❑ Must sit on dowel
s o
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sleeves
f inform
mer
⇒ page 38
atio
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❑ Install with silicone
c
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sealant -D 176 404 A2-
thi
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⇒ page 38 .
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❑ Do not additionally oil or

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grease the oil seal seal‐

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move oil residue from
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crankshaft journal using
AG.
a clean cloth.
❑ Renewing crankshaft oil
seal - belt pulley end ⇒
page 36 .
3 - Chain tensioner with ten‐
sioning rail, 15 Nm
❑ When installing, preten‐
sion spring and fit.
4 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 103 .
5 - Piston fitting tool
6 - Guide tube
7 - Dowel sleeves
8 - O-ring
❑ Renew.
104 Rep. gr.17 - Lubrication

9 - 15 Nm
10 - Suction line AG. Volkswagen AG d
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❑ Clean strainer olkifsw
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11 - Baffle plate
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12 - 15 Nm
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13 - 15 Nm
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14 - Oil sump
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❑ Clean sealing surface before fitting.
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❑ Install with silicone sealant -D176404A2- .
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spec
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15 - Oil drain plug, 30 Nm
❑ Renew.
rrectness of i
16 - 10 Nm
l purpos
17 - Oil level and oil temperature sender -G266-

❑ Black 3-pin connector
nform
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18 - Seal
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❑ Renew.
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19 - Oil pump
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❑ With 12 bar pressure relief valve.

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❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
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❑ Renew if running surfaces and gears are scored.
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20 - Chain sprocket for oil pump
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21 - Bracket
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❑ For oil level/temperature sender wiring harness.
22 - 20 Nm + turn (90°)
❑ Renew.
23 - Chain
24 - 25 Nm
❑ Insert without sealant.
25 - Oil spray jet
❑ For piston cooling.
Note
2.2 Removing and installing oil sump

2. Parts of lubrication system 105

♦ Hexagon key extension, 5 mm -3249-
♦ Hand drill with plastic brush attachment

♦ Silicone sealant -D176404A2- AG. Volkswagen AG d
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♦ Hand drill with plastic brush attachment d by ara
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♦ Eye protection s aut ra
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♦ Flat scraper
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2.2.1 Removing
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– Drain engine oil.
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Note
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Observe environmental regulations for disposal.
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– Pull 3-pin connector off oil level and oil temperature sender -
G266- .
nform
ercia
– Remove sump.
m
at
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ion
– Loosen sump with light blows of a rubber headed hammer if

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or
necessary.
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– Remove sealant residue from cylinder block with a flat scraper.

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– Remove sealant residue on sump with by Va rotating brush, e.g.
olk ot g
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an electric hand drill with a plastic rbrush
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tee
protection). utho
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– Clean sealing surfaces. They must be free of oil and grease.
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2.2.2 Installing
rrectness of i
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Note
nform
ercia
♦ Observe expiry date of sealing compound.

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♦ The sump must be installed within 5 minutes of applying sili‐
n
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cone sealing compound.
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– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3
um
for
mm).
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– Apply silicone sealing compound, as shown, to clean sealing t. C rig
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surface on sump. Sealant bead must be: yri
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♦ 2 ... 2…3 mm thick.
agen
Prote AG.
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealant bead must not be thicker, otherwise excess sealing

compound will enter the oil sump and may block the oil suction
line strainer.
– Apply silicone sealing compound bead as shown to the clean

sealing surface of the sump. (The figure shows the position of
the sealant bead on the cylinder block.)
– Install sump immediately and tighten all sump bolts lightly.
Ensure that sump is flush against intermediate plate and gear‐
box flange.
Note
When installing sump with engine removed, ensure that sump is

flush with cylinder block at flywheel end.
– Tighten sump bolts diagonally to 15 Nm.

– Tighten bolts securing sump to gearbox to 45 Nm.
Note
Let sealing compound dry for approx. 30 minutes after installing

oil sump. Only then fill with engine oil.
2. Parts of lubrication system 107

Further assembly is basically the reverse of the dismantling se‐

quence.
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3 Oil filter bracket, oil pressure, engine

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

2 - 15 Nm + turn (90°)
❑ Renew.
❑ First fit upper left and
lower right bolts and
then tighten all four bolts
diagonally.
3 - Seal n AG. Volkswagen AG do
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4 - Seal autho
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6 - Oil supply line, 22 Nm
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⇒ page 112
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7 - Cap, 25 Nm
8 - Seal
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❑ Renew.
9 - Oil filter element ss
❑ Ensure "Top" is upper‐
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most when fitting

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10 - Plug, 10 Nm
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om
❑ If seal is leaking, nip

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11 - Oil pressure switch -F1-

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12 - Plug, 25 Nm
13 - Seal
❑ Renew.
14 - Engine oil cooler
❑ Ensure clearance to adjacent components.
3. Oil filter bracket, oil pressure, engine oil cooler and oil supply line 109
❑ See note ⇒ page 104 .
❑ Checking engine oil cooler for leaks ⇒ page 134
15 - Seal
❑ Renew.
16 - Bracket
17 - 10 Nm
3.2 Checking oil pressure and oil pressure switch

equipment required
♦ Oil pressure tester -
V.A.G 1342-
♦ Voltage tester -
V.A.G 1527 B-
♦ Auxiliary measuring set -
V.A.G 1594 A-
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3.2.1 Test procedure

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warning: ⇒ Current flow diagrams, Electrical fault finding and Fit‐
AG.
ting locations Guided fault finding with VAS 5051.

– Remove oil pressure switch -F1- and screw into tester.

– Screw tester into oil filter bracket in place of oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester -V.A.G 1527 B- to battery positive (+)
and oil pressure switch using cable from auxiliary measuring
set -V.A.G 1594 A- . LED must not light up.
– Start engine and increase speed slowly.
– At 0.55 … 0.85 bar, the LED must light up; otherwise renew
oil pressure switch.
– Increase engine speed further. At 2000 rpm and an oil tem‐
perature of 80 °C the oil pressure should be at least 2.0 bar.
At higher engine speeds, oil pressure must not exceed 7.0 bar. If
necessary renew oil filter bracket.
3.3 Assembly overview - oil supply line to turbocharger
1 - Retaining clamp
2 - 25 Nm
3 - Oil supply line
4 - 10 Nm
5 - Bracket
6 - Union nut, 22 Nm n AG. Volkswagen AG do
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8 - Union nut, 22 Nm utho tee
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3.4 Removing and installing oil supply line

to turbocharger
3.4.1 Removing
– Remove engine cover. ⇒ page 5
pipe.
of mounting.
– Loosen securing bolts for retaining clips.
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– Loosen oil supply lineksunion
wage nuts on oil filter dbracket
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– Remove oilthsupply
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3.4.2 Installing
ility
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Note
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The procedure must be adhered to, this will ensure that the oil
supply line is installed tension-free.
rrectness of i
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– Loosen securing nut -2- from retainer -5-.
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– Start union nuts for oil supply line on connections.
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– Tighten union nut -8- on oil filter bracket hand tight.
– Tighten union nut -6- on turbocharger hand-tight.
– First tighten union nut -8- on oil filter bracket and then union
nut -6- on turbocharger to 22 Nm.
– Attach retaining clips -1- to brackets and tighten securing bolts
to 10 Nm.
– Tighten securing nut -2- to 25 Nm.
Further installation is basically the reverse of the removal proce‐
dure.
19 – Cooling
1 Parts of cooling system
WARNING

conditions:
sitions. en AG. V
olkswagen AG
ag does
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♦ Ensure that there is sufficient clearancey V to all moving or
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♦ When the engine is warm, the cooling system is under pres‐
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hole
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♦ Hoses are secured with spring-type clips. In case of repair,
t to the co
only use spring-type clips.
♦ Spring-type clip pliers -VAS 5024- or hose clip pliers -
rrectness of i
V.A.G 1921- are recommended for fitting spring-type clips.
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♦ When installing coolant hoses, route stress-free so that they

do not come into contact with other components (observe
markings on coolant connection and hose). nform
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114 Rep. gr.19 - Cooling

Perform leakage test of cooling system using cooling system

tester -V.A.G 1274- and adapters adapter -V.A.G 1274/8- and
adapter -V.A.G 1274/9- .
Parts of cooling system, body side (radiator with two radiator fans)
⇒ page 115 .
Parts of cooling system, body side (radiator with one radiator fan)
⇒ page 117
Removing and installing fan support with fans (Golf, Golf Plus,
Touran) ⇒ page 117
Removing and installing fan support with fans (Passat) ⇒ page
119
Parts of cooling system - engine side ⇒ page 120 .
Coolant hose schematic diagram ⇒ page 122 .
Draining and filling with coolant ⇒ page 123 .
Removing and installing radiator (Golf, Golf Plus, Touran) ⇒ page
126
Removing and installing radiator (Passat) ⇒ page 127
Removing and installing coolant pump ⇒ page 128 .
Removing and installing thermostat ⇒ page 130 .
Checking cooling system for leaks ⇒ page 132 .
Checking pressure relief valve in filler cap ⇒ page 133 .
AG . Volkswagen AG
Checking engine oil cooler for leaks ⇒ page 134
ksw
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1.1 Parts of cooling system, body side (radiator with two radiator fans) db ara
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1 - Upper coolant hose ss
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❑ Coolant hose schematic

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1. Parts of cooling system 115

diagram ⇒ page 122 .

2 - O-ring
3 - Cooler
4 - Cap
❑ Check using cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/9- .
❑ Test pressure 1.4 … 1.6 bar
5 - Connector
6 - 5 Nm
7 - Expansion tank
❑ Check using cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/8- .
8 - 5 Nm
9 - 10 Nm
10 - Fan support
11 - Additional fan
❑ Vehicles with optional equipment only. wage
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12 - Radiator fan byV ua
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13 - Connector auth or
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14 - Lower coolant hose
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❑ Coolant hose schematic diagram ⇒ page 122 .
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15 - Retaining clip
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16 - Radiator outlet coolant temperature sender -G83-
spec
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1.2 Assembly overview - parts of cooling system, body side (radiator with one
radiator fan)
1 - Upper coolant hose

2 - O-ring
3 - Radiator
⇒ page 126 AG. Volkswagen AG d
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❑ After renewing, renew ed byV gu
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entire coolant. horis nte
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4 - Seal ss c
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5 - Cap
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❑ Check using cooling
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system tester -
ility
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V.A.G 1274- and
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adapter -
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V.A.G 1274/9- .
spec
6 - Connector
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7 - 5 Nm
8 - Expansion tank
rrectne
❑ Check using cooling
system tester -
ss o
V.A.G 1274- and
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adapter -
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V.A.G 1274/8- .
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9 - Radiator mounting
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10 - 5 Nm
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11 - Mounting
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13 - Fan support rig ht
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14 - 5 Nm Prote
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agen
15 - 5 Nm
16 - Connector
18 - Retaining clip
19 - Radiator outlet coolant temperature sender -G83-
1.3 Removing and installing fan support

with fans (Golf, Golf Plus, Touran)

♦ Torque wrench (5... 50 Nm) -V.A.G 1331-
Removing
The procedure for the single fan is identical.
– Remove noise insulation ⇒ General body repairs, exterior;olksw
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does
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– Remove air intake duct from air filter. ed by ara
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– Bring lock carrier into service position
aut⇒ General body repairs, ra
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exterior; Rep. gr. 50 ; Body - front;ss Lock carrier - service po‐
ce
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sition.
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– Separate connector -1- and remove fan support securing bolts
erm
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-arrows-.
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– Remove fan support with fans upwards.
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– Separate connection -2- and free wiring.

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– Unclip connector -1- from fan support and free wiring.

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– Remove securing nuts -arrows- and remove fans.

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note the following:
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Specified torques: ⇒ Item 15 (page 117)
Component Nm
Radiator fan to fan support (single fan) 5
Radiator fan to fan support (double fan) 10
Fan support to radiator 5

1.4 Removing and installing fan support

with fans (Passat)
Removing
– Remove air intake duct from air filter.
– Separate connector -1- and remove fan support securing bolts
-arrows-. G. Volkswagen A AG do
agen es n
– Remove fan support with fans upwards. ksw
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– Unclip connector -1- from fan support and free wiring.

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– Remove securing nuts -arrows- and remove fans.

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note the following:

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Specified torques: ⇒ Item 15 (page 117)

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Component Nm
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Radiator fan to fan support (single fan) 5
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Radiator fan to fan support (double fan) 10
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Fan support to radiator 5

1.5 Parts of cooling system, engine side
1 - To top of expansion tank

2 - Upper coolant pipe
❑ Bolted to cylinder head
cover
3 - To bypass flap AG. Volkswagen AG d
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❑ Coolant hose schematic ed by
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5 - Retaining clip
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❑ Check for secure seat‐
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6 - Coolant temperature
spec
sender -G62-
es, in part or in w
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❑ With coolant tempera‐
ture display sender -G2-
rrectness of i
7 - To exhaust gas recircula‐
tion cooler.
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8 - Connection
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at
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9 - 10 Nm
ion
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10 - To heat exchanger
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11 - 40 Nm t. Cop py
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12 - T-piece p by
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13 - To bypass flap Prote AG.

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

❑ Checking: heat thermostat in water.
❑ Opening begins at approx. 85 °C.
❑ Ends at approx. 105 °C.
❑ Opening lift at least 7 mm.
22 - To heat exchanger
❑ Coolant hose schematic diagram ⇒ page 122
23 - Rear coolant pipe
24 - 10 Nm
25 - To auxiliary heater
26 - Coolant pipe
27 - To exhaust gas recirculation cooler.
❑ Removing and installing ⇒ page 109 lkswage es n
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29 - Coolant pump ir se
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❑ Check for ease of movement. aut or
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Golfho2004
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1.6 Coolant hose schematic diagram
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1 - Expansion tank
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2 - Rear coolant pipe
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spec
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3 - Bypass flap
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4 - Exhaust gas recirculation
cooler
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5 - Cylinder head/cylinder
block
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6 - Heat exchanger for heater

unit
nform
mercia
7 - Connection
at
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ion
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8 - Front coolant pipe
in t
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9 - Gearbox oil cooler
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❑ if fitted
for
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10 - Upper coolant hose
co Vo
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11 - Radiator
14 - Coolant pump and ther‐
mostat
15 - Upper coolant pipe
16 - Circulation pump -V55-
❑ if fitted
17 - Auxiliary heater
❑ Vehicles with optional
equipment only.
Note
Coolant hose schematic diagram for vehicles with optional equip‐

ment ⇒ Heating, ventilation, air conditioning system; Rep. gr.
82 ; Connection diagram for coolant hoses in vehicles with auxil‐
iary heater

1.7 Draining and filling coolant

equipment required
♦ Refractometer -T10007-
♦ Spring-type clip pliers -
VAS 5024 A-
♦ Cooling system charge unit
-VAS 6096-
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1.7.1 Draining
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– Open cap on coolant expansion tank.

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WARNING
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Hot steam may escape when expansion tank is opened. Place C py
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cloth over cap and open with caution.
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If drain plug is fitted:

– To drain coolant from radiator, open drain plug -arrow-.

If drain plug is not fitted:
AG. Volkswagen AG d
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– Pull off lower coolantbhoseyV
o retaining clip -arrow- and removegu
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coolant hose from orisquick-release connection of radiator.
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– To drain coolant from engine, also remove coolant hose from t to the co
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engine oil cooler -arrow-.
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Note
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Observe environmental regulations for disposal.

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1.7.2 Filling
Note
♦ In vehicles as of model year 2008, only G 12 plus-plus ac‐

cording to TL VW 774 G may be used as coolant additive.
♦ For vehicles up to and including model year 2007 coolant ad‐
ditive G 12 plus according to TL VW 774 F and G 12 plus-plus
according to TL VW 774 G can be used.
♦ The coolant additive G 12 plus-plus can be mixed with the
previous coolant additive G 12 plus. Identification: both are
coloured purple.
♦ Coolant additives marked „according to TL VW 774 G“ or „ac‐
cording to TL VW 774 F“ prevent agenfrost and corrosion
AG. Volkswagen AG d damage,
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scaling and also raise boiling olkswpoint of coolant. Therefore,not the
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cooling system must risebe filled all year round with coolant ad‐ante
d b ar
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♦ Because of itsshigher boiling point, the coolant improves en‐
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gine reliability under heavy loads, particularly in countries with

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♦ The coolant concentration must not be reduced by adding wa‐
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spec
ter even in warmer seasons and in warmer countries. The
es, in part or in w
coolant additive concentration must be at least 40 %.
t to the co
♦ If for climatic reasons greater frost protection is required, the
amount of coolant additive can be increased, but only up to 60
% (frost protection to about -40 °C). Otherwise frost protection rrectness of i
and cooling effectiveness are reduced again.
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♦ The refractometer -T10007- is recommended for determining

the current anti-freeze concentration.
nform
ercia
♦ If radiator, heat exchanger, cylinder head or cylinder head

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gasket is renewed, do not reuse old coolant.

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Recommended mixture ratios:

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-35 °C 50 % Prote 4.0 l AG.
4.0 l
1)The quantity of coolant can vary depending upon the vehicle
equipment.
– Close coolant drain plug.
– Connect coolant hoses to engine oil cooler.
– Install noise insulation. ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body - front; Assembly overview .
– Screw adapter -V.A.G 1274/8- onto expansion tank.
– Fill coolant circuit using cooling system charge unit -
VAS 6096-
Operating instructions for cooling system charge unit -VAS 6096-
are enclosed with unit.

Fill coolant expansion tank of -VAS 6096- with at least 8 litres of

pre-mixed coolant in correct mixture ratio.
Note
Exhaust air takes a slight quantity of coolant along with it; this
should be collected -2-.
1.8 Removing and installing radiator (Golf, Golf Plus, Touran)

equipment required
♦ Torque wrench -
V.A.G 1331- agen
AG. Volkswagen AG d
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olksw not
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♦ Spring-type clip pliers - ed by gu
ara
VAS 5024 A- horis nte
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aut ra
♦ Adapter -V.A.G 1274/8- ss c
ce
le
un
pt

an
d
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-VAS 6096-
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erm
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ility
ot p
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spec
t to the co
rrectness o
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f inform
mer
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om
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c
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Cop py
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Prote AG.

1.8.1 Removing (Golf, Golf Plus, Touran)

– Bring lock carrier into service position. ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier service
position .
AG. Volkswagen AG d
– Pull coolant hoses off radiator. agen oes
olksw not
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ara
– Separate connector for radiator fan.rised
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ut
– Remove radiator securing bolts.
ss a ra
c
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– Remove radiator downwards.
nl
pt
du
an
itte
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1.8.2 Installing (Golf, Golf Plus, Touran)
erm
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ility
ot p
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note the following:
h re
hole
spec
– Fill with coolant. ⇒ page 123
es, in part or in w
t to the co
1.9 Removing and installing radiator (Passat)
rrectness of i
l purpos
equipment required
nf
ercia
o
rm
m
1331/-
atio
om
n in
c
♦ Hose clip pliers -VAS 6340-

or
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Prote AG.

Removing
– Pull coolant hoses off radiator.
– Pull off connector for radiator fan.
– Remove cowling together with fans ⇒ page 119 .
– Remove bolts -arrow up- -arrow down- and lift radiator up and
out.
Installing
note the following:
– Replenish coolant ⇒ page 123 .
1.10 Removing and installing coolant pump

equipment required
♦ Torque wrench -
V.A.G 1331-
VAS 5024 A-
AG. Volkswagen AG d
agen oes
♦ Cooling system charge unit Volksw not
gu
-VAS 6096- d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
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
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cum
fo
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Cop py
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128
cted agen
Prote
Rep. gr.19 - Cooling
AG.
1.10.1 Removing
Note
Always renew seals and gaskets.

– Remove toothed belt ⇒ page 66 .
– Remove securing bolts -1- for coolant pump -2- and carefully
remove coolant pump.
1.10.2 Installing
note the following:
AG. Volkswagen AG d
– Moisten new O-ring -3- with coolant.
lksw
agen oes
not
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– Insert coolant pump edb
-2- in ricylinder block and tighten securing ara
s nte
bolts -1- to 15 Nm. ut
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ra
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nl
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Note
an
itte
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ab
The coolant pump plug faces downwards.

ility
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wit
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h re
– Install toothed belt ⇒ page 66 .

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
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t.
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Cop py
ht. rig
rig ht
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Prote AG.

1.11 Removing and installing thermostat

equipment required
♦ Torque wrench -
V.A.G 1331-
VAS 5024 A-
-VAS 6096-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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aut ra
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un
pt
an
d
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
1.11.1 Removing
l purpos
nform
ercia
Note
m
a
com
Always renew seals and gaskets.

ion in
r
te o
thi

s
iva
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cum
– Remove alternator. ⇒ Electrical system; Rep. gr. 27 ; Re‐

fo
en
g
moving and installing alternator with poly V-belt .

n
t.
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Cop py
t.
– Pull coolant hose off connection.
rig
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Prote AG.

– Remove securing bolts -1- of connection -2- and remove con‐

nection -2- with thermostat -4-.
– Turn thermostat -4- 1/4 turn (90°) anticlockwise and remove it
from connection -2-.
1.11.2 Installing
note the following:
– Moisten new O-ring -3- with coolant.
– Insert thermostat a-4-
geninto
olkswagen AG
AG. Vconnection -2-
doeand 1
lksw s no turn /4 turn (90°)
clockwise.
db
yV
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ss Note
ce
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un
pt
an
d
The brace on the thermostat must be almost vertical.

itte
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ility
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– Insert connection -2- with thermostat -4- in cylinder block.

wit
is n
h re
– Tighten securing bolts -1- to 15 Nm.

ole,
spec
– Replenish coolant. ⇒ page 123

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
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Prote AG.

1.12 Checking cooling system for leaks

AG. Volkswagen AG d
agen oes
Special tools and workshop olksw not
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equipment required rised b ara
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♦ Cooling system tester - aut ra
s c
V.A.G 1274- s
ce
le
un
pt
♦ Adapter for cooling system
an
d
itte
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tester -V.A.G 1274/8-
rm
ab
pe
ility
ot
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
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cum
fo
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t.
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Cop py
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rig ht
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Prote AG.
Test prerequisite
• Engine at operating temperature.
Test sequence:
WARNING
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.

– 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. wage
es n
olks ot g
byV ua
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un
pt
an
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ility
1.12.1 Checking pressure relief valve in filler
ot p
wit
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cap
h re
ole,
spec
t to the co
tester adapter -V.A.G 1274/9- to cap.
– Use hand pump on cooling system tester to create a pressure
of max. 1.6 bar.
rrectne
The pressure relief valve must not open.
ss
If the pressure relief valve opens prematurely:
o
cial p
f inform
– Renew sealing cap.
mer
atio
– Increase pressure to over 1.6 bar.
om
n
c
i
or
n
The pressure relief valve must open.
thi
te
sd
va
If the pressure relief valve does not open:

i
o
pr
cum
r
fo
en
– Renew sealing cap.
ng
t.
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Cop py
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pyri by
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co lksw
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Prote AG.

1.13 Checking engine oil cooler for leaks

equipment required
♦ Hose clamps up to 25 mm
-3094-
♦ Cooling system tester -
V.A.G 1274-
5024A-
AG. Volkswagen AG d
♦ Drip tray -VAS 6208- agen oes
olksw not
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ara
ed
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nl
pt
du
an
itte
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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
thi
te
sd
iva
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t.
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op py
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rig by
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Not illustrated:
♦ Expansion tank -1K0 121 407 A- or -6Q0 121 407 A- or -1J0
121 407 B-
♦ Plug -191 211 343-

♦ Cap -1J0 121 324-

♦ Coolant hose -251 265 056-
♦ Screw clamp
Test prerequisite:
• Engine cold
Test procedure
tion .
– Clamp supply line and return line off engine oil cooler using
hose clips to ∅ 25 mm -3094- .
– Loosen spring-type clips -arrows- using spring-type clip pliers
-VAS 5024A- .
AG. Volkswagen AG d
agen oes
olksw not
Note ed byV gu
ara
ris nte
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ut
Collect escaping coolant
ss a with drip tray -VAS 6208- . ra
c
ce
e
nl
pt
du
– Pull coolant hoses off engine oil cooler.
an
itte
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erm
ab
ility
ot p
– Push sealing cap -5- to rear connection of engine oil cooler
wit
, is n
h re
-4-.
hole
spec
– Secure sealing plug -2- to breather connection of expansion
es, in part or in w
t to the co
tank -1-.
– Secure coolant hose -3- to oil cooler and expansion tank. rrectness of i
– Fill expansion tank up to „Max“ marking.

l purpos

tester adapter -V.A.G 1274/8- to expansion tank.
nform
ercia
Use hand pump on tester to create a pressure of about 1.6 bar.

m
at
Watch pressure drop on pressure gauge. A pressure drop within

om
io
10 minutes is not permitted.

n
c
in t
or
his
e
If pressure drops:
at
do
priv
cum
– Renew engine oil cooler.

for
en
ng
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Assembly is carried out in the reverse order, note the following: . Cop py
rig
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– Check coolant level, if necessary replenish coolant.
rig by
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cted agen
Prote AG.

20 – Fuel supply system

1 Safety precautions
1.1 Safety precautions when working on fu‐

el supply system
WARNING

conditions:
sitions.
hot components.
carefully loosen connection to release the pressure! n AG. Volkswagen AG do
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♦ Wear eye and hand protection when performing any type byV
ol ot g
ua
of repair work on the fuel system! ir se
d ran
tee
tho
u or
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ss
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When removing and installing fuel gauge sender or fuel pump

nl
pt
du
(fuel delivery unit) from a full or partly full fuel tank, observe the
an
itte
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following:
erm
ab
ility
ot p
♦ Even before work commences, the extraction hose of an ac‐
wit
, is n
tivated fume extraction system has to be placed in the vicinity
h re
of the assembly opening of the fuel tank to extract any escap‐
hole
spec
ing fumes. If no exhaust extraction system is available, a radial
es, in part or in w
fan with a displacement greater than 15 m3/h can be used

providing that motor is not in air flow. t to the co
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
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Prote AG.
136 Rep. gr.20 - Fuel supply system

2 Rules for cleanliness
2.1 Rules for cleanliness when working on

fuel supply system
When working on the fuel supply and injection system, pay careful
attention to the following „6 rules“ for cleanliness:
Volkswa
♦ Thoroughly clean all
swa
genunions
AG. andgadjacent
en AG
does areas before dis‐
connecting.by Volk not
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a
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se
♦ Placethoremoved
ri parts on a clean surface and cover.
tee Use only
or
lint-free
ss
au
cloths. ac
ce
le
♦ Carefully cover opened components or seal if repairs cannot

un
pt
an
be carried out immediately.
d
itte
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erm
ab
♦ Install clean components only. Do not remove replacement
ility
ot p
parts from packing until immediately before installing. Do not
wit
is n
use parts that have not been stored in their packing (e.g. in
h re
ole,
tool boxes etc.).
spec
♦ When system is open: do not work with compressed air if this
t to the co
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
rrectne
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
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Cop py
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Prote AG.
2. Rules for cleanliness 137

. Volkswagen AG
gen AG
3 Parts of fuel supply system (Golf, a does
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Vol gu
by
Golf Plus) d ara
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ris
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Safety precautions ⇒ page 136 . ss c
ce
le
un
pt
Rules for cleanliness ⇒ page 137 .
an
d
itte
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Fuel tank, vehicles with front-wheel drive ⇒ page 138 .
erm
ab
ility
ot p
Fuel tank, vehicles with four-wheel drive ⇒ page 142 .
wit
is n
h re
ole,
Emptying fuel tank ⇒ page 148 .
spec
Removing and installing fuel delivery unit ⇒ page 150 .
t to the co
Removing and installing fuel gauge sender ⇒ page 151 .
Checking fuel pump ⇒ page 152 .
rrectne
Assembly overview - fuel filter ⇒ page 156 .
ss
Removing and installing fuel cooler ⇒ page 158 .
o
cial p
f inform
3.1 Fuel tank, vehicles with front-wheel
mer
atio
drive
om
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
cum
r
fo
en
ng
t.
yi
♦ Hose connections are secured with either spring-type or
Co
op py
clamp-type clips. t. C rig
gh ht
pyri by
♦ Always renew clamp-type clips with spring-type clips.
o Vo
by c lksw
cted agen
Prote AG.
♦ Spring-type clip pliers -VAS 5024/- or hose clip pliers -V.A.G
1921/- are recommended for installation of spring-type clips.

3.1.1 Assembly overview - fuel tank
1 - Cap
2 - 1.5 Nm
3 - Earth connection
ing.
4 - 10 Nm
AG. Volkswagen AG d
5 - Cable guide lksw
agen oes
not
Vo gu
by
6 - Fuel tank rised ara
nte
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❑ When removing, sup‐ aut
h
ra
port using engine and ss c
ce
e
gearbox jack -V.A.G

nl
pt
du
1383/A- .
an
itte
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erm
ab
ility
⇒ page 140
ot p
wit
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7 - 25 Nm
h re
hole
spec
❑ Renew.
es, in part or in w
t to the co
8 - Clamping washer
9 - Securing strap
rrectness of i
❑ Note installation posi‐
tion.
l purpos
10 - Heat shield
❑ For fuel tank.
nf
ercia
orm
m
11 - Seal
atio
om
n in
or c
thi
e
❑ Moisten with fuel when

t
sd
iva
installing
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12 - Fuel delivery unit

en
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❑ With fuel gauge sender C py
t. rig
(G).
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lksw
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Prote
tion of flange on fuel tank ⇒ page 162 .
AG.

❑ Checking fuel pump ⇒ page 152 .
❑ Removing and installing fuel gauge sender ⇒ page 170 .
13 - Locking ring
❑ Remove and install using wrench -T10202- .
❑ Specified torque: 110 Nm
14 - Supply line
❑ To fuel filter
❑ Clipped onto fuel tank.
❑ Black
❑ To pull off flange, press release button on connecting piece.
15 - Return line
❑ From fuel cooler
3. Parts of fuel supply system (Golf, Golf Plus) 139

16 - Tank flap unit
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit .
3.1.2 Removing and installing fuel tank

♦ Torque wrench -V.A.G 1331/-
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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aut ra
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un
pt
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rm
ab
pe
ility
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♦ Engine and gearbox jack -V.A.G 1383/A- 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
Removing
s
iva
do
r
rp
– Note safety precautions before beginning work ⇒ page 136 .

um
fo
en
ng
t.
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Observe rules for cleanliness ⇒ page 137 .
Co
Cop py
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rig ht
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by lksw
Note Prote
cted AG.
agen

♦ When lowering fuel tank, guide it carefully to prevent damage.
– Disconnect earth strap from battery with ignition switched off

⇒ Electrical system; Rep. gr. 27 ; Disconnecting and recon‐
necting battery .
– Remove rear seat bench (Golf Plus: rear right seat) ⇒ General
body repairs, interior; Rep. gr. 72 ; Rear seats; Removing and
installing seat bench .

– Remove cover from fuel delivery unit.

– Pull connector off flange.
– Remove fuel flap unit. ⇒ General body repairs, exterior; Rep.
gr. 55 ; Fuel flap unit
– Emptying fuel tank ⇒ page 148 .
– Remove rear right wheel housing liner: ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner .
– Remove bolts from filler neck -arrows-.
– Disconnect fuel lines at front right of fuel tank.
Note
Press buttons on hose couplings to do this.
– If vehicle has supplementary heating, separate connector to wagen AG. Volkswagen AG doe
metering pump and unclip wire. ⇒ Supplementary heating; Vol
ks s no
t gu
Rep. gr. 82 ; Removing and installing metering pump d by
-V54 ara
ise n r tee
ho
– Remove bolts -A- and remove heat shield for fuel
sa
uttank. or
ac
s
– Support fuel tank using engine and gearbox jack -V.A.G 1383/ ce
e
nl
pt
du
A- . an
itte
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erm
ab
ility
– Remove securing bolts -arrows- for the fuel tank.
ot p
wit
, is n
– Slowly lower fuel tank and pull it forwards.

h re
hole
spec
– Tilt fuel tank to get it past rear axle.

es, in part or in w
t to the co
Installing
rrectness of i
♦ Install breather and fuel hoses free of kinks.

l purpos

nf
ercia

rm
m
atio
m
♦ Clip supply and return lines onto fuel tank.

o
n in
or c
thi
te
sd
iva
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t.
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Prote AG.

3.2 Fuel tank, vehicles with four-wheel drive
1 - Supply line
❑ Black
❑ Check for secure seat‐ AG. Volkswagen AG d
agen oes
ksw
ing. by Vol not
gu
ara
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ise nte
2 - Return line thor eo
au ra
❑ blue ss c
ce
e
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pt
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an
ing.
itte
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erm
ab
3 - Seal
ility
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wit
❑ Renew.
, is n
h re
❑ When installing, fit dry in
hole
spec
fuel tank opening.
es, in part or in w
t to the co
❑ Moisten with fuel only
when installing flange.
rrectness of i
l purpos
⇒ page 150
❑ Checking fuel pump
nf
ercia
orm
tion on fuel tank ⇒
m
atio
m
page 143 .
o
n in
or c
❑ With fuel gauge sender
thi
te
sd
-G- .
iva
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cu
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f
en
ng
fuel gauge sender ⇒

t.
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page 170 . Cop py
t. rig
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5 - Locking ring, 110 Nm p by
co Vo
by lksw
cted
agen
Prote AG.
ing.
❑ Remove and install us‐
ing wrench -T10202- .
6 - Tank flap unit
❑ With rubber cup.
❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit .
7 - Cap
8 - Securing bolt
❑ Tighten to 1.5 Nm.
10 - 10 Nm
11 - Suction-jet pump
❑ Clipped onto fuel gauge sender 2 -G169-

12 - Fuel gauge sender 2 -G169-

13 - Fuel tank
❑ When removing, support using engine and gearbox jack -V.A.G 1383 A- .
14 - Securing strap
15 - 25 Nm
❑ Renew.
16 - Heat shield
❑ Riveted to exhaust pipe mounting
Installation position of flange for fuel delivery unit and fuel gauge
sender 2 -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.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss
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e
nl
pt
du
an
itte

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erm
♦ Torque wrench (5... 50 Nm) -V.A.G 1331- 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
♦ Engine and gearbox jack -V.A.G 1383 A-

c
in t
or
his
ate
do
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cum
for
en
ng
t.
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Prote AG.

AG. Volkswagen AG d
agen oes
Note Volksw not
gu
d by ara
ise nte
r
Before disconnecting battery,ut open fuel tank flap and if necessary
ho eo
ra
remove wheel lock adapterss afrom luggage compartment. c
ce
le
un
pt
– First check whether a coded radio is fitted. If so, obtain anti-
an
d
itte
y li
theft coding.
rm
ab
pe
ility
ot
wit
, is n
h re
necting battery .
hole
spec
es, in part or in w
If necessary, drain fuel tank using fuel extractor -VAS 5190- . ⇒
t to the co
page 148
– Remove rear right wheel.
rrectness of i
– Remove rear right wheel housing liner. ⇒ General body re‐
l purpos

housing liner; Rear wheel housing liner .
nform
ercia
– Unscrew securing bolts and remove tank flap unit. ⇒ General

body repairs, exterior; Rep. gr. 55 ; Fuel flap unit
m
a
com
tio
– Unscrew filler neck from body -arrows- and unclip electrical
n in
r
wire from filler neck.

te o
thi
s
iva
do
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
r
rp
cum
72 ; Rear seat; Removing and installing seat bench .
fo
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t.
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Cop py
t. rig
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Prote AG.
– Remove covers and separate electrical connectors -arrows-.

– Remove centre and rear silencers.
– Secure exhaust system to underbody using wire.

– Remove rear propshaft ⇒ Manual gearbox; Rep. gr. 39 ; Final
drive, differential, differential lock
WARNING
Fuel supply line is pressurised. Wear eye protection and pro‐

tective clothing to avoid possible injury and skin contact. Be‐
fore loosening hose connections, wrap a cloth around the
connection. Then release pressure by carefully pulling hose off
connection.

olksw
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en A, GGolf
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Plus 2005do➤
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ot g
ua l engine) - Edition 08.2010
e ran
ris tee
ho
– Pull off adapter cable on afour-wheel
ut drive control unit -J492- . or
ac
ss
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le
un
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pe
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Support fuel tank using engine and gearbox jack -V.A.G 1383
A- and unscrew tensioning straps and securing bolts.
nform
ercia
– Slowly lower fuel tank.

m
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tion in
Note
r
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The filler neck must be „guided out“ between body and rear axle.
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To do this, take the fuel tank off engine and gearbox jack -V.A.G
en
ng
t.
1383 A- with the assistance of a 2nd mechanic.
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Cop py
t. rig
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pyri by
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by
cted agen
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– Clip in cable for four-wheel drive control unit -J492- on fuel
tank.
– With the aid of a 2nd mechanic, guide the filler neck in between
rear axle and body. Then place the fuel tank on the engine and
gearbox jack -V.A.G 1383 A- .
– Raise fuel tank slowly up to installation position and secure it

in place.

– 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.
♦ Ensure that fuel line connections are tight.
♦ Check earth connection on fuel tank and body to filler neck.
3.2.3 Removing and installing fuel gauge

sender 2 -G169-
• The fuel tank should be no more than half full
Note
♦ Ensure that the fuel gauge sender is not bent.

♦ If necessary, drain fuel tank using fuel extractor -VAS 5190- .
⇒ page 148
♦ Note safety precautions before beginning work ⇒ page 136 .
♦ Observe rules for cleanliness ⇒ page 137 .
Removing:
theft coding.
necting battery . G. Volkswagen nA AG do
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– Remove bench seat ⇒ Generaly Vbody olks repairs, interior; Rep. gr.
s no
t gu
72 ; Rear seat; Removingrisand
ed b
installing seat bench . ara
nt ee
tho or
– Remove left cover (ass auseen facing direction of normal travel) ac
from fuel gauge sender
s 2 -G169- .
ce
e
nl
pt
du
– Disconnect electrical connectors.

an
itte
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erm
ab
– Open locking ring using wrench -T10202- .

ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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or c
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Cop py
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146
co Vo
by lksw
Rep. gr.20 - Fuel supply system cted agen
Prote AG.
– Pull fuel gauge sender 2 -G 169- upwards slightly and unclip

it from the suction-jet pump. gen AG
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Installing: byV gu
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Cautionss a c
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When installing do not bend fuel gauge sender 2 -G169- float
an
itte
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arm.
erm
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ility
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– Place fuel gauge sender 2 -G 169- in fuel tank.
hole
spec
es, in part or in w
t to the co
– Fit suction-jet pump on sender on inside of fuel tank. Locating
lugs must engage.
– Place a new flange seal dry into aperture in fuel tank and
rrectness of i
moisten only inside (contact to flange) with fuel.
l purpos
– Note installation position of fuel gauge sender 2 -G169- ⇒

page 143
nform
ercia
– Check correct position of seal.

m
at
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ion
c
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ate
do
priv
cum
for
en
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t.
– Tighten locking ring using wrench -T10202- . Specified torque:
yi Co
op py
110 Nm. t. C rig
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pyri by
– Fit connectors.
co Vo
by lksw
cted agen
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– Install cover.
– Install bench seat. ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seat; Removing and installing seat bench .
3.2.4 Removing and installing suction-jet

pump
Note
♦ On vehicles with four-wheel drive, fuel must be pumped from

the area of fuel gauge sender 2 -G169- , to the fuel pump with
a suction-jet pump due to the shape of the fuel tank.
♦ Checking is only necessary when the engine stops due to lack
of fuel, even though the fuel gauge shows that the tank is still
1/4 full.
Procedure
– Remove fuel delivery unit ⇒ page 150 .

– Pull return hose of suction-jet pump out of fuel delivery unit

-arrow-.
– Separate quick-release coupling of supply line from suction-
jet pump on Y-piece of fuel delivery unit.
– Remove fuel gauge sender 2 -G 169- ⇒ page 146 .
– Now the suction-jet pump can be pulled out from the side of
the fuel gauge sender 2 -G169- (left side of vehicle).
– Check that the fuel lines on suction-jet pump are fitted securely
and are not damaged.
– Additionally check suction-jet pump for possible soiling.
3.3 Emptying fuel tank

♦ Fuel extractor -VAS 5190-
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♦ Fuel tank sender unit tool -T10202-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
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ion
c
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or
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Emptying fuel tank if it is more than 3/4 full ⇒ page 148 . Cop py
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Emptying fuel tank if it is less than 3/4 full ⇒ page 149 .
cop Vo
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Prote AG.
3.3.1 Emptying fuel tank if it is more than 3/4

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

part of the body.

AG. Volkswagen AG d
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– Remove cotter ed by-2- from shaft -1- of fuel extractor -VAS
gu
ara 5190- .
ris nte
o
– At distance
aut -a- = 1180 mm from end, mark extraction hose
h eo
r a with
insulating
ss tape -arrow-. c
ce
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nl
pt
du
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itte
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erm
ab
ility
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es, in part or in w
t to the co
rrectness of i
– Remove filler cap from fuel tank filler neck.
– Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel
l purpos
filler neck.
nform
ercia
– Push extraction hose into fuel tank until marking on hose

-arrow- coincides with shaft end.
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ate
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for
en
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Prote
Note
AG.
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; it must not be damaged by the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
– Empty fuel tank as far as possible.

– Carefully pull out extraction hose.
Note
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
♦ If the fuel tank has to be drained fully, proceed as follows: ⇒
page 149
3.3.2 Emptying fuel tank if it is less than 3/4 full

– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats; Removing and installing bench seat .
WARNING

connection. Then release pressure by carefully pulling hose off
connection.

– Pull connector and fuel lines off flange.
Note
– Open locking ring using fuel tank sender wrench -T10202- .

– Lift sender flange.
– Insert extraction hose of fuel extractor -VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, reinstall sender flange.
3.4 Removing and installing fuel delivery

unit
♦ Wrench -T10202-
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spec
t to the co
rrectness o
cial p
f inform
Removing
mer
atio
m
Observe safety precautions ⇒ page 136 .

o
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– Disconnect earth strap from battery with ignition switched off C py
t. rig
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necting battery .
cop Vo
by lksw
cted agen
Prote AG.

– Remove rear seat bench (Golf Plus: rear right seat) ⇒ General
body repairs, interior; Rep. gr. 72 ; Rear seats; Removing and
installing seat bench .
– Pull 5-pin connector and fuel lines off flange.
Note
WARNING
– Remove union nut with wrench -T10202- .

– Pull fuel delivery unit and seal out of the opening in fuel tank.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐ AG. Volkswagen AG d
agen
posal. V olksw
oes
not
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Installing tho
or
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– Installing the fuel delivery unit is carried out in reverse order
ce
le
un
of removal.
pt
an
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pe
ility
ot
Note
wit
, is n
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hole
spec
♦ Do not bend fuel gauge sender when installing.
es, in part or in w
♦ Insert seal for flange or fuel delivery unit dry into opening of t to the co
fuel tank.
♦ Moisten seal with fuel only when installing flange or fuel de‐
rrectness of i
livery unit.
l purpos

♦ After installing fuel delivery unit, check that the supply, return
nform
ercia
and breather lines are still clipped onto the fuel tank.
m
a
com
ti
♦ Note installation position of fuel delivery unit flange: mark on

on in
flange must align with mark on fuel tank -arrows-.

r
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3.5 Removing and installing fuel gauge

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sender Cop py
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rig ht
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Removing co Vo
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Prote
AG.

– Release connector lugs on lines -3- and -4- and pull off.
– Lift retaining tabs -1- and -2- using a screwdriver and pull fuel
gauge sender off downwards -arrows-.
Installing
– Insert fuel sender into guides on fuel delivery unit and press
upwards until it engages.
3.6 Checking fuel pump n AG. Volkswagen AG do

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Note tho tee
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Check fuel filter connections for correct arrangement, before
ce
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nl
pt
starting to check the fuel pump ⇒ page 156
du
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itte
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ab
3.6.1 Checking delivery pressure of fuel pump
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spec
♦ Pressure gauge -VAS 6550-
es, in part or in w
t to the co
♦ Vehicle diagnosis tester
Test prerequisite:
rrectness of i
• Fuses must be OK.
l purpos
• Battery voltage at least 12 V
nf
• All electrical consumers, e.g. lights and rear window heating,
ercia
o
must be switched off.
rm
m
atio
m
– Separate quick-release coupling -A- (completely black or with

o
n in
c
black marking) of fuel supply line.

or
thi
te
sd
iva
– Connect pressure tester -VAS 6550- with cables -VAS 6550/1- o

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cu
and -VAS 6550/2- to open ends of fuel supply line.
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f
en
ng
t.
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– Switch on pressure tester -VAS 6550- by pressing On/Off
Co
Cop py
button.
t. rig
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pyri by
Vo
co
– Open shut-off taps „A“ and „B“ of pressure tester and close
by lksw
cted agen
Prote
shut-off tap „C“.
AG.
– Start engine and run at idling speed.

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

3.6.2 Checking fuel pump delivery rate

♦ Container > 3 litre with measuring scale
Test prerequisite:
• Battery voltage at least 12 V agen
AG. Volkswagen AG d
oes
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V gu
• All electrical consumers, e.g. lights and rear windowedheating,
by ara
nte
must be switched off. horis
eo
aut ra
ss c
ce
le
Note un
pt
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d
itte
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rm
ab
The delivered fuel may be cloudy. This is normal and can be ig‐
pe
ility
nored.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Connect -VAS 6550/1- pressure tester line to fuel supply -A-.
– Guide open end of line into measuring container.
rrectness of i
– Connect vehicle diagnosis tester and perform guided function
l purpos
„checking electric fuel pump(s)“.
nform
ercia
Note
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tion in
The fuel pump is now activated for 30 seconds.
r
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iva
do
– After fuel flow, read quantity of fuel delivered on measuring
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container, specification: min. 1000 ml/30 s.
fo
en
ng
t.
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If the specification is not attained: ht. Cop py
rig
rig ht
– Check fuel supply line between fuel pump and engine com‐ py by
co Vo
partment for kinks, crushes or damage.
by lksw
cted agen
Prote AG.
– If necessary, renew defective line and repeat test.
– If it is not kinked, crushed or damaged, remove rear seat bench
⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats .
– Detach carpet under seats and fold it back. ⇒ General body
repairs, interior; Rep. gr. 70 ; Load and luggage compartment
trim; Removing and installing luggage compartment floor
Note
Press in securing ring to release fuel line.

Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ G , Touran 2003 ➤
n A . Volkswagen AG do
lkswage08.2010
4-cylinder diesel engine (1.9 l engine) - Edition es n
o o V t gu
by ara
ed nte
– Pull fuel supply line (black or black marking)
ho
ris
-A- off fuel deliv‐ eo
ery unit. aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
– Connect diagnosis tester and perform the guided function
ot p
wit
„Checking electric fuel pump(s)“.
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
rrectness of i
l purpos

If the specification is not attained:
nform
ercia
– Check voltage supply ⇒ page 154 and current draw ⇒ page

m
at
155 of fuel pump.
om
ion
c
in t
or
his
e
3.6.3 Checking voltage supply of fuel pump

at
do
priv
cum
or

f
en
ng
t.
yi Co
op
♦ Hand-held multimeter -V.A.G 1526D- C py
t. rig
gh ht
yri
♦ Pickup clamp -V.A.G 1526B/2-
p by
co Vo
by lksw
cted agen
♦ Test instrument adapter/DSO (5-pin) -VAS 5565-
Prote AG.
Test prerequisites
• The battery voltage must be at least 12 V, if necessary connect
a battery charger.
– Remove seat bench ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats .
– Switch on ignition. The fuel pump must be heard to run for
about 2 seconds.
– Switch off ignition.
If the fuel pump does not start:
– Pull connector off fuel delivery unit flange.

– Connect test instrument adapter/DSO (5-pin) -VAS 5565- be‐

tween connector and flange.
– Connect hand-held multimeter -V.A.G 1526D- to contacts -1-
and -5- of adapter.
Note
– Read voltage value on hand-held multimeter -V.A.G 1526D- :

Specification = battery voltage.
If no voltage is present:
– Check activation of fuel pump relay and wiring for an open or
short circuit ⇒ Vehicle diagnostic, testing and information sys‐
tem VAS 5051.
Voltage supply OK:
– Check that electrical wiring between flange and fuel pump is
connected and has continuity.
If no open circuit can be found:
– Renew fuel delivery unit.
3.6.4 Checking current draw of fuel pump

Special tools and workshop equipment required agen
AG. Volkswagen AG d
oes
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♦ Hand-held multimeter -V.A.G 1526D- or pickup clamp d-V.A.G
by V gu
ara
1526B/2- orise nte
eo
th
u ra
ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
The battery voltage and the diesel fuel temperature have a great h re
hole
influence on the current draw of the fuel pump. For this reason spec
es, in part or in w
ensure that the battery voltage is at least 12 V whilst checking and

t to the co
the diesel fuel temperature does not fall to the freezing point.
rrectness of i
Test prerequisites
l purpos

• Diesel fuel temperature above (10 ) C
nf
ercia

rm
m
72 ; Rear seats .
atio
om
n in
c

or
thi
e

t
sd
iva

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f
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ng

t.
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Cop py
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by
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran n AG. Volkswagen AG do
lkswage 2003 ➤ es n
4-cylinder diesel engine (1.9 l engine) - Editiond b08.2010
yV
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e ran
ris tee
– Pull connector -C- off flange. utho or
a ac
ss
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nl
pt
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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
– Connect test instrument adapter/DSO (5-pin) -VAS 5565- to

connector and fuel delivery unit.
nform
ercia
– Connect pick-up clamp -A- to red terminal with lettering „pick-

up clamp“ for test instrument adapter/DSO (5-pin) -VAS
m
at
om
5565- .
ion
c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
t.
Pickup clamp of hand-held multimeter -V.A.G 1715- can also be
yi Co
op
connected to red terminal with lettering „pickup clamp“ of test in‐
C py
t. rig
gh
strument adapter/DSO (5-pin) -VAS 5565- .
ht
pyri by
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by
cted agen
Prote AG.
– Switch on ignition.
Note
– Read current draw on hand-held multimeter -V.A.G 1526D- .

Specification: max. 7.5 amps.
– If the measured value is not within specifications:
– Renew fuel delivery unit ⇒ page 180 .
3.7 Assembly overview - fuel filter
Note
Note that there are different versions of fuel filter upper part ⇒
page 158 .

1 - Supply line
❑ From fuel tank.
❑ White or with white
marking.
ing.
2 - 5 Nm
3 - Return line AG. Volkswagen AG d
agen oes
ksw
❑ To fuel cooler by
Vol not
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ara
ed
❑ Check for secure seat‐ horis nte
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ing. aut ra
c
ss
❑ Blue or with blue mark‐
ce
le
un
ing.
pt
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d
itte
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4 - Plug for water extraction
erm
ab
ility
ot p
❑ Remove and extract
wit
is n
about 100 cm3 liquid us‐
h re
ole,
ing hand-operated vac‐
spec
uum pump with acces‐
sories -V.A.G 1390- and
t to the co
water drainage contain‐
er -V.A.G 1390/1- .
rrectne
5 - Seal
❑ Renew.
ss o
6 - Supply line
cial p
f inform
❑ To tandem pump
mer
atio
7 - Return line
om
n
c
i
❑ From tandem pump
or
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ing.
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ng

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op
ing. C py
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8 - Upper part of fuel filter
p by
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9 - Fuel temperature sender -G81-
Prote AG.
10 - Seal
❑ Renew.
11 - Filter insert
12 - Seal
❑ Renew.
13 - Lower part of fuel filter
14 - 8 Nm
15 - Bracket
16 - Seal
❑ Renew.
17 - Retaining clip
18 - Connection
19 - From tandem pump.

3.7.1 Upper part of fuel filter

Type A ⇒ page 158
Type B ⇒ page 158
Upper part of fuel filter, type A
1 - 8 Nm
2 - Plug for water extraction (remove and extract about 100 cm3
liquid using hand-operated vacuum pump with accessories -
V.A.G 1390- and water drainage container -V.A.G 1390/1- , renew
seal)
3 - Fuel supply line from fuel tank, white or white marking. Check
for secure seating.
4 - Fuel return line to fuel tank, blue or blue marking. Check for
secure seating.
5 - Fuel supply line to engine, white or white marking. Check for
secure seating.
6 - Fuel return line from engine, blue or blue marking. Check for
secure seating.
AG. Volkswagen AG d
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Upper part of fuel filter, type B by
Vol not
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1 - 5 Nm hor eo
aut ra
2 - Fuel return line to fuel tank,
ss
blue or blue marking. Check for c
ce
e
secure seating.
nl
pt
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itte
3 - Fuel supply line from fuel tank, white or white marking. Check y li
erm
ab
for secure seating. ility
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secure seating.
hole
spec

es, in part or in w
t to the co
secure seating.
3.8 Removing and installing fuel cooler

rrectness of i
l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
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cum
for
en
ng
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Cop py
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Removing

wage es n
Note yV
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ua
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The fuel cooler is located in the
au return line to fuel tank. It is located
tho
or
ac
on the vehicle underbody. ss
ce
le
un
pt
an
d
– Remove underbody panel.
itte
y li
erm
ab
– Separate fuel lines at fuel cooler.
ility
ot p
wit
is n
– Remove securing nuts -arrows-.
h re
ole,
Installing
spec
t to the co
♦ Tighten fuel cooler securing nuts to 15 Nm.
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.

. Volkswagen AG
gen AG does
swa
Golf 2004 ➤ , Golf y V Plus 2005 ➤ , Passat 2006 ➤
olk not , Touran
gu 2003 ➤
b ara
4-cylinder diesel
rised
engine (1.9 l engine) - Edition 08.2010 nte
ho eo
aut ra
ss c
4 Parts of fuel supply system (Touran)
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
♦ Hose connections are secured with either spring-type or
hole
spec
clamp-type clips.
es, in part or in w
t to the co
♦ Always renew clamp-type clips with spring-type clips.
♦ Spring-type clip pliers -VAS 5024/- or hose clip pliers -V.A.G
rrectness of i
1921/- are recommended for installation of spring-type clips.
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.

Safety precautions ⇒ page 136 . en AG. Volkswagen AG

ag does
ksw not
Vol 137 .
Rules for cleanliness ⇒ page gu
by d ara
ise n
Assembly overview
ut
ho- fuel tank with attachments ⇒
r
page 161 . tee o
ra
sa c
Emptying fuel tank
s ⇒ page 162 .
ce
e
nl
pt
du
Removing and installing fuel tank ⇒ page 165 .
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
Removing and installing fuel delivery unit ⇒ page 169 .
spec
es, in part or in w
Removing and installing fuel gauge sender ⇒ page 170 .
t to the co
rrectness of i
4.1 Assembly overview - fuel tank with attachments
l purpos
1 - Cap
nf
ercia
o
2 - 1.5 Nm
rm
m
atio
m
3 - Tank flap unit

o
n in
or c
❑ Removing and in‐
thi
te
stalling. ⇒ General
sd
iva
o
r
body repairs, exterior;

rp
cu
o
m
Rep. gr. 55 ; Fuel flap
f
en
ng
t.
yi
unit
Co
Cop py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote
ing.
AG.
5 - 10 Nm
6 - Pressure retention valve
with connecting hose
7 - Gravity/overflow valve
8 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack -V.A.G
1383/A- .
⇒ page 165 .
9 - Heat shield
❑ For fuel tank.
10 - Securing strap
11 - 20 Nm + turn (90°)
❑ With fuel gauge sender
(G).
tion of flange on fuel
tank ⇒ page 162 .
❑ Removing and installing fuel sender ⇒ page 170 .
❑ Clean strainer if soiled.
4. Parts of fuel supply system (Touran) 161

13 - Seal
❑ Renew.
❑ Moisten with fuel when installing.
14 - Union nut, 80 Nm
❑ Remove and install using union nut tool -3217- .
15 - Supply line
❑ To fuel filter
❑ Black
16 - Return line
❑ From fuel cooler
Installation position of fuel delivery unit

Marking on flange must align with marking on fuel tank -arrows-.
Black supply line -1- to connection marked -V-.
Return line -2- (blue or with blue marking) to connection
marked -R-.
Note
After installing fuel delivery unit flange, check that supply, return n AG. Volkswagen A
and breather lines are still clipped onto fuel tank. olks
wage
G do
es n
o
yV t gu
db ara
rise nte
tho eo
4.2 Emptying fuel tank ss au ra
c
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
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
162
cted agen
Prote AG.
Rep. gr.20 - Fuel supply system
♦ Union nut tool -3217-
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
Emptying fuel tank if it is more than 3/4 full ⇒ page 163 .
t to the co
Emptying fuel tank if it is less than 3/4 full ⇒ page 164 .
rrectness of i
l purpos
full
nform
ercia
Caution
m
a
com
tion in
Secure earth wire of fuel extractor -VAS 5190- to a bare metal

r
te o
thi
part of the body.

s
iva
do
r
rp
cum
fo
en
ng
– Remove cotter -2- from shaft -1- of fuel extractor -VAS 5190- .
t.
yi Co
Cop py
t. rig
– At distance -a- = 1,200 mm from end, mark extraction hose yri
gh by
ht
with insulating tape -arrow-.
op Vo
by c lksw
cted agen
Prote AG.

– Remove filler cap from fuel tank filler neck.

– Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel
filler neck.
– Push extraction hose into fuel tank until marking on hose
-arrow- coincides with shaft end.
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; it must not be damaged by the extraction hose -3-.
Therefore push hose into filler neck only as far as marking
-arrow-.
– Drain fuel tank as much as possible through fuel filler neck.

AG. Volkswagen AG d
– Carefully pull out extraction hose. lksw
agen oes
not
Vo gu
by ara
d
rise nte
o eo
Note auth
ra
ss c
ce
e
nl
♦ When no more fuel is extracted, the tank is emptied just
pt
du
an
enough for the sender flange to be opened without danger.
itte
y li
The tank may be removed while containing remaining fuel.
erm
ab
ility
ot p
♦ If work must be performed on fuel pump or fuel tank sender,
wit
, is n
proceed as follows:
h re
hole
spec
es, in part or in w
t to the co
– Fold rear seats forwards.
rrectness of i
l purpos

nf
ercia
– Remove cover from fuel delivery unit. orm

m
atio
om
n in
WARNING
or c
thi
te
sd
iva

o
r
rp
cu

o
m
f
en
ng

t.
yi Co
op
connection. Then release pressure by carefully pulling hose off C py
t. rig
connection.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull connector and fuel lines off flange.
Note

– Open locking ring using union nut tool -3217- .

– Raise fuel delivery unit.
If fuel tank needed only to be emptied, install fuel delivery unit
again ⇒ page 169 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
4.3 Removing and installing fuel tank aut
ho eo
ra
ss c
ce
e
nl
pt
du
an
♦ Torque wrench -V.A.G 1331/- 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
ercia
♦ Engine and gearbox jack -V.A.G 1383/A-

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
o
by c lksw
cted agen
Prote AG.
Removing
– Note safety precautions before starting work ⇒ page 136 .
Note


necting battery .


– Pull connector off flange.
– Remove fuel flap unit. ⇒ General body repairs, exterior; Rep.
gr. 55 ; Fuel flap unit
– Draining fuel tank ⇒ page 162
AG. Volkswagen AG d
– Remove rear right wheel housing liner: ⇒ General body re‐ lkswagen oes
not
pairs, exterior; Rep. gr. 66 ; Removing and installing wheeldb
yV
o gu
ara
housing liner . or
ise nte
th eo
– Remove bolts from filler neck -arrows-. au ra
c
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
rrectne
– Disconnect fuel lines at front right of fuel tank.
ss o
cial p
f inform
mer
Note
atio
om
n
c
i
or
n thi
te
sd
iva
o
– If vehicle has supplementary heating, separate connector to
pr
cum
r
fo
metering pump and unclip wire. ⇒ Supplementary heating;
en
ng
t.
Rep. gr. 82 ; Removing and installing metering pump -V54
yi Co
Cop py
ht. rig
– Remove bolts -A- and remove heat shield for fuel tank. rig ht
py by
co Vo
by lksw
– Support fuel tank using engine and gearbox jack -V.A.G 1383/ Prote
cted AG.
agen
A- .
– Remove securing bolts -B- and remove retaining strap.

– Slowly lower fuel tank and pull it forwards.
– Tilt fuel tank to get it past rear axle.
Installing
♦ Install breather and fuel hoses free of kinks.
♦ Clip supply and return lines onto fuel tank.


❑ Observe various types
⇒ page 167
2 - Fuel temperature sender -
G81-
❑ Installed in engine re‐
turn line
3 - Seal
❑ Renew.
4 - Filter insert
❑ Observe change inter‐
vals.
5 - Seal
❑ Renew.
6 - Fuel filter lower part
7 - 8 Nm
8 - Bracket
9 - Seal
❑ Renew.
10 - Retaining clip
❑ Check for secure seat‐agen
AG. Volkswagen AG d
oes
ing. Volksw not
g by ua
ed ran
11 - Connection ris for fuel tem‐ tee
tho -G81-
perature sender or
au ac
ss
12 - From tandem pump.
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

Type A ⇒ page 167
rrectne
Type B ⇒ page 168

s

s o
cial p
f i
1 - 8 Nm
nform
mer
atio
m

o
n
c
i
or

thi
e
seal)
t
sd
iva
o
pr
cum
r
fo
en
ng
for secure seating.

t.
yi Co
Cop py
t. rig
gh ht
yri
secure seating.
p by
o Vo
by c lksw
cted agen
Prote AG.
secure seating.

secure seating.
Upper part of fuel filter, type B

1 - 5 Nm
secure seating.
for secure seating.
secure seating.
secure seating.

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
Removing
h re
hole
spec
– Note safety precautions before starting work ⇒ page 136 .

es, in part or in w
t to the co

rrectness of i
Note
l purpos
The fuel cooler is located in the return line to fuel tank. It is located
on the vehicle underbody.
nform
ercia

m
a
com
tion in
– Separate fuel lines at fuel cooler.

r
te o
thi

s
iva
do
r
rp
cum
Installing
fo
en
ng
t.
yi Co
Install in reverse order. In the process, note the following: Cop py
t. rig
gh ht
yri
♦ Tighten fuel cooler securing nuts to 15 Nm. p by
o Vo
by c lksw
cted agen
Prote AG.

4.6 Removing and installing fuel delivery

unit
♦ Union nut tool -3217-
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
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
Removing
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.

theft coding.
necting battery .
– Pull 5-pin connector and fuel lines off flange.
Note

WARNING
– Unscrew union nut with union nut tool -3217- wrench .

– Pull fuel delivery unit and seal out of the opening in fuel tank.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
Installing
of removal.
Note
♦ Do not bend fuel gauge sender when installing.

♦ Insert seal for flange or fuel delivery unit dry into opening of
fuel tank.
livery unit. wage
e ks s no
Vol t gu
ed
by ara
is nte
or
♦ After installing fuel delivery unit, check
au
th that the supply, return eo
ra
and breather lines are still clippeds onto the fuel tank.
s c
ce
e
nl
pt
♦ Note installation position of fuel delivery unit flange: mark on

du
an
itte
flange must align with mark on fuel tank -arrows-.

y li
erm
ab
ility
ot p
wit
, is n
4.7 Removing and installing fuel gauge

h re
hole
sender
spec
es, in part or in w
t to the co
Removing
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
170
c by lksw
cted agen
Rep. gr.20 - Fuel supply system Prote AG.
– Release connector lugs on lines -3- and -4- and pull off.
– Lift retaining tabs -1- and -2- using a screwdriver and pull fuel
gauge sender off downwards -arrows-.
Installing
– Insert fuel sender into guides on fuel delivery unit and press
upwards until it engages.
4.8 Checking fuel pump
Note


Test prerequisite:
agen
AG. Volkswagen AG d
oes
black marking) of fuel supply line. yV
olksw not
g b ua
ed ran
– Connect pressure tester -VAS 6550- with cables ris-VAS 6550/1- tee
tho
and -VAS 6550/2- to open ends of fuel supply
sa
u line. or
ac
s
ce
le
un
pt
button.
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
min. 0.5 bar.

rrectness of i

l purpos

nform
ercia
unit ⇒ page 180 .

m
a
com

ion in

r
te o
thi
s
iva
do
r
rp
rate ⇒ page 172 .

um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
171
c by lksw
cted agen
Prote 4. Parts of fuel supply system (Touran)
AG.

♦ Container > 3 litre with measuring scale
Test prerequisite:
Note
AG. Volkswagen AG d
agen oes
olksw not
The delivered fuel may be cloudy. This is normal
d by
V and can be ig‐ gu
ara
nored. orise nte
eo
h
aut ra
ss c
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
Note
rrectne
– After fuel flow, read quantity of fuel delivered on measuring ss o

cial p
f i
nform
mer

atio
om
n
c
– Check fuel supply line between fuel pump and engine com‐
i
or
n thi

te
sd
iva
o
r

p
cum
r
fo
en
ng
t.
– If it is not kinked, crushed or damaged, remove rear seat bench op
yi Co
C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
Note

– Pull fuel supply line (black or black marking) -A- off fuel deliv‐
ery unit.
– Connect -VAS 6550/1-
wage
n AGpressure
. Volkswagetester
n AG d line to fuel supply -A-.
oes
ks not
Vol g
– Guide open
ed
by end of line into measuring container.
ua
ran
is tee
or
– Connect
au
th vehicle diagnosis tester and perform guided
or function
ac
„checking
ss electric fuel pump(s)“.
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Check voltage supply ⇒ page 173 and current draw ⇒ page
174 of fuel pump.
ss o
cial p
f inform
mer

atio
om
♦ Hand-held multimeter -V.A.G 1526D- n

c
i
or
n thi
e

t
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.
Test prerequisites
a battery charger.
72 ; Rear seats .
about 2 seconds.


and -5- of adapter.
AG. Volkswagen AG d
Note lksw
agen oes
not
o
byV gu
ara
ed
horis nte
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
tem VAS 5051.
spec
es, in part or in w
Voltage supply OK:
t to the co
rrectness of i
– Check that electrical wiring between flange and fuel pump is
connected and has continuity.
l purpos
If no open circuit can be found:
nform
ercia
– Renew fuel delivery unit.

m
at
om
i
on
c
in t
or
his
e

at
do
priv
♦ Hand-held multimeter -V.A.G 1526D- or pickup clamp -V.A.G cum

for
en
g
1526B/2-
n
t.
yi Co
Cop py
♦ Test instrument adapter/DSO (5-pin) -VAS 5565- ht. rig
rig ht
py by
o Vo
♦ Vehicle diagnosis tester by c lksw
cted agen
Prote AG.
Note
The battery voltage and the diesel fuel temperature have a great
influence on the current draw of the fuel pump. For this reason
Test prerequisites
• Diesel fuel temperature above (10 ) C
72 ; Rear seats .

– Pull connector -C- off flange.

5565- .
Note

Note
The fuel pump is now

genactivated
AG. Volkswfor
agen30
AGseconds.
da oes
ksw not
Vol gu
by
– Readriscurrent
ed draw on hand-held multimeter a-V.A.G
ran
tee 1526D- .
Specification:
tho max. 7.5 amps. 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
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.

5 Parts of fuel supply system (Passat)

Safety precautions ⇒ page 136 .
AG. Volkswagen AG d
Rules for cleanliness ⇒ page 137 . agen oes
olksw not
y V gu
b ara
Fuel tank, vehicles with front-wheel drive ⇒ page 176 . rise
d
nte
tho eo
u
Removing and installing fuel delivery unit ⇒ page 180ss.a ra
c
ce
le
Emptying fuel tank, vehicles with front-wheel drive ⇒ page
un
pt
an
d
183
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
5.1 Fuel tank, vehicles with front-wheel
drive
rrectne
ss o
cial p
f inform
mer
1 - Cap
atio
m
2 - 1.5 Nm
o
n
c
i
or
n thi
e
3 - Tank flap unit

t
sd
iva
o
r
❑ With rubber cup.

p
cum
r
fo
en
ng

t.
yi Co
⇒ General body re‐ Cop py
t. rig
pairs, exterior; Rep. gr. yri
gh by
ht
55 ; Tank flap unit cop Vo
by lksw
cted agen
Prote
AG.

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

12 - Metering pump -V54-

For supplementary heater
❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 82 .
13 - Seal
❑ Renew.
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
❑ With fuel gauge sender (G).
❑ Removing and installing fuel gauge sender ⇒ page 183 .
15 - Suction-jet pump
❑ Clean strainer if soiled.
❑ Not necessarily installed
16 - Flange
❑ For fuel delivery unit
❑ Note installation position of flange on fuel tank ⇒ page 178 .
17 - Locking ring, 110 Nm AG. Volkswagen AG d
agen oes
ksw
❑ Check for secure seating.byV
ol not
gu
ara
ed
❑ Remove and install
horis using wrench -3087- . nte
e
t or
au ac
18 - Supply line ss
ce
le
❑ For auxiliary heater.

un
pt
an
d
itte
❑ To metering pump -V54- .

y li
rm
ab

pe
ility
ot
wit

, is n
h re

hole
spec
es, in part or in w
19 - Return line
t to the co
❑ From fuel cooler.

rrectness of i

l purpos

nform
ercia
20 - Supply line
m
❑ To fuel filter
com
tion in

r
te o
thi
s

iva
do
r
rp
❑ Black
um
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
5. Parts of fuel supply system (Passat) 177

Installation position of fuel delivery unit

Marking -4- on flange points opposite direction of travel.
Note
The fuel delivery unit flange can be installed only in this position.
G. Volkswage
A n AG d
agen oes
ksw not
Vol
Connect black supply line -1- with »arrow« to ed union on flange.
by gu
ara
ris nte
o eo
Return line -2- (blue or with blue marking)
au to connection marked
th
ra
»-R-«. ss c
ce
e
nl
pt
Black supply line -3- to metering pump -V54- for auxiliary heater.
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
After installing fuel delivery unit flange, check that fuel lines are
spec
still clipped onto fuel tank.
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
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rp
cu
o
m
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Engine and gearbox jack -V.A.G 1383/A-
Removing
Note
♦ The rear axle must be lowered to remove the fuel tank.

♦ Before disconnecting battery, open fuel tank flap and if nec‐
essary remove wheel bolt lock adapter from luggage compart‐
ment.


Note

– With the ignition switched off, disconnect battery earth strap.

– Remove rear bench seat ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seat; Removing and installing bench A
seat
G. Vo.lkswagen
agen AG do
ksw es n
– Remove cover from fuel delivery unit. by Vol ot g
ua
ed ran
– Pull 5-pin connector -5- off fuel ris flange.
deliverythounit tee
or
au ac
– Open fuel tank filler flap. ss
ce
e
nl
pt
– Unscrew securing bolt and remove tank flap unit with rubber
du
an
itte
cup ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap
y li
erm
ab
unit .
ility
ot p
wit
– Empty fuel tank ⇒ page 183 .
, is n
h re
hole
– Remove right rear wheel.
spec
es, in part or in w
– Remove rear right wheel housing liner ⇒ General body re‐
t to the co
housing liner .
rrectness of i
– Remove bolts from filler neck -arrows-.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
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t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
– Unclip ABS sensor wiring on fuel tank filler neck -arrows-.
Prote AG.
WARNING

AG. Volkswagen AG d
agen oes
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran Vol
ksw 2003 ➤ not
gu
by
4-cylinder diesel engine (1.9 l engine) - Editionris08.2010
ed ara
nte
tho eo
au ra
– Separate return line -1- and supply line -2- at connections.
ss c
ce
e
nl
– Separate fuel line -3- for metering pump -V54- at connections.
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
Press in securing ring to release fuel lines.
spec
es, in part or in w
t to the co
– Pull connector -arrow- off metering pump -V54- .
– Support rear axle using engine and gearbox jack -V.A.G 1383
A- .
rrectness of i
l purpos
– Remove securing bolts -arrows- and lower rear axle.
nform
ercia
– Then support fuel tank using engine and gearbox jack -V.A.G
1383 A- .
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.
– Remove securing strap bolts.

– Slowly lower fuel tank. When doing this, pull fuel tank forwards,
turn and guide filler neck between rear axle and body.
Installing
– Tighten bolts of rear axle to body ⇒ Running gear, axles,
steering; Rep. gr. 42 .
♦ Fuel lines are to be installed free of kinks.
♦ Ensure that line connections are tight.
♦ Connections for fuel lines must engage audibly when joined.
♦ Check earth connection between body and filler neck for prop‐
er seating.
♦ Clip fuel lines onto fuel tank.
5.1.3 Removing and installing fuel delivery

unit

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
Removing
ab
ility
ot p

wit
, is n
h re

hole
spec
es, in part or in w

t to the co
theft coding.
– With the ignition switched off, disconnect battery earth strap.
rrectness of i
– The fuel tank must not be more than 1/2 full when removing
l purpos
the suction-jet pump. Empty fuel tank if necessary ⇒ page

183 .
nform
ercia
– Remove rear bench seat ⇒ General body repairs, interior;

Rep. gr. 72 ; Rear seat; Removing and installing bench seat .
m
at
om
ion

c
in t
or
his
te
– Pull supply line -1-, return line -2-, supply line -3- to metering
a
do
riv
pump -V54- and 5-pin connector -5- off fuel delivery unit
p
cum
or
flange.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
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Note p by
co Vo
by lksw
cted agen
Prote AG.
Press in securing ring to release fuel lines.


– Pull fuel line -1- off suction-jet pump (if fitted).
Note
– Press tab -2- of suction-jet pump in -direction of arrow- and

unclip from fuel delivery unit
– Pull fuel delivery unit along with suction-jet pump out of open‐
ing in fuel tank.
AG. Volkswagen AG d
agen oes
olksw not
V gu
Note d by ara
rise nte
tho eo
u ra
If delivery unit is to be renewed,
ss a drain old delivery unit before dis‐ c
posal.
ce
e
nl
pt
du
an
itte
y li
Installing
erm
ab
ility
ot p

wit
, is n
of removal.
h re
hole
spec
es, in part or in w
Note
t to the co
♦ For fuel delivery units of the new generation the suction-jet

rrectness of i
pump is no longer available. If the fuel delivery unit is to be

renewed, remove suction-jet pump.
l purpos
♦ When inserting fuel delivery unit, ensure that fuel gauge

sender is not bent.
nform
ercia
♦ Insert seal for flange or fuel delivery unit dry into opening of
m
at
fuel tank.
om
ion
c
in t
r
o
his
e
livery unit.
at
do
priv
cum
♦ Fuel lines are to be installed free of kinks.

for
en
ng
t.
yi Co
♦ Do not interchange supply line and return line (return line blue Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
♦ Connections for fuel lines must engage audibly when joined.
♦ After installing fuel delivery unit, check that fuel lines are still
clipped onto fuel tank.
♦ Observe installation position of fuel delivery unit ⇒ page 178 .

5.1.4 Removing and installing fuel gauge

sender
Removing
– Release connector tabs of wires -arrows- and pull them off.
– Lift up retaining tabs -1- using a screwdriver and pull off fuel
gauge sender upwards in direction of -arrow-.
Installing
– Insert fuel gauge sender into guides on fuel delivery unit and
press downwards until it engages.
– Install fuel delivery unit ⇒ page 180 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
5.2 aut
ho
Emptying fuel tank, vehicles with front- eo
ra
c
s
s
wheel drive 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
tio

n in
r
te o
thi
s
iva
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fo
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Cop py
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by c lksw
cted agen
Prote AG.

Emptying fuel tank if more than 3/4 full ⇒ page 184
Emptying fuel tank if less than 3/4 full ⇒ page 184

full
Procedure
Note safety precautions before beginning work ⇒ page 136 .
– At distance -a- = 990 mm from end, mark extraction hose with
insulating tape -arrow-.
– Open fuel tank filler flap.
– Push extraction hose of fuel extractor -VAS 5190- into fuel filler
neck until the previously made marking aligns with filler neck.
lkswage es n
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yV ua
Note ir se
d b ran
o tee
th or
u
♦ The shaft piece -1- is not used.
a ac
ss
ce
e
nl
♦ A flap is located on the lower end of the fuel filler neck, this
pt
du
an
must not be damaged by the extraction hose. Therefore, push
itte
y li
erm
the extraction hose into the fuel filler neck only up to previously
ab
made marking. ility
ot p
wit
, is n
h re
hole
– Empty fuel tank as far as possible.

spec
es, in part or in w
– Then carefully remove extraction hose.

t to the co
Note
rrectness of i
l purpos
When no more fuel is extracted, the tank is emptied just enough

for the sender flange to be opened without danger. The tank may
be removed while containing remaining fuel.
nform
mercia
at
om
io

n
c
in t
or
his
ate
Procedure
do
priv
cum
or

f
en
ng
t.
yi Co
op
– Remove rear bench seat ⇒ General body repairs, interior; C py
t. rig
Rep. gr. 72 ; Rear seat; Removing and installing bench seat .
gh ht
pyri by
Vo
co lksw
by
– Remove cover from fuel delivery unit. cted agen
Prote AG.
WARNING

– Pull supply line -1-, return line -2-, supply line -3- to metering
pump -V54- and 5-pin connector -5- off fuel delivery unit
flange.
AG. Volkswagen AG d
agen oes
Note olksw not
byV gu
ara
ed
ris nte
Press in securing
ut
ho ring to release fuel lines. eo
ra
s a c
s
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
If fuel tank needed only to be emptied, reinstall sender flange ⇒
page 180 .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
5.3 Checking fuel pump

t
sd
iva
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f
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Note ht. Cop py
rig
rig ht
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by lksw
cted
agen
Prote AG.

Test prerequisite:
– Connect pressure tester -VAS 6550- with cables -VAS 6550/1-
and -VAS 6550/2- to open ends of fuel supply line.
button.
min. 0.5 bar.


unit ⇒ page 180 .
rate ⇒ page 186 .

♦ Pressure gauge -VAS 6550- agen
AG. Volkswagen AG d
oes
olksw not
♦ Container > 3 litre with measuring scale ed by
V gu
ara
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♦ Vehicle diagnosis tester aut
ho eo
ra
ss c
Test prerequisite:
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
Note
The delivered fuel may be cloudy. This is normal and can be ig‐
rrectne
nored.
ss o
cial p
f i
nform
mer
atio
om
n
c

i
or
n thi
te
sd
a

iv
o
pr

um
r
fo
en
ng
t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
agen
Prote AG.

– Check fuel supply line between fuel pump and engine com‐
– If it is not kinked, crushed or damaged, remove rear seat bench

Note
– Pull fuel supply line (black or black marking) -A- off fuel deliv‐
ery unit.
AG. Volkswagen
– Connect -VAS 6550/1- pressure tester
lksw line to fuel supply -A-.es n
agen AG do
Vo ot g
by ua
– Guide open end of line into rmeasuring
ise
d container. ran
tee
tho or
– Connect vehicle diagnosis au tester and perform guided function ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Check voltage supply ⇒ page 187 . Measure current draw
⇒ page 188 of fuel pump.
l purpos
nform
mercia
at
om
ion
c
♦ Hand-held multimeter -V.A.G 1526D- in t

or
his
ate

do
priv
cum
or

f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Test prerequisites
a battery charger.
72 ; Rear seats .


about 2 seconds.
and -5- of adapter.
Note

tem VAS 5051.
Voltage supply OK:
– Check that electrical wiring between flange and fuel pump is wage
es n
connected and has continuity. yV
olks ot g
ua
d b ran
If no open circuit can be found: ir se tee
tho
u or
a ac
– Renew fuel delivery unit. ss
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
♦ Hand-held multimeter -V.A.G 1526D- or pickup clamp -V.A.G
hole
1526B/2-
spec
es, in part or in w
♦ Test instrument adapter/DSO (5-pin) -VAS 5565- t to the co

rrectness of i
Note
l purpos
The battery voltage and the diesel fuel temperature have a great
nform
ercia
influence on the current draw of the fuel pump. For this reason
m
a
com
ti
on in
r
te o
thi
s
Test prerequisites
iva
do
r
rp
cum
fo

en
ng
t.
yi Co
• Diesel fuel temperature above (10 ) C Cop py
t. rig
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– Remove seat bench ⇒ General body repairs, interior; Rep. gr. p by
co Vo
by lksw
72 ; Rear seats . Prote
cted AG.
agen

4-cylinder diesel engine
n AG. Volkswagen AG d (1.9 l engine) - Edition 08.2010
lkswage oes
not
Vo gu
y
– Detach carpet ed under
b seats and fold it back. ⇒ General
ara
nte body
ris
repairs, uinterior;
tho Rep. gr. 70 ; Load and luggage compartment eo
trim; Removing
ss
a and installing luggage compartment floorr ac
ce
e

nl
pt
du
an
itte
y li
– Pull connector -C- off flange.
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
m

o
n in
or c
thi
te
sd
a

iv
o
r
rp
cu
5565- .
o
m
f
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ng
t.
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Cop py
.
Note
t rig
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co lksw
by
cted
agen
Prote AG.
Note
– Read current draw on hand-held multimeter -V.A.G 1526D- .

Specification: max. 7.5 amps.
Note
Note that there are different versions of fuel filter upper part ⇒
page 191 .

1 - Return line
❑ To fuel cooler
ing.
ing.
2 - 6 Nm
3 - Washer
4 - Supply line
❑ From fuel tank.
❑ White or with white
marking.
ing.
5 - Return line lkswage es n
o ot g
byV ua
❑ From tandem pump. ir se
d ran
tee
ho
❑ Blue marking aut or
ac
ss
ce
le
un
ing.
pt
an
d
itte
y li
6 - Supply line
erm
ab
ility
ot p
❑ To tandem pump.
wit
is n
❑ White marking
h re
ole,
spec
ing.
t to the co
8 - Fuel temperature sender -
rrectne
G81-
s
9 - Seal
s o
cial p
f
❑ Renew.
inform
mer
10 - Filter insert
atio
m
❑ Observe change intervals.

o
n
c
i
or
n thi
11 - Lower part of fuel filter
te
sd
iva
o
r
12 - 10 Nm
p
cum
r
fo
en
ng
13 - Connection for fuel temperature sender -G81-

t.
yi Co
Cop py
. rig
14 - Retaining clip
t
gh ht
pyri by
Vo
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c by lksw
cted agen
Prote AG.
15 - O-ring
❑ Renew.


Type A ⇒ page 191
Type B ⇒ page 191
1 - 8 Nm
seal)
for secure seating.
secure seating. . Volkswag AG en AG
agen doe
5 - Fuel supply line to engine, white
yV
olor
kswwhite marking. Check for
s no
t gu
secure seating. ised b ara
n r tee
ho
6 - Fuel return line from sengine,
au
t
blue or blue marking. Check for or
ac
secure seating. s
ce
e
nl
pt
du
an
itte
Upper part of fuel filter, type B
y li
erm
ab
ility
1 - 5 Nm
ot p
wit
, is n
h re
hole
secure seating.
spec
es, in part or in w
t to the co
for secure seating.
rrectness of i
secure seating.
l purpos

secure seating.
nf
ercia
or

m
m
atio
om
n in
c

or
thi
te
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.
Removing

Note
The fuel cooler is located in the return line to fuel tank. It is located
on the vehicle underbody.

– Pull fuel lines -1- and -2- off fuel cooler.
Installing
♦ Tighten fuel cooler securing nuts to 15 Nm.
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
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
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pr
cum
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fo
en
ng
t.
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Cop py
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by
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Prote AG.

6 Accelerator mechanism
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b
6.1 Assembly overview - accelerator mech‐
d ara
rise nte
ho eo
anism
ut ra
s a c
s
ce
le
Removing and installing accelerator mechanism ⇒ page 193 .

un
pt
an
d
itte
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erm
ab
1 - Connector
ility
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wit
is n
❑ Black, 6-pin.
h re
ole,
2 - Accelerator position sender
spec
-G79-
t to the co
❑ Not adjustable.
❑ The accelerator position
rrectne
sender passes the posi‐
tion of the accelerator
on to the engine control
ss
unit.
o
cial p
f in
❑ -A- openings for release
form
mer
tool
atio
m
❑ Remove footwell cover

o
n
c
to remove sender.
i
or
n thi
te
sd
a
3 - 10 Nm
iv
o
pr
cum
r
fo
4 - Cap
en
ng
t.
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6.1.1 Removing and installing accelerator

module
♦ Release tool -T 10269- (for right-hand drive vehicles -
T10297- ).
6. Accelerator mechanism 193

AG. Volkswagen AG d
agen oes
ksw
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran by
V 2003 ➤
ol not
gu
d ara
orise nte
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aut ra
c
♦ Torque wrench (5... 50 Nm) -V.A.G 1331- 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
Removing cial p
f inform
mer
– Lever off cap ⇒ Item 4 (page 193) using a screwdriver.
atio
om
n
– Remove securing bolt beneath it.
c
i
or
n thi
te
Golf, Golf Plus and Passat:
sd
iva
o
pr
cum
r
– To remove accelerator module, push release tool -T 10238-

fo
en
ng
(for right-hand drive models -T10240- ) into openings provided

t.
yi Co
op
to stop. C py
t. rig
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Touran: op Vo
by c lksw
cted agen
Prote AG.
– To remove accelerator module, push release tool -T 10269-

(for right-hand drive models -T10297- ) into openings provided
to stop.
Continuation for all vehicle types:
– Pull connector off accelerator module.
– Pull wiring guide off accelerator pedal module.
– Pull out accelerator pedal module vertically.
Installing
note the following:
– Attach connector and wiring guide to accelerator pedal mod‐
ule.
– Press accelerator pedal module onto securing pins.
– Insert centring pin into hole in vehicle underbody.
– Secure accelerator module with securing bolt -3-. Specified
torque: 9 Nm.
– Attach cap.
– Install steering column cover.

7 Tandem pump
Checking tandem pump ⇒ page 195 .
Removing and installing tandem pump ⇒ page 198 .
7.1 Checking tandem pump

Checking delivery pressure ⇒ page 195
n AG. Volkswagen A ge G do
swa es n
Checking for internal leaks ⇒
by
page
Vol
k
196 ot g
ua
ed ran
ris
7.1.1 Checking
tho delivery pressure
tee
or
au ac
ss
ce
le
un
pt
an
d
♦ Tandem pump tester -VAS 5187-

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
ercia
♦ Banjo bolt with seals -VAS 5187/1A-

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
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co Vo
by lksw
cted agen
Prote AG.
Test prerequisites
• Coolant temperature must be at least 85 °C.
• Unit injectors OK.
• Fuel filter and fuel lines must not be blocked.
7. Tandem pump 195

Procedure
– Remove air filter housing.
– Remove screw plug -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Connect tandem pump tester -VAS 5187- if necessary, with
erm
ab
adapter -VAS 5187/7- or banjo bolt with seal -VAS 5187/1A-
ility
ot p
as shown.
wit
, is n
h re
– Install air filter housing again.
hole
spec
es, in part or in w
– Start engine and raise engine speed to 4000 rpm.
t to the co
– Observe pressure indicated on pressure gauge.
Specification: at least 7.5 bar, tandem pump OK.
rrectness of i
l purpos
– Renew fuel filter.

nform
ercia
– Repeat check.
m
at
If the specifications are still not attained:

om
ion
c
in t
r
– Using a hose clip, clamp-off return line between fuel filter and
o
his
te
tandem pump.
a
do
priv
cum
or
– Repeat check.
f
en
ng
t.
yi Co
If specification is now obtained: Cop py
t. rig
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– Tandem pump is OK. Renew unit injector O-rings. p by
o Vo
by c lksw
cted agen
If the specification is not attained: Prote AG.
– Renew tandem pump ⇒ page 198 .
Note
After removing pressure gauge, tighten plug to 25 Nm. Always

renew seal.
7.1.2 Checking for internal leaks
Note
The tandem pump must be checked for internal leaks between

fuel side and oil side after reinstalling a used tandem pump, e.g.
after renewing or repairing a cylinder head and/or when installing
a "short" engine. When leaking it is possible for the fuel to mix
with the oil which may cause the engine to fail.

♦ Tester -V.A.G 1687-
Procedure
– Pull fuel supply hose (white marking) and fuel return hose
(blue marking) off tandem pump.
– Seal fuel return union on tandem pump with a plug. Secure
sealing plug with a spring-type clip.
Prepare test unit -V.A.G 1687- as follows:
– Unscrew pressure regulating valve -2- and close valves -3-
and -4-.
– Connect test connection -5- to fuel supply union of tandem
pump using a commercially available compressed air connec‐ AG. Volkswagen AG d
tion and a section of fuel hose. Use a spring-typeolclipagen
ksw to secure.
oes
no t gu
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Note aut ra
c
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nl
To turn the pressure regulating valve -2- the knob must be pulled
pt
du
an
upwards.
itte
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erm
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ility
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, is n
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hole
spec
es, in part or in w
– Connect compressed air hose -1- (compressed air source) to t to the co

charge air system tester -V.A.G 1687- . rrectness of i
Note
l purpos
If there is water in the sight glass, drain at water drain screw -6-.
nf
ercia
or
– Open valve -3-.

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

n in
or c
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Caution
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The maximum test pressure is 1.3 bar and this must not be
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– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 1.0 bar.
– Close valve -3- to retain pressure and observe the pressure
drop over a period of 1 minute.
If the pressure does not drop the tandem pump can be reused, if
the pressure drops the tandem pump must be renewed.
7. Tandem pump 197

7.2 Removing and installing tandem pump
DANGER!
The tandem pump may, under no circumstances, be disman‐

tled as the vacuum part could otherwise malfunction. This
would result in the failure of the brake servo.

equipment required
1331-
♦ Hand vacuum pump with
accessories -V.A.G 1390-
♦ Water drainage container -
V.A.G 1390/1-
5024 A-
lkswage es n
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ility
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, is n
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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
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t.
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198
Prote AG.
Rep. gr.20 - Fuel supply system
7.2.1 Removing
– Pull supply hose -1- (white marking) and return hose -2- (blue
marking) off fuel filter.
– Connect hand vacuum pump with accessories -V.A.G 1390-
and water drainage container -V.A.G 1390/1- to return hose
AG. Volkswagen AG d
-2-. ksw
agen oes
n ol ot g
yV ua
Be careful that no fuel is sucked into hand vacuum pump.
ise
db ran
r tee
ho
– Operate lever of hand vacuum pump until no more
sa
ut fuel comes or
ac
out of return hose. s
ce
e
nl
pt
du
– Remove air filter housing ⇒ page 238 .
an
itte
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erm
ab
ility
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– Pull vacuum hose -arrow- off tandem leading to brake servo.
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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atio
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n in
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– Disconnect fuel supply hose -2- from tandem pump.

t
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– Disconnect fuel return hose -1- (blue marking) from fuel pipe.
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Prote AG.
– Unscrew bolts -arrows-.

– Remove tandem pump from cylinder head.
7.2.2 Installing
note the following:
7. Tandem pump 199

Note
♦ Renew tandem pump gaskets.

♦ Ensure proper seating of tandem pump actuator in camshaft.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
– Install tandem pump and tighten upperswsecuring

agen
AG. Vbolts to
olkswagen AG
does
20 Nm. by
Volk not
gu
ara
ed nte
ris 10 Nm.
– Tighten lower securing boltsthoto e
u or
sa ac
– Attach return hose (blue smarking) to return connection of tan‐
ce
e
dem pump.
nl
pt
du
an
itte
– Attach supply hose (white marking) to supply connection of
y li
erm
ab
tandem pump.
ility
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wit
– Reconnect vacuum line to tandem pump leading from brake
, is n
h re
servo.
hole
spec
– Attach supply hose -1- (white marking) to fuel filter.
es, in part or in w
t to the co
and water drainage container -V.A.G 1390/1- to return hose
-2- (blue marking) of fuel filter.
rrectness of i
– Operate hand vacuum pump until fuel comes out of return
l purpos
hose. Be careful that no fuel is sucked into hand vacuum

pump.
nform
ercia
– Attach return hose (blue marking) to fuel filter.

m
at
om
– Carry out a leakage test ⇒ page 196 . ion

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ate
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Prote AG.

21 – Turbocharging/supercharging
1 Charge air system with turbocharger
Installing hose connections with connector couplings ⇒ page
202
Assembly overview - turbocharger ⇒ page 203 .
Removing and installing turbocharger ⇒ page 216 .
Assembly overview - parts of charge air cooling ⇒ page 218 .
Checking charge air system for leaks ⇒ page 221
1.1 Safety precautionsVolkswa

AG. gen AG
agen does
olksw not
V gu
WARNING edb
y ara
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r is
ho eo
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When doing sany
s a repair work, especially in the engine com‐ ac
ce
le
un
pt
conditions:
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vated charcoal filter system, coolant and refrigerant, brake ility
ot p
fluid and vacuum) and electrical wiring in their original po‐ wit
is n
h re
sitions.
ole,
spec

t to the co
hot components.
rrectne
Note the following if testers and measuring instruments have to

be used during a road test:
ss
♦ Test and measuring instruments must always be secured to

o
cial p
rear seat and operated by a second person from this location.

inform
mer
If test and measuring instruments are operated from front pas‐

atio
senger seat and the vehicle is involved in an accident, there is a

om
possibility that the person sitting in this seat may receive serious
c
i
or
n thi
injuries when the airbag is triggered.

te
sd
iva
o
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1.2 Rules for cleanliness

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When working on the turbocharger, pay careful attention to the Cop py
following rules for cleanliness:
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♦ Thoroughly clean all unions and adjacent areas before dis‐ by c lksw
cted agen
connecting.
Prote AG.
♦ Place removed parts on a clean surface and cover. Use only

lint-free cloths.
tool boxes etc.).
♦ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
♦ When making repairs, remove oil from connection and hose
ends.
1. Charge air system with turbocharger 201


essary.
1.3 Hose connections
1.3.1 Installing hose connections with con‐

nector couplings
Caution
The seal in the plug-in connector can be damaged if the se‐

curing clip is in the locked position when fitting the connector.
This can cause leakage. Observe installation instructions.
Removing
– Release plug-in connector by pulling out retaining clip
-arrow-. Separate hose/pipe without tools.
Installing
– If renewed, place oil seal in groove of charge air hose. Ensure
the seal is correctly seated in the groove.
– Lubricate sealing surface and seal with oil.
– Bring retaining clip to release position -1-.
– Push charge air hose into coupling to stop.
– Bring securing clip to locking position -2- and then push charge
air hose again.
– Check if connector coupling seats correctly andgeisAproperly
G. Volkswagen AG d
a n
engaged by pulling hose. Volksw
oes
not
by gu
ara
ed nte
oris eo
th
au ra
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nl
pt
du
an
itte
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erm
ab
ility
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
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202
by lksw
cted agen
Rep. gr.21 - Turbocharging/supercharging Prote AG.
1.3.2 Hose connections with spring band ring
Note
There is a danger of a „hose detaching“ whilst driving after re‐

moving and reinstalling charge pressure lines with spring-type
clips. For this reason, spring band rings are used which can be
opened if a defect item requires the charge pressure line has to
be disconnected. In cases of repair, the charge air pipe must be
removed if necessary, the spring band ring must be destroyed
using a suitable tool (e.g. angle grinder) and must be renewed by
a replacement part according to ⇒ ETKA (electronic parts cata‐
logue) .
1.4 Assembly overview - turbocharger
Note
♦ All hose connections are secured.

♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts. . Volkswagen AG
gen AG doe
swa
♦ Before screwing on oil supply
yV
olk line, fill turbocharger atsconnec‐
not
gu
tion with engine oil.rised b ara
nte
tho eo
♦ After installing sturbocharger,
au run engine for about 1 minute at r ac
idling speed tos ensure that oil is supplied to turbocharger.
ce
le
un
pt
an
d
itte

y li
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
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or
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te
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rig ht
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co Vo
by lksw
cted agen
Prote AG.

Engine codes AVQ, BJB, BKC, BRU, BXE and BXF ⇒ page
204
Engine codes BLS and BXJ ⇒ page 206
Changing and adjusting vacuum unit on turbocharger - only ve‐
hicles with engine code: BLS from model year 2008 ⇒ page
208
1.4.1 Engine codes AVQ BJB, BKC, BRU, BXE and BXF
1 - 10 Nm
3 - Oil supply line
❑ Before installing oil sup‐
ply line, ensure that it is AG. Volkswagen AG d
agen
not blocked. olksw
oes
not
byV gu
ara
❑ Before installing, fill tur‐ rised
nte
bocharger with engine ut
ho eo
ra
oil through oil supply line ss a c
connection.
ce
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nl
pt
du
an
itte
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⇒ page 112
erm
ab
ility
ot p
wit
, is n
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5 - Seal
hole
spec
❑ Renew.
es, in part or in w
t to the co
tion.
6 - Washer
rrectness of i
7 - 25 Nm
l purpos
❑ Renew.
nform
ercia
8 - Support
m
❑ Between turbocharger at
om
io
and cylinder block.
n
c
in t
or
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e
9 - 40 Nm
at
do
riv
❑ First hand tighten all

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10 - Connecting pipe C py
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rig ht
❑ Air filter/turbocharger py by
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11 - Connecting piece Prote AG.
12 - Seal
❑ Renew.
13 - Seal
❑ Renew.
14 - Union, 40 Nm
15 - Oil return line
❑ To cylinder block.
❑ Tighten union nut to 30 Nm.
16 - 17 Nm
17 - Vacuum hose
❑ To solenoid valve block
204 Rep. gr.21 - Turbocharging/supercharging

18 - Turbocharger
❑ Can only be renewed with exhaust manifold.
❑ To remove turbocharger, remove right drive shaft ⇒ Running gear, axles, steering; Rep. gr. 40 ; Re‐
moving and installing drive shafts .
19 - 20 Nm
❑ First hand tighten all bolts
20 - 20 Nm
❑ Renew.
21 - Heat shield
22 - Seal
❑ Renew.
23 - Clamp, 7 Nm
24 - Front exhaust pipe
25 - Bracket agen
AG. Volkswagen AG d
oes
lksw not
❑ For oil supply line ⇒ Item 3 (page 204) . d by Vo gu
ara
❑ Before installing, secure oil supply line. rise nte
tho eo
au ra
26 - 22 Nm ss c
ce
le
un
❑ Renew.
pt
an
d
itte
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27 - Connecting pipe
rm
ab
pe
ility
❑ To bypass flap
ot
wit
, is n
h re
28 - Union, 30 Nm
hole
spec
❑ Renew.
es, in part or in w
t to the co
❑ Coat threads and bolt head seating surface with „G 052 112 A3“.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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fo
en
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t.
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t. rig
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by
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Prote AG.

1.4.2 Engine codes BLS and BXJ

AG. Volkswagen AG d
agen oes
olksw not
yV gu
1- 10 Nm ed b ara
nte
ris
ho eo
2- Bracket aut ra
c
ss
3 - Heat shield
ce
e
nl
pt
du
an
itte
4 - Oil supply hose
y li
erm
ab
❑ To oil supply line con‐
ility
ot p
nection on turbocharger
wit
, is n
h re
❑ Before installing oil sup‐
hole
ply line, ensure that it is
spec
es, in part or in w
not blocked.
t to the co
❑ Before installing, fill tur‐
bocharger via oil supply
hose with engine oil
rrectness of i
5 - Turbocharger
l purpos
❑ Can only be renewed

with exhaust manifold.
nform
ercia

m
⇒ page 216
at
om
ion
c
6 - Vacuum hose in t
or
his
ate
7 - Seal
do
priv
cum
or
❑ Renew.
f
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ng
t.
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tion.
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ht ht
rig by
py Vo
8 - To particulate filter
co lksw
by
cted agen
Prote AG.
9 - Clamp, 7 Nm
❑ For turbocharger/partic‐
ulate filter
10 - Exhaust manifold
❑ Can only be renewed to‐
gether with turbocharg‐
er
11 - 25 Nm
❑ Renew.
12 - 25 Nm
13 - Seal
❑ Renew.
❑ For exhaust gas recirculation.
❑ Assembly overview - parts of exhaust gas recirculation ⇒ page 267 .
15 - 25 Nm
❑ Renew.
16 - 15 Nm
17 - O-ring
❑ Renew.
18 - Banjo bolt, 60 Nm
❑ Renew.

19 - Support
❑ For turbocharger
❑ With oil return line
20 - Exhaust gas temperature sender bank 1 -G235- , 45 Nm
❑ Lubricate thread of sender using high-temperature paste -G 052 112 A3-
❑ To remove and install, use wrench -T10395-
21 - Heat shield
22 - Connection
❑ For intake hose for air filter/turbocharger
❑ Assembly overview - air filter ⇒ page 238 .
23 - 9 Nm
24 - 10 Nm
Installation position of exhaust gas temperature sender with an‐

gled cable guide
Note
. Volkswagen AG
gen AG
When the exhaust Vol
kgas
swa temperature sender with
does
not angled cable
guide is being ed bremoved, the distance -a- of 3 ... 5umm
y g
ara to screw
support against
thoris turbocharger. nte
e or
au ac
ss
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
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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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1.4.3 Changing and adjusting vacuum unit on turbocharger - only vehicles with
engine code: BLS from model year 2008
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
or c
thi
te
sd
iva
o
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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.

equipment required
♦ Hand vacuum pump -VAS 6213-
♦ Turbocharger tester -V.A.G 1397A-
♦ Pressure regulating valve -VAS 6342-
♦ Ring spanner -T10423-
♦ Allen key, long reach -T10454-
Caution
The special tools indicated, in particular the socket inset, -

T10454- is designed solely for use according to the following
work instructions and must not be used for other threaded con‐
nections. There is a danger of deformation if high torques are
applied.
Note
n AG. Volkswagen AG
A replacement parts kswkit is available when changing
age does
not the vacuum
Vol
unit ⇒ Electronic
db
y parts catalogue . gu
ara
e nte
ris
utho eo
Removing
ss
a ra
c
ce
le

un
pt
an
d
itte
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– Pull cover off air duct (release clips on sides) -arrows-.

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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t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
Golf 2004 ➤ , Golf Plus 2005 d by ➤ , Passat 2006 ➤ , Touran 2003
V gu ➤
ara
e nte
4-cylinder diesel engine hori(1.9
s
l engine) - Edition 08.2010 eo
aut ra
ss c
– Unclip lower air duct -2- by releasing retaining clips on left and
ce
e
nl
right -arrow A-.
pt
du
an
itte
y li
– Unclip air duct at mountings -3-.
erm
ab
ility
– Swing air duct downwards and slightly to rear for this. ot p
wit
, is n
h re
– Detach air pipe -1- from lower air duct -arrow B-.
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
or
– Disconnect electrical connector -1- from air mass meter -

f
en
ng
G70- .
t.
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Cop py
t. rig
– Pull off vent hose -3- and also air duct hose -2-. opyri
gh by
Vo
ht
by c
– Remove bolt -4- and remove air filter housing.
lksw
cted agen
Prote AG.
– Detach hose -2- from crankcase breather.

– Lay aside ventilation hose -4- and vacuum hoses -1- at air
hose.
– Unscrew bolt -3-.
– Swing air duct hose to rear and pull off of turbocharger.
– Seal opening in turbocharger with the plug from the spare-
parts kit.
– Pull off vacuum hose on turbocharger.
Golf Plus, Touran
– Remove plenum chamber bulkhead ⇒ General body repairs,

– Depending on version, unscrew nut -arrow- where the oil sup‐

ply line/vacuum line is connected to the cylinder head.
Caution
When detaching the oil supply line, counterhold the connec‐

tion. Risk of damage as a consequence!
– Prepare a 14 mm open-ended wrench for counterholding.
14 mm tool for counterholding connection piece of oil supply line

♦ A = 110 mm
♦ B = 25 mm
. Volkswagen AG
gen AG does
– Counterhold connection piece and unscrew oil supply
Vol
ksw line
a
not
-arrow- from turbocharger. ed
by gu
ara
is nte
or eo
– Seal oil supply opening in turbochargerauwith
th the plug from the ra
spare-parts kit. 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
– Counterhold lock nut -B- with ring spanner -T10423- and un‐
rrectness of i
screw securing nut -A- from the control rod using socket inset
-T10454- .
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.

– Remove bolt -1-, then bolt -2- and remove vacuum unit -A-.
Installing
– Colour mark vacuum unit and control rods -as shown-.
Note
AG. Volkswagen AG d
agen oes
The colour marks show that the control rods are adjusted cor‐Volksw not
gu
rectly, after tightening. Adjustments should then be madeseas
db
y ara
nte
necessary. thori eo
au ra
c
ss
ce
le
un
pt
Caution
an
d
itte
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erm
ab
Only use new bolts and nuts from the spare-parts kit!
ility
ot p
wit
is n
h re
ole,
– If necessary, remove lower securing nut of the control rod from
spec
the new vacuum unit.
t to the co
– Screw locknut by hand onto the control rod as far as possible
in the direction of the vacuum unit.
rrectne
– Push control rod through the adjusting lever on turbocharger,
fit vacuum unit -A- and lock.
ss o
cial p
f
– Fit bolts -1- and -2- from repair kit.
inform
mer
– Tighten bolts -1- and -2- to 8 Nm.
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.
– Switch on turbocharger tester -V.A.G 1397A- and set sliding

switch to position „I“.
– Subtract 600 mbar from atmospheric pressure displayed and
note value. (Value 1)
– Subtract 650 mbar from atmospheric pressure displayed and
note value. (Value 2)

– Connect test and measuring instruments together as illustrat‐

ed and connect to connection „I“ -arrow- of turbocharger tester
-V.A.G 1397A- and to turbocharger vacuum unit.
– Close lever -1- on pressure regulating valve -VAS 6342- .
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
– Move slide ring -1- on hand vacuum pump -VAS 6213- to po‐
sition -A- for „vacuum“.
l purpos
Caution
nf
ercia
orm
m
Excessive pressure may damage the vacuum unit. atio

om
n in
c
The pressure must not fall below the read atmospheric pres‐
or
thi
e
sure minus 800 mbar.

t
sd
iva
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♦ An accuracy of +/- 20 mbar is acceptable when setting value Prote AG.
2.
♦ Make sure that the turbocharger adjusting lever moves easily
on the control rod.
– Operate hand vacuum pump -VAS 6213- several times until

noted value 2 is attained on turbocharger tester -V.A.G
1397A- .

– Open pressure regulating valve -1- until value 1 is set exactly.
– Screw nut -A- up a couple of threads on control rod.
AG. Volkswagen AG d
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hole
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– Hold adjusting lever -1- on »stop« of adjustment screw -2- by
es, in part or in w
hand.
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Note
Co
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♦ During next procedure, ensure adjusting lever -1- remains
py by
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against stop screw -2- and is not already contacting the se‐ Prote
cted AG.
agen
curing nut -A-.
♦ Screw securing nut -A- back if this occurs.

Volkswa
– Screw control rod lock nut -B- down agslowly,
en AG. by hand, until
gen AG
doesit
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contacts the adjusting lever b-1-,
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– Screw securing nut -A-thoup
ri on control rod until it lies against tee
or
adjusting lever. ss
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Note
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ility
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Ensure control rod does not move while tightening securing nut
wit
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-A-.
h re
ole,
spec
– Counterhold lock nut -B- with ring spanner -T10423- and tight‐
t to the co
en securing nut -A- using socket inset -T10454- .
– Check colour marks on control rod, the must align
rrectne
-as shown-.
ss o
cial p
f inform
mer
atio
om
n
c
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or
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sd
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t.
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Cop py
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– Release vacuum, move slide ring -1- on hand vacuum pump
p by
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to position -B- for this, then move slide ring back to position Prote
cted AG.
agen
-A- again.
Note
There very little space between cylinder head and turbocharger.

Ensure you are aware of where the feeler gauge (0.05 mm) is
positioned.
– The feeler gauge (0.05 mm) must be positioned between ad‐

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

– Seal connection between control rod and securing nut with

sealing paint from the spare-parts kit.
– Press locking plate by hand onto the control rod and turn 90°
in the -direction of the arrow-.
Value not OK.
Repeat adjustment procedure again.
Continuation
14 mm tool for counterholding connection piece of oil supply line

♦ A = 110 mm
♦ B = 25 mm
– Counterhold connection piece and tighten oil supply line

-arrow- on turbocharger.
AG. Volkswagen AG d
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olksw not
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un
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ab
– Depending on version, reconnect oil supply line/vacuum line

ility
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to the cylinder head and tighten nut -arrow-.

wit
is n
h re
ole,
Golf Plus, Touran

spec

t to the co

rrectne
– Complete the engine.

s
– Start motor and delete event memory ⇒ Vehicle diagnostic,

s o
testing and information system VAS 5051.

cial p
f inform
mer
atio
m
1.5 Removing and installing turbocharger

o
n
c
i
or
n thi
te

sd
iva
o
pr
cum
r

fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Lambda probe open ring spanner set -3337-

AG. Volkswagen AG d
agen oes
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un
pt
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d
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erm
ab
ility
ot p
wit
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spec
t to the co
♦ Tool set -T10395-
rrectness 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
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t.
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Cop py
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Caution p by
co Vo
by lksw
cted agen
Prote AG.
When a mechanical fault is found on the turbocharger, e.g. a
destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To prevent this from causing further damage,
perform the following repairs:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing and charge air cooler
for foreign objects.
If foreign objects are found in the charge air system, the
charged air routing must be cleaned and the charge air cooler
must be renewed, if necessary.
Removing
Rep. gr. 50 ; Body - front; Noise insulation .
– Remove front propshaft ⇒ Final drive 02D, 0AV; Rep. gr. 39 ;
Assembly overview - repairing propshaft .
Rep. gr. 40 .
– Pull electrical connector off exhaust gas pressure sensor 1 -
G450- in engine compartment and unscrew securing bolts.
– Separate electrical connectors to particulate filter.
– Remove subframe including steering and right drive shaft ⇒
Running gear, axles, steering; Rep. gr. 40 .

– Remove particulate filter.

– On vehicles with four-wheel drive remove the bevel box to
reach the threaded connection for turbocharger support ⇒ 6-
speed manual gearbox; Rep. gr. 34 ; Removing and installing
bevel box .
– Disconnect fasteners -arrows- of coolant pipes for auxiliary
heater, if part of original equipment.

– Remove support and oil return line or combi support ⇒ Item 19
(page 206) for turbocharger.
– Remove connecting pipe to exhaust gas recirculation cooler.
– Separate charge pressure line from turbocharger.
– Pull vacuum hose off turbocharger.
AG. Volkswagen AG d
– Separate oil supply line from turbocharger. lksw
agen oes
not
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by
– Unscrew securing bolts for exhaust manifold.rise d ara
nte
ho eo
– Tilt the engine forwards in lower mountingaut and remove tur‐ ra
s c
bocharger with exhaust manifold downwards.
s ce
e
nl
pt
du
Installing
an
itte
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erm
ab
– Install in reverse order.
ility
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wit
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Note
hole
spec
es, in part or in w
t to the co
Torque setting of pendulum support ⇒ page 22 .

rrectness of i
1.6 Assembly overview - parts of charge air

cooling
l purpos
nform
ercia
Note
m
at
om
ion
♦ Charge air system must be free of leaks.

c
in t
or
his
te
♦ When making repairs, remove oil from connection and hose

a
do
riv
ends.
p
cum
for
en
g
♦ All hose connections of charge air system are secured by

n
t.
yi Co
op
spring-type clips or by connector couplings. C py
t. rig
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yri by
♦ Checking charge air system for leaks ⇒ page 221 op Vo
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cted agen
Prote AG.

Engine codes AVQ BJB, BKC, BRU, BXE and BXF ⇒ page
219
Installing hose connections with connector couplings ⇒ page
202
1.6.1 Engine codes AVQ BJB, BKC, BRU, BXE and BXF
1 - 8 Nm
❑ Fitting location ⇒ page
220
2 - Bracket
tion.
3 - Charge air cooler
AG. Volkswagen AG d
agen oes
4 - Connecting hose olksw not
byV gu
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ed
5- 8 Nm horis nte
eo
aut ra
6- To turbocharger.
ss c
ce
le
un
7 - Connecting pipe
pt
an
d
itte
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8 - To intake connecting pipe.
erm
ab
ility
ot p
9 - Vacuum reservoir
wit
is n
h re
10 - 15 Nm
ole,
spec
11 - 8 Nm t to the co
12 - O-ring
rrectne
13 - Charge air pressure

sender -G31- with intake air
ss
temperature sender -G42-

o
cial p
f in
14 - 3 Nm
form
mer
atio
om
n
c
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or
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te
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AG. Volkswagen AG d
agen oes
olksw not
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1 - 8 Nm rise
d b ara
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Fitting location ⇒ page 220 s au ra
c
s
ce
e
nl
2 - Bracket
pt
du
an
itte
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erm
ab
tion.
ility
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wit
3 - Charge air cooler
, is n
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❑ To remove, bring lock
hole
spec
carrier into service posi‐
es, in part or in w
tion ⇒ General body re‐
t to the co
pairs, exterior; Rep. gr.
50 ; Body - front; Lock
carrier - service position
rrectness of i
4 - Sealing strip
l purpos
❑ Pushed onto top and

bottom of charge air
nform
ercia
cooler
m
at
5 - 3 Nm
om
ion
c
in t
r
6 - Charge air pressure sender

o
his
te
-G31- with intake air tempera‐

a
do
riv
ture sender -G42-

p
cum
for
en
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7 - O-ring
n
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
8 - Bracket
co lksw
by
cted agen
Prote AG.
9 - 5 Nm
10 - Connecting hose
11 - Charge air pipe
❑ To intake manifold flap
motor -V157-
❑ Assembly overview - in‐
take manifold ⇒ page 235 .
13 - 8 Nm
Securing bolts for charge air cooler

To loosen or tighten securing bolts -arrows- remove bumper cov‐
er.

1.7 Checking charge air system for leaks

♦ Charge air system tester -V.A.G 1687-

– Remove intake hose -1- from air filter.
– Insert adapter -V.A.G 1687/10- in intake hose -1- and secure
with clip. agen
AG. Volkswagen AG d
oe w s no
olks t gu
Prepare charge air system tester -V.A.G 1687- as
ed
bfollows:
yV ara
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un
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d
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ab
ility
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wit
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spec
t to the co
rrectness o
cial p
f inform
– Turn pressure regulating valve -2- anti-clockwise onto stop.

mer
atio
m
– Close valves -3- and -4-.

o
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
cum
r
fo
en
ng
t.
To turn the pressure regulating valve -2- the knob must be pulled
yi Co
op py
upwards. t. C rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Connect charge air system tester -V.A.G 1687- to adapter -

V.A.G 1687/10- as shown.
– Connect compressed air hose -1- (compressed air source) to

charge air system tester -V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.

– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
AG. Volkswagen AG d
agen oes Caution
olksw not
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The pressure must thor not exceed 0.5 bar! If the pressure is tooeo
high this cans acause damage to the engine.
u ra
c
s
ce
e
nl
pt
du
an
itte
– Open valve -4- and wait until the test circuit is filled. If neces‐
y li
erm
ab
sary readjust pressure to 0.5 bar.

ility
ot p
– Check the charge air system for leaks by hearing, touching,

wit
, is n
h re
with leak detector spray or using ultrasonic tester -V.A.G

hole
1842- .
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ How to use the ultrasonic tester -V.A.G 1842- ⇒ operating

instructions
l purpos
♦ If leaks occur, when doing any repair work observe notes for
charge air system ⇒ page 218 .
nform
ercia
♦ Depressurise test circuit by detaching coupling from adapter -

m
at
om
V.A.G 1687/10- before removing adapter.

on
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.

1.8 Vacuum hose schematic diagram

Vehicles with particulate filter ⇒ page 223
Vehicles without particulate filter ⇒ page 224
1.8.1 Vehicles with particulate filter
1 - Turbocharger
2 - Connecting pipe air filter/
turbocharger
3 - Non-return valve
tion.
4 - To brake servo
5 - Charge pressure control
solenoid valve -N75-
6 - Air filter
block
8 - Intake manifold
AG. Volkswagen AG d
agen oes
9 - Bypass flap olksw not
byV gu
ara
❑ For exhaust gas recircu‐ rised
nte
lation cooler. aut
ho eo
ra
ss c
10 - Radiator
ce
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nl
pt
du
❑ For exhaust gas recircu‐
an
itte
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lation.
erm
ab
ility
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valve -N18-
h re
hole
spec
es, in part or in w
cooler changeover valve -
t to the co
N345-
rrectness of i
tion.
l purpos
14 - Vacuum unit nform

ercia
❑ Turbocharger
m
at
om
ion
c
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or
his
ate
do
priv
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for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ by
,VTouran 2003 ➤
ol not
gu
d ara
4-cylinder diesel engine (1.9 l engine) - Editionoris 08.2010
e nte
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1.8.2 Vehicles without particulate filter s
ce
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nl
pt
du
an
itte
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erm
ab
1 - Solenoid valve block
ility
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wit
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hole
spec
tion.
es, in part or in w
t to the co
3 - To brake servo
4 - Connecting pipe air filter/
turbocharger
rrectness of i
5 - Air filter
l purpos
6 - Intake manifold
nform
ercia
m
block
at
om
ion
c
8 - Vacuum reservoir
in t
or
his
ate
9 - Bypass flap
do
priv
cum
for
en
g
lation cooler.
n
t.
yi Co
Cop py
10 - Radiator
t. rig
gh ht
pyri by
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cted
lation.
agen
Prote AG.

valve -N18-
12 - Turbocharger
tion.

23 – Mixture preparation - injection

1 Diesel direct injection system
The diesel direct injection system control unit is equipped with a
fault memory. Read fault memory before and after making repairs
or adjustments.
Removing and installing pre-wired wiring harness for unit injec‐
tors and glow plugs ⇒ page 226
Assembly overview - unit injector ⇒ page 229
Removing and installing unit injector ⇒ page 230
Adjusting non-contact gap of unit injectors ⇒ page 232
Removing and installing O-rings for unit injector ⇒ page 233 .
Repairing intake manifold flap ⇒ page 235
Assembly overview - air filter ⇒ page 238 .
1.1 Safety precautions

lkswage es nWARNING
o ot g
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ir se tee
When doing any uth repair work, especially in the engine com‐
o
or
partment, pay
ss
a attention to the following due to the cramped ac
conditions:
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nl
pt
du
an
itte
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erm
ab
ility

ot p
sitions.
wit
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hole

spec
hot components.
es, in part or in w
t to the co
Note the following if testers and measuring instruments have to

rrectness of i
be used during a road test:

l purpos
♦ Test and measuring instruments must always be secured to

rear seat and operated by a second person from this location.
nf
ercia
♦ If test and measuring instruments are operated from front pas‐

or
senger seat and the vehicle is involved in an accident, there

m
m
atio
is a possibility that the person sitting in this seat may receive

om
n in
serious injuries when the airbag is triggered.

or c
thi
te
To prevent injuries to persons and/or destruction of the injection

sd
iva
o
r
and glow plug system, the following must be noted:

rp
cu
o
m
f
en
ng
♦ The ignition must be switched off before connecting or dis‐

t.
yi Co
op
connecting injection or glow plug system wiring or tester ca‐ C py
t. rig
bles.
gh ht
pyri by
Vo
co lksw
by
♦ If the engine is to be turned at starter speed, without starting, cted agen
Prote AG.
e.g. when checking compressions, disconnect unit injector
connector on cylinder head.
♦ Before disconnecting battery, obtain radio code for radios with
anti-theft coding.
1. Diesel direct injection system 225

AG. Volkswagen AG d
4-cylinder diesel swagen (1.9 l engine)
engine - oEdition
es n 08.2010
olk t gu o
yV
e db ara
♦ Disconnecting hori and connecting the battery must only bendone
s tee
with the ignition
aut switched off, as otherwise the control unit for
or
ac
ss
diesel direction injection system could become damaged.
ce
e
nl
pt
du
1.2 Rules for cleanliness
an
itte
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erm
ab
When working on fuel supply and injection system, pay careful
ility
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attention to the following rules for cleanliness:
wit
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♦ Thoroughly clean all unions and adjacent areas before dis‐
hole
spec
connecting.
es, in part or in w
t to the co
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
rrectness of i
l purpos

nf
ercia
orm
tool boxes etc.).
m
atio
om
n in
or c
thi
te
sd
a
essary.
iv
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♦ Also ensure that no diesel fuel comes into contact with the
f
en
ng
t.
yi
coolant hoses. Should this occur, the hoses must be cleaned
Co
op py
immediately. Damaged hoses must be renewed. t. C rig
gh ht
pyri by
1.3 Removing and installing pre-wired

co Vo
by lksw
cted agen
Prote AG.
wiring harness for unit injectors and
glow plugs
♦ Puller -T10312-
♦ Special wrench -T10310-
226 Rep. gr.23 - Mixture preparation - injection

AG. Volks4-cylinder
wagen AG
dodiesel engine (1.9
l engine) - Edition 08.2010
agen es n
olksw ot g
byV uara
ed
Removing oris nte
eo
h
aut ra
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Caution
ce
e
nl
pt
du
an
itte
y li
Removal and installation of the pre-wired wiring harness may
erm
ab
only be undertaken by unscrewing the clips. Releasing the ca‐
ility
ot p
ble channel at the clips bends the clips which may break the
wit
, is n
cables due the excessive play. This also applies when chang‐
h re
hole
ing the unit injectors and all work which does not require the
spec
central connector to be completely removed.
es, in part or in w
t to the co
rrectness of i
Note
l purpos
Disconnecting connectors on piezo unit injectors may only be un‐

dertaken using special tool puller -T10312- .
nf
ercia
orm
m
atio
om
n in
c
To do this, pull engine cover upwards abruptly at front and right

or
thi
e
-arrows A- and then pull forwards out of rear fastening

t
sd
iva
-arrow B-.
o
r
rp
cu
o
m
f
en
– Remove cylinder head cover ⇒ page 64 .
ng
t.
yi Co
op py
– Disconnect central connector on cylinder head.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Fit special wrench -T10310- on adapter ring and release it by

turning key through 90° (1/4 turn) in -direction of arrow-.
– Pull the securing clip -1- upwards lightly with a screwdriver and
press the central connector -2- through inwards.

AG. Volkswagen AG d
4-cylinder diesel engine (1.9 l engine)
lkswagen - Edition 08.2010 oes
n
o ot g
yV ua
edb ran
– Slide the puller -T10312- onto ho
risthe unit injector connector from tee
the side and pull it off in -direction
aut of arrow-. Use pointed pliers or
ac
for the older connector version.
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
– Pull connectors off glow plugs -1- Unscrew securing bolts -2-
l purpos
of steel clips and remove complete pre-wired wiring harness.

Installing
nform
ercia

m
a
note the following:
com
tion in
r
– Route pre-wired wiring harness and tighten securing bolts to

te o
thi
10 Nm.
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
– Guide central connector through opening in retaining frame, Prote AG.
ensure securing clips -arrows- are seated correctly when do‐
ing this.
– Fit adapter ring (colour marked „longer“ stud -arrow- faces 12

o'clock)

– Fit special wrench -T10310- on adapter ring and lock it by AG. Volkswagen AG d
turning key through 90° (1/4 turn) in opposite olksw
agen oes
not
V
-direction of arrow-. ed by gu
ara
ris nte
ho eo
aut ra
ss c
Note
ce
le
un
pt
an
d
itte
When adapter ring is installed correctly the colour marked „short‐
y li
rm
ab
er“ stud faces 12 o'clock.
pe
ility
ot
wit
, is n
– Fit central connector to cylinder head and lock in position.
h re
hole
spec
– Install cylinder head cover ⇒ page 64 . es, in part or in w
t to the co
1.4 Assembly overview - unit injector
rrectness of i
l purpos
♦ Observe rules for cleanliness ⇒ page 226 .

♦ Always renew seals and O-rings
nform
mercia
a
1 - 20 Nm + turn (90°)
com
tion in
❑ Renew.
r
te o
thi
s
iva
2 - Rocker arm shaft
do
r
rp
cum
fo
❑ With rocker arms
en
ng
t.
yi
Co
Cop py
⇒ page 230
t. rig
gh ht
pyri by
Vo
o
3 - Lock nut, 30 Nm by c lksw
cted agen
Prote AG.
4 - Adjuster screw
❑ Renew.
5 - Ball stud
❑ Renew.
6 - Unit injector
⇒ page 230
7 - O-ring
❑ Renewing ⇒ page
233 .
8 - O-ring
233 .
9 - O-ring
233 .
10 - Heat shield seal
❑ Renew.
11 - Circlip
12 - Cylinder head
13 - Tensioning block
14 - 12 Nm + turn (270°)
❑ Renew.

1.5 Removing and installing unit injector

equipment required
♦ Universal dial gauge brack‐
et -VW 387-
-3410-
-T10054-
♦ Puller -T10055-
AG. Volkswagen AG d
agen oes
♦ Torque wrench - olksw not
y V gu
V.A.G 1331- ise
d b ara
nte
or eo
th
au ra
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– Remove toothed belt guard upper part.
– Remove cylinder head cover. ⇒ page 64
– Turn crankshaft until the cam pair point evenly upwards for the
unit injector which is to be removed.
– Loosen lock nuts of adjustment screws -1- and remove ad‐
justment screws.
– Remove rocker arm securing bolts -2- (from outwards to in‐
wards) with socket XZN 10 -3410- and remove rocker arm
shaft.
– Remove tensioning block securing bolt -3- with special
wrench, long reach -T10054- and remove the block.
– Lever connector off unit injector using a screwdriver. Support
opposite side of connector with light finger pressure to prevent
canting.
Observe unit injector cylinder allocation.

– Insert puller -T10055- in place of the clamping block in the slot

on the side of the unit injector.
– Pull unit injector out of cylinder head seat by gently tapping
upwards.
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Installing
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♦ Each time work is performed which requires adjustment of the

h re
hole
unit injector, the adjustment screw in the rocker arm and also
the unit injector ball stud must be renewed. spec
es, in part or in w
t to the co
♦ New unit injectors are supplied with O-rings and heat shield
seal.
rrectness of i
– Heat shield seal and O-rings must be renewed if old unit in‐
l purpos
jector is reused. ⇒ page 233

– Check that the 3 O-rings and the heat shield seal along with
nf
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securing clip are seated correctly before installing unit injector.

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The seals must not be twisted.

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head with great care.
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stop.
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– Insert tensioning block in slot on side of unit injector.
Note
If the unit injector is not at right angles to the tensioning block the
securing bolt may loosen and this can damage the unit injector or
the cylinder head.
– Therefore align the unit injector as follows.

– Screw new securing bolt into clamping block, but do not tighten
(it must still be possible to turn the unit injector slightly).
– Now align unit injector at right angles to camshaft bearing seat.

– Check dimension „a“ from outer edge of cylinder head to

rounded edge of unit injector with a vernier gauge (measuring
range at least 400 mm).
Cylinder Dimension „a“
1 333.0 ± 0.8 mm
2 245.0 ± 0.8 mm
3 153.6 ± 0.8 mm
4 65.6 ± 0.8 mm
– If necessary, adjust the unit injector and tighten the securing
bolt as follows: n AG. Volkswagen A ge G do
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– Tighten securing bolt to 12 Nm and turn 270° (3/4 turn)
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– Fit rocker arm shaft and tighten new securing
s bolts as follows:
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– First evenly tighten inner bolts -2- and then outer bolts -1-
an
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hand-tight. Then using same sequence, tighten to 20 Nm and
erm
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90° (1/4 turn) further evenly.
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– Adjust non-contact gap of unit injectors ⇒ page 232 .
, is n
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spec
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t to the co
rrectness of i
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1.6 Adjusting non-contact gap of unit injec‐
nform
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tors
m
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– Fit dial gauge onto adjustment screw of unit injector as shown.
om
ion
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– Turn crankshaft in direction of engine rotation until roller of

o
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rocker arm is located at tip of drive cam. Roller side

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-arrow A- positioned at highest point, dial gauge -arrow B- po‐

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or
sitioned at lowest point.

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– Remove dial gauge. C py
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– Now turn the adjuster screw into rocker arm until significant
op Vo
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Prote AG.
– Turn adjustment screw 180° back off stop.

– Hold adjuster screw in this position and tighten lock nut to 30
Nm.
– Connect unit injector connector.
– Install cylinder head cover ⇒ page 64 .

1.7 Removing and installing O-rings for unit

injector
♦ Assembly sleeves -T10056-
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1.7.1 Removing
h re
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spec
– Lever old O-rings very carefully out of unit injector.
es, in part or in w
t to the co
– Above all ensure that burrs are not caused on O-ring seating.
1.7.2 Installing
rrectness of i
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Note
nform
ercia
♦ Always use the assembly sleeves to fit the O-rings. There is a

m
danger of damaging the O-rings if the sleeves are not used.
a
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♦ Gradual introduction of O-rings without different coloured
r
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markings. Note the correct allocation of O-rings to grooves:
s
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the thickness of the rings reduces towards injector nozzle.
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♦ Prevent O-rings from rolling when sliding them on. The O-rings
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must not be twisted in their seats in unit injector. Cop py
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– Pull heat shield seal off together with securing clip.
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cted agen
Prote AG.
– Clean seating surfaces for O-rings on unit injector very care‐
fully.
– Place assembly sleeve -T10056/1- onto stop on unit injector.
– Push the upper, thicker O-ring carefully onto assembly sleeve
and into seat on unit injector.
– Remove assembly sleeve.

– Place assembly sleeve -T10056/2- onto stop on unit injector.

– Slide the middle, thinner O-ring carefully onto assembly sleeve
and into seat on unit injector.
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– Place assembly sleeve -T10056/3- onto stop
aut on unit injector. ra
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– Push the lower O-ring carefully onto the assembly sleeve and
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into the seat of the unit injector.
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– Fit new heat shield seal together with securing clip.
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1.8 Assembly overview - intake manifold

Engine codes AVQ BKC, BRU, BXE and BXF ⇒ page 235
Engine code BJB ⇒ page 236
1.8.1 Engine codes AVQ, BKC, BRU, BXE and BXF
1 - Intake manifold
❑ Tighten securing bolts
to 22 Nm.
2 - O-ring
❑ Renew.
3 - Intake connecting pipe
❑ With exhaust gas recir‐
culation valve
4 - 10 Nm
5 - Intake manifold flap motor -
V157-
❑ The intake manifold flap
is closed for approx. 3
seconds when stopping
engine and then opens
again. This reduces the
stop jolt.
6 - 10 Nm
7 - Connecting pipe
❑ To exhaust gas recircu‐
lation cooler.
8 - 22 Nm
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9 - Seal yV
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❑ Renew. o
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Prote 1. Diesel direct injection system
AG.
1.8.2 Engine code BJB
1 - Intake manifold
to 22 Nm.
2 - O-ring
❑ Renew.
3 - Intake connecting pipe
culation valve and in‐
take manifold flap
4 - 10 Nm
5 - Seal AG. Volkswagen AG d
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7 - 10 Nm
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8 - Bracket
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9 - Vacuum actuator
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10 - To solenoid valve block
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11 - 22 Nm
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1 - Seal
❑ Renew.
2 - Intake manifold
to 22 Nm
3 - Seal
❑ Renew.
4 - Connection
5 - Intake manifold flap motor -
V157-
❑ The intake manifold flap
is closed for approx. 3
seconds when stopping
engine and then opens
again. This reduces the
stop jolt.
6 - From charge air cooler
7 - 10 Nm
valve -N18- with exhaust gas
recirculation potentiometer -
G212-
❑ Assembly overview - ex‐
haust gas recirculation
⇒ page 267
9 - Seal agen
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10 - Connecting pipe uthor eo
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❑ For exhaust gas recircu‐ ss c
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❑ Assembly overview -
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⇒ page 264
h re
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spec
11 - 22 Nm
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12 - Bracket
13 - 22 Nm
rrectness of i
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1.9 Cleaning the intake manifold flap sup‐

nform
ercia
port, Engine code BLS and BXJ

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Note
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Carbon deposits can occur in the throttle valve support through

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when disassembling the exhaust gas recirculation valve -N18- or
Co
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the intake manifold flap motor -V157,- , the support will have to
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be cleaned. p by
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WARNING
Acetone is highly inflammable. Please observe the accidental

regulations and safety notes when handling with highly in‐
flammable fluids. Wear eye protection and protective clothing
to avoid possible injury and skin contact.
– Remove intake manifold flap connection.

– Remove the exhaust gas recirculation valve -N18- and the in‐
take manifold flap motor -V157- .
– Thoroughly clean intake manifold flap support, especially
around exhaust gas return valve, using commercially available
acetone according to DIN 53247 and cleaning brush.
– Wipe off intake manifold flap support using a lint-free cloth.
– Allow the acetone to evaporate fully, assemble the cleaned
intake manifold flap support, replace the seals and insert it
back in position.
1.10 Assembly overview - air filter
1 - Intake hose
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2 - Air mass meter -G70- orise nte
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4 - 8 Nm
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5 - Air filter upper part

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6 - 8 Nm
h re
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spec
7 - Vacuum hose
es, in part or in w
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❑ To solenoid valve block

8 - Filter element
rrectness of i
9 - Air duct
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❑ To lock carrier.
10 - Air filter lower part
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11 - 10 Nm
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2 Engine control unit

n AG . Volkswage
Reading and clearing engine controlksunit
wagefault memory ⇒ page
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239 . Vol gu
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Adapting functions and components
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⇒ page 240 . tee
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Removing and installings engine control unit (Golf) ⇒ page 240
ce
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Removing and installing anti-theft engine control unit (Golf) ⇒
an
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page 241
erm
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Removing and installing engine control unit (Golf Plus) ⇒ page
wit
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243
h re
ole,
Removing and installing anti-theft engine control unit (Golf
spec
Plus) ⇒ page 244
t to the co
Removing and installing engine control unit (Touran) ⇒ page
240
rrectne
Removing and installing anti-theft engine control unit (Touran) ⇒
page 247
ss o
Removing and installing engine control unit (Passat)
cial p
f inform
2.1 Reading and clearing engine control unit
mer
atio
fault memory
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♦ Vehicle diagnostic, testing and information system -VAS 5051-
um
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– Connect vehicle diagnostic, testing and information system -

VAS 5051- as follows:
– Push diagnosis cable connector onto diagnosis connector.
Only when engine does not start:
Select operating mode
– Press button on display for „Vehicle self-diagnosis“.
Select vehicle system
– Press button „01 - Engine electronics“ on display.
The control unit identification and engine control unit coding are
indicated on display.
Select diagnostic function
– Press button „02 - Read fault memory“ on display.
2. Engine control unit 239

– If no fault is stored in engine control unit „0 fault detected“ is

displayed.
– If faults are stored in the engine control unit, these are shown
one below the other on the display.
– Press the ← button.
– Press button „05 - Clear fault memory“ on display.
– Press function „06-End output“.
2.2 Adapting functions and components

♦ Vehicle diagnostic, testing and information system -VAS 5051-
AG. Volkswagen AG d
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Select „guided fault finding“ in vehicle diagnostic, testing and in‐
hole
spec
formation system -VAS 5051- .
es, in part or in w
t to the co
When all control units have been read:
– Press „GoTo“ button.
rrectness of i
– Select „Function/component selection“.
l purpos
– Select „Drive train“.

– Select „Engine code“.
nform
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– Select „01 Systems capable of self-diagnosis“.

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– Select „Engine management“.

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– Select „Functions“.
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– Select „Function or component“.

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2.3 Removing and installing engine control
Co
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unit (Golf)
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cted agen
– Before removing engine control unit, read control unit identifi‐ Prote AG.
cation and, with it, coding of current control unit as well ⇒ page
240 .
Removing
– Remove wiper arms, plenum chamber cover and plenum
chamber bulkhead: ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing windscreen
wiper system .

– Bend catch open slightly -1-.

– Then push engine control unit out of retainer -arrow-.
– Release now connector from engine control unit, disconnect
connector.
Installing
– Fit connector to engine control unit and lock connector in po‐
sition.
– Push engine control unit onto bracket.
– Press catch -1- against engine control unit.

– Install plenum chamber bulkhead, plenum chamber cover and
wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen
wiper system; Removing and installing windscreen wiper sys‐
tem .
2.4 Removing and installing anti-theft en‐

gine control unit
lksw
age(Golf)
es n
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Removing and installing edanti-theft engine control unit Golf Plusra⇒
b a
nte
ris
page 244 . ut
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sa ac
Special tools ands workshop equipment required
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♦ Electric cutter -V.A.G 1561 A-

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♦ Saw set -V.A.G 1561/14-

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♦ Grip pliers
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t to the co
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nform
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Note
♦ If the engine control unit is to be renewed, connect vehicle

diagnostic, testing and information system -VAS 5051B- and
perform „Renewing engine control unit“ in guided functions.
♦ The shear-head bolt threads are coated with locking com‐
pound. To simplify removing, the shear-head bolts can be
heated using hot air blower -VAS 1978/14- . When doing this,
ensure that no adjacent cables, connectors or components are
damaged!
Removing
– Remove wiper arms, plenum chamber cover and plenum
chamber bulkhead: ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing windscreen
wiper system .
– Cut into heads of shear-head bolts so that 2 parallel surfaces
are created -arrows-.
– Remove bolts with grip pliers .
lkswage es n
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– Insert a screwdriver between protective housing -A- and
itte
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bracket -arrow-.
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es, in part or in w
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nf
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– Lever up protective housing using screwdriver -A- and pull to

rm
m
side off bracket -arrow-.

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– Bend catch open slightly -1-.

– Then push engine control unit out of retainer -arrow-.
– Release now connector from engine control unit, disconnect
connector.
Installing
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– Fit connector to engine control unit yand Vo lock connector in po‐
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– Push engine control unit ontoau bracket.
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– Press catch -1- against engine control unit.
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– Push protective housing onto bracket.
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spec
t to the co
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cial p
f inform
mer
atio
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– Tighten new shear-head bolts -1- evenly until heads shear-

o
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head off.
i
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sd
a
– Install plenum chamber bulkhead, plenum chamber cover and

iv
o
r
wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen

p
cum
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fo
wiper system; Removing and installing windscreen wiper sys‐ en

ng
t.
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tem .
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unit (Golf Plus)
Note
If the engine control unit is to be renewed, connect vehicle diag‐

nostic, testing and information system -VAS 5051B- and perform
„Renewing engine control unit“ in guided functions.
Removing:
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .

– Loosen securing nuts -arrows-.

nector.
– Push bracket -1- off engine control unit in direction of arrow.

Installing:
– Push bracket onto engine control unit.
– Tighten securing nuts -arrows- to 10 Nm.

– Fit connectors and lock in position.
– Install plenum chamber bulkhead ⇒ General body repairs;
AG. Volkswagen AG d
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spec
♦ Grip pliers
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Note
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♦ If the engine control unit is to be renewed, connect vehicle

ss
diagnostic, testing and information system -VAS 5051B- and

o
cial p
f i
perform „Renewing engine control unit“ in guided functions.

nform
mer
♦ The shear-head bolt threads are coated with locking com‐

atio
m
pound. To simplify removing, the shear-head bolts can be

o
n
c
heated using hot air blower -VAS 1978/14- . When doing this,
i
or
n thi
e
ensure that no adjacent cables, connectors or components are

t
sd
va
damaged!
i
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cum
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fo
en
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Removing
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– Twist shear-head bolts -arrows- out using grip pliers and re‐
move cover from protective housing.
– Then remove securing nuts for control unit bracket -arrows-.
olkswagen AG
en AG. V
– Release connector from engine control
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does
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– Press catches -1- and -2- outwards. Then pull engine control
rrectne
unit off control unit bracket in direction of arrow.
Installing ss o
– Push engine control unit onto control unit bracket until it en‐
cial p
f in
gages in catches.
form
mer
– Fit connectors to engine control unit and lock in position.

atio
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– Tighten securing bolts -arrows- to 10 Nm.
ht
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cted
– Install cover of protective housing.
agen
Prote AG.

– Tighten new shear-head bolts -arrows- evenly until heads

shear off.

unit (Touran)
– Before removing engine control unit, read control unit identifi‐
cation and, with it, coding of current control unit as well ⇒ page
240 .
2.7.1 Removing
– Remove plenum chamber bulkhead. ⇒ General body repairs;
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
– Loosen securing nuts -arrows-.
nector.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
– Push bracket -1- off engine control unit in direction of arrow.

ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
2.7.2 Installing
om
n
c
i
or
n thi
– Push bracket onto engine control unit.

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.

– Tighten securing nuts -arrows- to 10 Nm.

– Fit connectors and lock in position.
– Check previous coding and adapt coding of the new control
unit ⇒ page 240 .
– Read fault memory of new engine control unit and erase fault
memory if necessary. ⇒ page 239
– Carry out a road test.
– Read control unit fault memory again.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
ise nte
or eo
h
ut ra
gine control unit (Touran)
ss a c
ce
le
un
pt
an
d
itte
y li
rm
♦ Grip pliers
ab
pe
ility
ot
♦ Hot air blower from wiring harness repair set -VAS 1978-
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
Note
r
rp
cum
fo
en
ng
t.
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op
nostic, testing and information system -VAS 5051B- and perform
C py
ht. rig
„Renewing engine control unit“ in guided functions.
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

– Turn temperature settings potentiometer -2- to a maximum

heat output of 600 °C.
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear bolt.

– Switch on hot air blower and heat the bolts.
– Unscrew shear-head bolts -arrows- out using pliers and re‐

move cover from protective housing.
– Then remove securing nuts for control unit bracket -arrows-.

nector.
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
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Press catches -1- and -2- outwards. Then pull engine control
es, in part or in w
unit off control unit bracket -in direction of arrow-.

t to the co
Installing
– Push engine control unit onto control unit bracket until it en‐
rrectness of i
gages in catches.
l purpos
– Fit connectors to engine control unit and lock in position.

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.

– Tighten securing bolts -arrows- to 10 Nm.

– Install cover of protective housing.
– Tighten new shear-head bolts -arrows- evenly until heads

shear off.
– Install plenum chamber bulkhead ⇒ General body repairs;
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
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3 Engine control unit (Passat)

Removing and installing engine control unit ⇒ page 250 .
Removing and installing anti-theft engine control unit ⇒ page
251 .

unit
nosis, testing and information system -VAS 5051B- and perform
guided functions „Renewing control unit“.
DANGER!
For vehicles with heavy duty running gear; vehicle must be re‐
stricted to a maximum of 210 km/h via the engine control unit.
Drive shafts can be damaged at speeds above 210 km/h. Per‐
form function „Restricting maximum speed“ in guided function
using vehicle diagnostic, testing and information system -VAS
5051B- .
Removing
– Remove wiper arms ⇒ Rep. gr. 92 .
– Remove plenum chamber cover ⇒ Rep. gr. 64 .
– Pull connector -1- off heated windscreen control unit -J505- .
– Slide connector locking devices -2- on engine control unit out‐
wards and pull off both connectors.
– Remove securing bolts -3-.
AG. Volkswagen AG d
agen oes
– Remove retainer frame with engine control unit from plenum olks
w not
yV gu
chamber. d b ara
ise nte
or th eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Press locking device -1- outwards and slide engine control unit
wit
, is n
h re
-2- in -direction of arrow-.
hole
spec
Installing
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
250
Prote AG.
Rep. gr.23 - Mixture preparation - injection
AG. Volkswagen AG d
agen oes
olksw no
d byV Golf 2004 ➤ , Golft gPlus
ua 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
ran
e
horis 4-cylinder diesel
tee engine (1.9 l engine) - Edition 08.2010
ut or
a ac
ss
– Slide engine control unit -1- into retaining frame in
ce
e
nl
-direction of arrow-.
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
– Fit retainer frame with engine control unit onto retainer -4-.
nform
ercia
Specified torque of securing nuts for retainer -4-: 6 Nm.

m
at
om
– Tighten securing bolts -3- to 7 Nm.
ion
c
in t
or
– Fit connectors to engine control unit and slide locking devices
his
ate
-2- inwards.
do
priv
cum
or
-
f
en
ng
t.
yi Co
op
– Fit connector -1- to heated windscreen control unit -J505- . C py
ht. rig
rig ht
– Install plenum chamber cover ⇒ Rep. gr. 64 .
py by
co Vo
by lksw
cted agen
– Install wiper arms ⇒ Rep. gr. 92 .
Prote AG.

gine control unit
♦ Hot air blower from wiring harness repair set -VAS 1978-
♦ Nozzle attachment from wiring harness repair set -VAS 1978-

nosis, testing and information system -VAS 5051B- and perform
guided functions „Renewing control unit“.
DANGER!
For vehicles with heavy duty running gear; vehicle must be re‐
stricted to a maximum of 210 km/h via the engine control unit.
Drive shafts can be damaged at speeds above 210 km/h. Per‐
form function „Restricting maximum speed“ in guided function
using vehicle diagnostic, testing and information system -VAS
5051B- .
3. Engine control unit (Passat) 251

Removing
– Remove wiper arms ⇒ Rep. gr. 92 .
– Remove plenum chamber cover ⇒ Rep. gr. 64 .
Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
olkswagen AG
en AG. V
Cover lines, connections and control ksw units in the vicinity ofethe
ag do s
not
Vol
engine control unit to prevent
ed
bydamage through heat. gu
ara
ris nte
ho eo
aut ra
ss c
Perform settings on hot air blower -4- as shown:
ce
le
un
pt
an
– Turn temperature setting potentiometer -2- to maximum heat
d
itte
y li
output (600 °C).
erm
ab
ility
ot p
– Set two-stage switch for volume of air -3- to position 3.
wit
is n
h re
ole,
spec
WARNING
t to the co
When shear-head bolts are heated up, parts of the protective
housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
rrectness
– Place nozzle of hot air blower close to shear-head bolt.

o
cial p
f in
– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
form
mer
onds.
atio
om
n
c
– Unscrew shear-head bolt -2- using pliers on bolt head.

or
n thi
te
sd
a
The procedure for the second shear-head bolt is exactly the

iv
o
pr
same.
um
r
fo
en
ng
t.
yi
– Pull connector -1- off heated windscreen control unit -J505- .
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Lift cover -1- and pull it forwards.
– Slide connector locking devices -1- on engine control unit out‐

wards and pull off both connectors.
– Remove retainer frame with engine control unit from plenum
chamber.
lkswage es n
o ot g
byV ua
– Press locking device -1- outwardsorand
ise slide engine control unit
d ran
tee
-2- in -direction of arrow-. auth or
ac
ss
Installing
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
– Slide engine control unit -1- into retaining frame in

l purpos
-direction of arrow-.
– Fit retainer frame with engine control unit onto retainer in
nf
ercia
plenum chamber.
orm
m
Specified torque of securing nuts for retainer: 6 Nm.

atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Engine control unit (Passat) 253

– Fit connectors to engine control unit and slide locking devices

-1- inwards.
– Slide cover -1- over engine control unit and press it down‐
wards.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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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
– Tighten new shear-head bolts -2- evenly until bolt head shears
t to the co
off.
– Fit connector -1- to heated windscreen control unit -J505- .
rrectness of i
– Install plenum chamber cover ⇒ Rep. gr. 64 .
l purpos
– Install wiper arms ⇒ Rep. gr. 92 .
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.

26 – Exhaust system
1 Exhaust system
Assembly overview - front exhaust pipe with catalytic converter
Golf, Golf Plus, Touran, Passat ⇒ page 255 .
Assembly overview - front exhaust pipe with particulate filter Golf,
Golf Plus, Touran, Passat ⇒ page 256 .
Assembly overview - silencers (vehicles with front-wheel drive)
Golf, Golf Plus, Touran ⇒ page 258 .
Assembly overview - silencer with mountings (vehicles with four-
wheel drive) ⇒ page 262 .
Assembly overview - silencers (Passat) ⇒ page 261 .
1.1 Assembly overview - front exhaust pipe with catalytic converter
1 - Front exhaust pipe with cat‐

alytic converter
2 - 40 Nm
AG. Volkswagen AG d
agen oes
3 - Support Volksw not
gu
d by ara
e
4 - Marking horis nte
eo
ut
❑ For clamp. ss a ra
c
❑ Installation position of
ce
e
nl
pt
du
clamp ⇒ page 256 .

an
itte
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erm
ab
5 - To front silencer
ility
ot p
wit
6 - 25 Nm
, is n
h re
hole
7 - Mounting spec
es, in part or in w
t to the co
8 - 7 Nm
9 - Seal
rrectness of i

l purpos
tion.
10 - Clip
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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Prote AG.
1. Exhaust system 255

Installation position of clamp

Position clamp at distance -a- = 5 mm from marking on front ex‐
haust pipe.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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ce
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un
pt
1.2 Assembly overview - front exhaust pipe
an
d
itte
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rm
with particulate filter
ab
pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
If the particulate filter or the exhaust gas pressure sensor 1 -
G450- is changed, the exhaust gas pressure sensor 1 -G450-
must always be adapted using diagnosis tester : Guided func‐
rrectness of i
tions; adapting exhaust pressure sensor 1 -G450- .
l purpos

♦ Lambda probe open ring spanner set -3337-
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.
♦ Tool set -T10395-
Note
If the particulate filter or the exhaust gas pressure sensor 1 -

G450- is changed, the exhaust gas pressure sensor 1 -G450-
must always be adapted using diagnosis tester : Guided func‐
tions; adapting exhaust pressure sensor 1 -G450- .
256 Rep. gr.26 - Exhaust system

1 - 8 Nm
2 - Exhaust gas pressure sen‐
sor 1 -G450-
3 - Bracket
❑ For control lines
4 - 10 Nm
5 - Control line, 45 Nm
AG. Volkswagen AG d
6 - Lambda probe -G39- , 50 lkswagen oes
not
Nm db
yV
o gu
ara
e nte
❑ Grease only the ho threads
ris
eo
aut
with high-temperature ra
ss c
paste -G 052 112 A3- ;
ce
le
high-temperature paste
un
pt
an
d
-G 052 112 A3- must not

itte
y li
get into the slots of
erm
ab
ility
probe body.
ot p
wit
is n
❑ To remove use Lambda
h re
ole,
probe open ring span‐
spec
ner set -3337- .
t to the co
7 - Exhaust gas temperature
sender bank 2 -G448- , 45 Nm
❑ Lubricate thread of
rrectne
sender using high-tem‐
perature paste -G 052
s
112 A3-
s o
cial p
f in
8 - Particulate filter
form
mer
❑ is removed downwards
atio
m
with exhaust gas pres‐

o
n
c
sure sensor 1 -G450-

i
or
n thi
te
❑ To remove, remove
sd
iva
o
r
subframe and steering

p
cum
r
fo
⇒ Running gear, axles,

en
ng
t.
yi
steering; Rep. gr. 40 .
Co
Cop py
t. rig
9 - Front exhaust pipe
gh ht
pyri by
Vo
co lksw
by
10 - Marking cted agen
Prote AG.
❑ For clamp.
❑ Installation position of clamp ⇒ page 258 .
11 - To front silencer
12 - 25 Nm
13 - Mounting
14 - Temperature sender after particulate filter -G527-
❑ 45 Nm
❑ Lubricate thread of sender using high-temperature paste -G 052 112 A3-
15 - From turbocharger
16 - Clamp, 7 Nm
17 - Seal
❑ Renew.

18 - 40 Nm
19 - Bracket agen
AG. Volkswagen AG d
oes
lksw not
❑ Bolted to cylinder head. by
Vo gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
– Position double clamp -a- = 5 mm from marking on front ex‐
itte
y li
haust pipe of particulate filter.
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
1.3 Assembly overview - silencer with mountings (vehicles with front wheel
nf
ercia
drive)
orm
m
atio
om
n in
or c
1 - 25 Nm
thi
te
sd
a
❑ Renew.
iv
o
r
rp
cu
o
m
2 - Retaining ring
f
en
ng
t.
yi Co
❑ Renew if damaged. t. Cop py
rig
gh ht
yri
3 - Separating point p by
o Vo
by c lksw
❑ Marked by indentation cted agen
Prote AG.
on exhaust pipe
❑ During production, front
and rear silencers are
installed as a single
component. For repairs,
front and rear silencers
are supplied separately.
❑ The connection is made
with a clamp.
❑ Separating exhaust end
pipe ⇒ page 259
❑ Installation position of
rear clamp (repair dou‐
ble clamp) ⇒ page
259 .
❑ Evenly tighten threaded
connections of clamping
sleeve (repair double
clamp)
❑ Specified torques for
clamp (repair double
clamp): M8 = 25 Nm,
M10 = 40 Nm
❑ Before tightening, align
cold exhaust system
free of tension ⇒ page
262

4 - Rear silencer
5 - Mounting
6 - 25 Nm
7 - Tunnel bridge
8 - Front silencer
9 - Mounting
Installation position of rear clamp (repair double clamp)

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
• Bolt connection faces to left.
1.3.1 Separating front and rear gsilencers

en AG. V
olkswagen AG
d a oes
lksw not
Special tools and workshop equipment
db
yrequired
Vo gu
ara
e nte
ris
♦ Pneumatic sabre saw -V.A.Guth1523
o A- eo
ra
a c
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
♦ Eye protection
Procedure
nform
mercia
WARNING
at
om
ion
c
in t
or
Wear eye protection.

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.

– Cut exhaust end pipe at right angles at separating point

-arrow 2-.
– When installing, position repair double clamp -4- at side mark‐
ings -arrow 1- and -arrow 3-. 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
– Install repair double clamp so that end of bolt does not extend
h re
beyond lower edge of clamp.
hole
spec
es, in part or in w
• Bolted connection faces rear.
t to the co
– Align cold exhaust system free of stress ⇒ page 262 .
– Tighten bolts on repair double clamp.
rrectness of i
Tightening torque M8: 25 Nm
l purpos
Specified torque, M10: 40 Nm
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.4 Assembly overview - silencers (Passat)
1 - From front exhaust pipe

2 - Clamp
❑ Before tightening, align
cold exhaust system
free of tension ⇒ page
262
❑ Tighten bolted connec‐
tions evenly.
❑ Specified torque: M8 =
25 Nm, M10 = 40 Nm.
3 - Front silencer
4 - Mounting
5 - 25 Nm
❑ Renew.
6 - Separating point
❑ Marked by impressions
on exhaust pipe.
❑ During production, front
and rear silencers are
installed as a single
component. In event of
repair, front and rear si‐
lencers are supplied in‐
dividually and with a n AG. Volkswagen AG do
clamping sleeve for pur‐ lkswage es n
Vo ot g
poses of connection d by ua
ran
ir se tee
❑ Cut through exhaust utho
or
pipe at right angles at ss
a ac
separating point
ce
le
un
pt
-arrow A- using e.g.

an
d
itte
body saw -V.A.G 1523-

y li
erm
ab
(wear eye protection)

ility
ot p
❑ During installation, posi‐

wit
is n
tion repair double clamp at side markings -arrows B-

h re
ole,
spec
❑ Evenly tighten threaded connections of clamping sleeve (repair double clamp)

❑ Specified torques for clamp (repair double clamp): M8 = 25 Nm, M10 = 40 Nm.
t to the co
❑ Before tightening, align cold exhaust system free of tension ⇒ page 262
7 - Retaining ring
rrectne
ss
8 - Rear silencer
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.

1.5 Assembly overview - silencer with mountings (vehicles with four-wheel

drive)
1 - From particulate filter

2 - Clamp
❑ Align exhaust system
free of stress before
tightening clamp ⇒ page
262 .
❑ Installation position ⇒ agen
AG. Volkswagen AG d
oes
page 262 . Volksw not
gu
by ara
❑ Tighten bolted connec‐rise
d
nte
tions evenly. aut ho eo
ra
ss c
3 - Bracket
ce
e
nl
pt
du
❑ For retaining ring
an
itte
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erm
ab
4 - 25 Nm
ility
ot p
wit
5 - Retaining ring
, is n
h re
hole
spec
es, in part or in w
6 - Rear silencer
t to the co
7 - Mounting
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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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.

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
1.6 Aligning exhaust system free of stress

Prerequisite
• Engine must be cold

Procedure
– Loosen bolted connection of clamp between front exhaust
pipe and silencer.
– Position clamp at distance -a- = 5 mm from marking on front
AG. Volkswagen AG d
exhaust pipe and lightly tighten front bolted
lkswconnection.
agen oes
n o ot g
yV ua
edb ran
ris tee
tho or
au ac
ss
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
– Push exhaust end pipe with silencer forwards into clamp until
dimension -a- 15…17 mm is attained between mounting at‐
tachment points for body and rear silencer. -Arrow- points in
rrectness of i
direction of travel.
l purpos
– Align rear silencer horizontally.

– With parts in this position, tighten bolted connections of clamp.
nform
ercia

m
at
om
ion
c
in t
or
his
te
– Once clamp has been tightened, check distance -a- and cor‐
a
do
riv
rect if necessary.
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2 Exhaust gas recirculation system
2.1 Assembly overview - parts of exhaust

gas recirculation
Engine codes AVQ, BKC, BRU, BXE, BXF ⇒ page 264
Engine code BJB ⇒ page 266
Check mechanical exhaust gas recirculation valve AVQ, BKC,
BRU, BXE, BXF ⇒ page 268 .
2.1.1 Engine codes AVQ, BKC, BRU, BXE

and BXF
Note
♦ The exhaust gas recirculation system is activated by the diesel

direct injection system control unit -J248- via exhaust gas re‐
circulation valve -N18- (electric-pneumatic) to the exhaust gas
recirculation valve (mechanical).
♦ The electro-pneumatic exhaust gas recirculation valve -N18-
is located in the solenoid valve block.
♦ The cone-shaped plunger in the mechanical exhaust gas re‐
circulation valve ensures that various cross sectional openings
are possible at different plunger lifts.
♦ Pulsed control enables every conceivable valve position.
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1 - 22 Nm
2 - Intake manifold
take manifold flap motor
-V157- .
to 22 Nm.
3 - Seal
❑ Renew.
4 - Connecting pipe
5 - Radiator
lation.
6 - 10 Nm
7 - Exhaust manifold
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8 - Connecting pipe Volksw
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Tightening sequence: orise nte
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u ra
❑ 1. Attach to bypass flap ss a c
ce
le
❑ 2. Attach to manifold
un
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an
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itte
❑ 3. Tighten to bypass flap
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❑ 4. Tighten to manifold
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9 - Bypass flap
h re
ole,
❑ When activated, directs
spec
exhaust gas to exhaust
t to the co
gas recirculation cooler
via the electro-pneu‐
matic exhaust gas recir‐
culation valve -N18- .
rrectne
10 - Bracket
ss
❑ For bypass flap
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11 - 5 Nm f inform
mer
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Connector assignment on solenoid valve block, engine codes

thi
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BKC, BRU, BXE and BXF

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1- Vacuum connection (on non-return valve for brake servo)

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4- Air filter Prote AG.
5- Vacuum reservoir
6- Vacuum unit on turbocharger
2. Exhaust gas recirculation system 265

2.1.2 Engine code BJB
Note

direct injection system control unit -J248- via exhaust gas re‐
circulation valve -N18- (electric-pneumatic) to the exhaust gas
recirculation valve (mechanical).
♦ The electro-pneumatic exhaust gas recirculation valve -N18-
is located in the solenoid valve block.
♦ The cone-shaped plunger in the mechanical exhaust gas re‐
circulation valve ensures that various cross sectional openings
are possible at different plunger lifts.
♦ Pulsed control enables every conceivable valve position.
♦ Renew self-locking nuts.
1 - Intake manifold
take manifold flap.
to 22 Nm.
2 - From charge air cooler
3 - Seal
❑ Renew.
4 - 22 Nm AG. Volkswagen AG d
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5 - Exhaust manifold d by Vo gu
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6 - Connecting pipe utho eo
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Pin assignment on solenoid valve block for engine code BJB

1- Vacuum connection (on non-return valve for brake servo)
2- Exhaust gas recirculation valve
3- Intake manifold flap
4- Air filter
5- Vacuum reservoir
6- Vacuum unit on turbocharger
Note

direct injection system control unit -J248- via the exhaust gas
recirculation potentiometer -G212- .
♦ Renew self-locking nuts.
1 - Coolant hose
❑ To connection
2 - Seal
❑ Renew.
3 - 22 Nm
4 - Connecting pipe
5 - From exhaust manifold lkswage es n
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6 - 25 Nm ir se
d ran
tee
o
❑ Renew. auth or
ac
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7 - To connection for exhaust
ce
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un
pt
gas recirculation valve -N18-

an
d
itte
with exhaust gas recirculation

y li
erm
ab
potentiometer -G212-
ility
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❑ Assembly overview - in‐

wit
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take manifold ⇒ page

h re
ole,
237 .
spec

t to the co
cooler
9 - 10 Nm
rrectne
10 - Coolant hose
s
❑ From rear coolant pipe

s o
cial p
f i
nform
mer

atio
m
cooler changeover valve -

o
n
c
N345-
or
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14 - Vacuum actuator
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❑ For bypass flap. C py
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2. Exhaust gas recirculation system 267

with exhaust gas recirculation cooler
2.2 Checking mechanical exhaust gas re‐

circulation valve
♦ Hand vacuum pump with accessories -V.A.G 1390-
lkswage es n
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Test procedure
hole
spec
es, in part or in w
– Pull vacuum hose off exhaust gas recirculation valve.
t to the co
to valve.
rrectness of i
– Operate hand vacuum pump a few times.
l purpos
– Pull hand vacuum pump hose off exhaust gas recirculation

valve. The diaphragm rod must audibly return to its original
nform
position.
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tion in
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28 – Glow plug system

1 Checking glow plug system
Removing, installing and checking glow plugs ⇒ page 269
Characteristics of ceramic glow plugs ⇒ page 270
Removing, installing and checking ceramic glow plugs ⇒ page
271
1.1 Removing, installing and checking glow

plugs
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Test requirements
es, in part or in w
t to the co
• Battery voltage at least 11.5 V

• Ignition switched on
rrectness of i
Checking
l purpos
The glow plug system is monitored by the engine control unit's

self-diagnosis system.
nform
ercia
The necessary checks are performed with Guided fault finding.

m
Removing glow plugs

com
tion in
r
– Remove glow plugs using U/J extension and socket -3220- .

te o
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Installing glow plugs

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– Install glow plugs using jointed extension and socket -3220- .

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1. Checking glow plug system 269

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1.2 Characteristics of ceramic glow plugs ol ot g
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WARNING ss
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an
The ceramic glow plugs ⇒ page 270 are sensitive to jolts and
itte
y li
bending. For this reason a glow plug which has dropped from
erm
ab
a small height (approx. 2 cm) must not be used. Even if no
ility
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damage is apparent. It is absolutely necessary to follow the
wit
, is n
installation instructions, otherwise the heater pin of the glow
h re
hole
plug can break and cause engine damage.
spec
es, in part or in w
t to the co
Visual features of ceramic glow plugs
rrectness of i
Vehicles with 2 valves per cylinder head
-A- = Metal glow plug, colour-coded -arrow-.
l purpos
-B- = Ceramic glow plug with support tube -arrow-, not colour-
nf
ercia
coded.
orm
m
Vehicles with 4 valves per cylinder head
atio
om
n in
c
-C- = Metal glow plug, colour-coded -arrow-.

or
thi
te
sd
a
-D- = Ceramic glow plug with support tube -arrow-, not colour-
iv
o
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rp
cu
coded.
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t.
Remove and install or check ceramic glow plugs ⇒ page 271 .
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270 Rep. gr.28 - Glow plug system

AG. Volkswagen AG d
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Golf 2004 ➤ , Golf Plusd2005by
V
➤ , Passat 2006 ➤ , Tourant g2003 ua
ran ➤
e
4-cylinder horidiesel
s
engine (1.9 l engine) - Edition 08.2010
tee
aut or
ac
ss
1.3 Removing, installing and checking ceramic glow plugs
ce
le
un
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an
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ility
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equipment required
wit
is n
h re
ole,
spec
t to the co
-V.A.G 1331-
♦ Hand-held multimeter -
V.A.G 1526 A-
rrectne
♦ Auxiliary measuring set -
s
V.A.G 1594 C-
s o
cial p
f inform
mer
atio
om
n
c
i
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sd
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Test prerequisites
• Engine is cold
• Ignition switched off
Procedure
Note
Do not cant ceramic glow plugs when removing and installing.

Remove any components hindering assembly.
– Pull connectors off ceramic glow plugs.

– Remove ceramic glow plugs using U/J extension and socket,
10 mm -3220- .
note the following:
– Before installing the drilling in cylinder head and the threads
must completely cleaned of all deposits.
1. Checking glow plug system 271

Note
Do not oil or grease thread of cylinder head bore or of ceramic

glow plugs.
– Screw ceramic glow plugs into cylinder head by hand using U/

J extension and socket, 10 mm -3220- .
– Then tighten the ceramic glow plugs. Specified torque: 15 Nm.
WARNING
♦ After installing and before the engine is started, perform a

resistance test on all ceramic glow plugs when engine is
cold.
♦ If the defective ceramic glow plug is broken, remove all
fragments from the engine, otherwise these can cause
damage to the engine.
♦ Specification: max. 1 Ω
– If the specification is exceeded, renew the defective ceramic
glow plug.
AG. Volkswagen AG d
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es, in part or in w
t to the co
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Rep. gr.28 - Glow plug system

Elektromehanika Vjezbe

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Service

4-cylinder diesel engine (1.9 l engine)

Service Department. Technical Information

15 - Cylinder head, valve gear

28 - Glow plug system

All rights reserved.

Copyright © 2010 Volkswagen AG, Wolfsburg D3E801CBF41

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.3 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.5 Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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

1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

2.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

2.3 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

2.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

1.3 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

1.6 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

5.4 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

23 - Mixture preparation e-ninjection

1.4 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

1.5 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

1.6 Adjusting non-contact gap of unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

1.7 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

1.8 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

1.10 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

2.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

2.3 Removing and installing engine control unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

2.7 Removing and installing engine control unit (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

3 Engine control unit (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

3.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

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

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

Edition 07.2010 Version 5.0

AVQ BJB BKC BRU BLS BXE BXF BXJ

10 – Removing and installing engine

Assembly mountings ⇒ page 22

1.1 Removing engine (Golf, Golf Plus)

♦ Engine and gearbox sup‐

♦ Workshop hoist -V.A.G

♦ Drip tray -V.A.G 1306-

1. Removing and installing engine 3

♦ Torque wrench -V.A.G

♦ Before carrying out further work, disconnect battery earth

anti-theft coding if necessary.

♦ The engine is removed downwards together with the gearbox.

removed must be replaced in the same position when engine

4 Rep. gr.10 - Removing and installing engine

When doing any repair work, especially in the engine com‐

Two-piece engine cover

– Remove battery and battery tray.

– Disconnect fuel supply and return lines as well as coolant line

1. Removing and installing engine 5

– Remove noise insulation ⇒ General body repairs, exterior;

To facilitate removing and installing engine without opening re‐

– Remove poly V-belt ⇒ page 25 .

– Remove air conditioner compressor ⇒ Heating, air condition‐

ing; Rep. gr. 87 ; Removing and installing compressor brack‐