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15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling
20 - Fuel supply system 21 - Turbocharging/supercharging 23 - Mixture preparation - injection 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 1.1 1.2
1
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1 1.1 1.2 1.3 1.4 1.5 1.6
Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing engine (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing engine (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing engine (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 3 9 14 20 21 22
Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .en. A. G . ..V.o.lk.sw . a. g.e.n.A.G. . . . . . . . . . . . . . . . . . . . . . do ag Assembly overview - crankshaft . . . . .V.ol.ks.w. . . . . . . . . . . . . . . . . . e.s.n.ot.g. . . . . . . . . . . . . . . . y ua b Pistons and conrods . . . . . . . . .or.ise.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an.te. . . . . . . . . . . . eo th Assembly overview - pistons and au conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.ac. . . . . . . . . ss Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 4 4.1 4.2 4.3 4.4 4.5
24 24 28 29 32 33 33 34 36 38 40 46 48 48 54 54 55 56 57 57
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 r fo ng
1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.4 2.5
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 c o p yri gh t . C op yi
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 agen lksw Vo by
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Contents
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.......................... ............................ Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter bracket, oil pressure, engine oil cooler and oil supply line . . . . . . . . . . . . . . . . . . Assembly overview - oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . rrectne s s o f i t to the co n form spec atio h re n wit i n thi sd o c um en
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1.1 1.2 1.3 2 2.1 2.2 3 3.1 3.2 3.3 3.4
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103 103 103 104 104 105 109 109 110 111 112
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Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of cooling system, body side (radiator with two radiator fans) . . . . . . . . . . . . . . . . . . Assembly overview - parts of cooling system, body side (radiator with one radiator fan) . . Removing and installing fan support with fans (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . Removing and installing fan support with fans (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing radiator (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing radiator (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . agen lksw Vo by
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1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 114 115 117 117 119 120 122 123 126 127 128 130 132 134
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 1 1.1 2 2.1 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 5 5.1 5.2 5.3
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Contents
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . Parts of fuel supply system (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel tank, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of fuel supply system (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of fuel supply system (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emptying fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
136 136 137 137 138 138 142 148 150 151 152 156 158 160 161 162 165 167 168 169 170 171 176 176 183 185
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 5.4 5.5 6 6.1 7 7.1 7.2
Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
189 191 193 193 195 195 198
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201 201 201 202 203 216 218 221 223
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sn ks Diesel direct Vol injection system . . . . . . . o.t .gu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by ara d e Safety ris precautions . . . . . . . . . . . . . . . . . . . .n.te.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o h t Rules for cleanliness . . . . . . . . . . . . . . . . . . . . .or.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . au c ss Removing and installing pre-wired wiring harness for unit injectors and glow plugs . . . . . . Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting non-contact gap of unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the intake manifold flap support, Engine code BLS and BXJ . . . . . . . . . . . . . . . . Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading and clearing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine control unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing anti-theft engine control unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine control unit (Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing anti-theft engine control unit (Golf Plus) . . . . . . . . . . . . . . . . . . . . Removing and installing engine control unit (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing anti-theft engine control unit (Touran) . . . . . . . . . . . . . . . . . . . . . . Engine control unit (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3 3.1 3.2
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225 225 226 226 229 230 232 233 235 237 238 239 239 240 240 241 243 244 246 247 250 250 251
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . . . Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . Assembly overview - silencer with mountings (vehicles with front wheel drive) . . . . . . . . . . Assembly overview - silencers (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - silencer with mountings (vehicles with four-wheel drive) . . . . . . . . . . Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - parts of exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking mechanical exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . AG.
1 1.1 1.2 1.3 1.4 1.5 1.6 2 2.1 2.2
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23 - Mixture preparation e-ninjection . G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 AG. Volkswage.n A
Contents
255 255 256 258 261 262 262 264 264 268
iii
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 1 1.1 1.2 1.3
Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing, installing and checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Characteristics of ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing, installing and checking ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents
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269 269 270 271
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
00 –
Technical data
1
Technical data
Engine number ⇒ page 1 Engine data ⇒ page 1 un le
Engine number
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1.1
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Additionally there is a sticker on the toothed belt guard with „en‐ gine code“ and „serial number“.
1.2
Engine data
Edition 07.2010 Version 5.0 AVQ
BJB
BRU
10.03 ►
04.04 ► 02.06 ► 03.06 03.06
r fo ng
Golf/Golf Plus produc‐ 10.03 ► tion Passat production Touran 02.03 ► production Emissions fulfil EU4 stan‐ EU3 dard standard
BKC
BLS
BXE
BXF
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05.05► 03.06 ► 10.03 ► 10.04 02.06 ► 03.06 ► EU4 EU4 EU4 EU4 standard stan‐ stan‐ stan‐ dard dard dard Capacity l 1.9 1.9 1.9 1.9 1.9 1.9 Output kW at rpm 74/4000 77/ 77/ 66/ 77/ 77/ 4000 4000 4000 4000 4000 Torque Nm at 250/1900 250/ 250/ 210/ 250/ 250/ rpm 1900 1900 1800 ...2 1900 1900 500 Bore ∅ mm 79.5 79.5 79.5 79.5 79.5 79.5 Stroke mm 95.5 95.5 95.5 95.5 95.5 95.5 Valves per cylinder 2 2 2 2 2 2 Compression ratio 19.0 19.0 19.0 19.0 18.5 18.5 Fuel according DIN EN DIN EN DIN EN DIN EN DIN EN DIN to 590 590 590 590 590 EN 590 Firing or‐ 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4der 2 Catalytic yes yes yes yes yes yes converter Exhaust yes yes yes yes yes yes gas recir‐ culation
BXJ 11.07
12.04►
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The engine code is also included on the vehicle data sticker.
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The engine number („code letters“ and „serial number“) can be found at the joint between engine and gearbox.
03.06 ► 10.06 ► EU4 stan‐ dard 1.9 66/ 4000 210/ 1800
EU4 stan‐ dard
1.9 66/ 4000 210/ 1800 ...25 00 79.5 79.5 95.5 95.5 2 2 19.0 19.0 DIN EN DIN EN 590 590 1-3-4-2
1-3-4-2
yes
yes
yes
yes
1. Technical data
1
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 AVQ
ProCarManuals.com
Tur‐ bocharg‐ ing/super‐ charging Charge air cooler Particulate filter
BJB
BKC
BRU
BLS
BXE
BXF
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
no
no
yes
no
no
yes
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Rep. gr.00 - Technical data
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2
BXJ
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
10 –
Removing and installing engine
1
Removing and installing engine
Removing engine (Golf, Golf Plus) ⇒ page 3 AG. Volkswagen AG d Removing engine (Touran) ⇒wpage agen 9 oes ks Vol
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Removing engine (Golf, Golf Plus)
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1.1
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Notes on installing ⇒ page 21 .
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Special tools and workshop equipment required ♦ Lifting tackle -2024 A♦ Support clamp -VW 313♦ Engine and gearbox sup‐ port -VW 540-
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♦ Workshop hoist -V.A.G 1202 A♦ Drip tray -V.A.G 1306-
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♦ Engine bracket -T10012-
1. Removing and installing engine
3
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ♦ Torque wrench -V.A.G 1331♦ Torque wrench -V.A.G 1332♦ Engine and gearbox jack V.A.G 1383 A♦ Spring-type clip pliers -VAS 5024♦ Stepladder -VAS 5085♦ Guide rods -T10093♦ Cable ties
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Note
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♦ Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted and obtain anti-theft coding if necessary. ♦ The engine is removed downwards together with the gearbox.
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Rep. gr.10 - Removing and installing engine
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♦ All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 WARNING
When doing any repair work, especially in the engine com‐ partment, pay attention to the following due to the cramped conditions: ♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions. ♦ Ensure that there is sufficient clearance to all moving or hot components. Procedure – With ignition switched off, disconnect earth strap from battery. One-piece engine cover
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a – Remove air filter housing with air mass meter and connecting ss pipe.
– Remove bolt -arrow A- and pull air filter housing upwards out of mounting. – Remove battery and battery tray.
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– Disconnect fuel supply and return lines as well as coolant line on cylinder head.
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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-.
1. Removing and installing engine
5
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 WARNING
♦ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! ♦ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! ♦ Wear eye and hand protection when performing any type of repair work on the fuel system! – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Assembly overview - Body - front . – Bring lock carrier into service position ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐ sition . – Drain coolant ⇒ page 123 . Vehicles with air conditioner AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r To prevent damage to condenser or to refrigerant lines/hoses, o eo h t ra au hoses are not stretched, kinked or bent. ensure that the lines sand c s
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– Remove poly V-belt ⇒ page 25 . – Remove air conditioner compressor ⇒ Heating, air condition‐ ing; Rep. gr. 87 ; Removing and installing compressor brack‐ et . – Secure air conditioner compressor to lock carrier so that re‐ frigerant lines/hoses are free of stress. – Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐ ing and installing alternator and poly V-belt . Continuation for all vehicles – Remove connecting pipes between charge air cooler and en‐ gine. – Unbolt left and right-hand drive shafts from gearbox ⇒ Run‐ ning gear, axles, steering; Rep. gr. 40 ; Removing and in‐ stalling drive shaft . Prote cted by c o p yri gh t. C op yi
– Release connector from engine control unit, disconnect con‐ nector. AG.
Rep. gr.10 - Removing and installing engine
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– Remove front exhaust pipe ⇒ page 255 .
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To facilitate removing and installing engine without opening re‐ frigerant circuit:
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Note
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– Open all cable guide fasteners
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– Pull off or disconnect all other electrical connections from en‐ gine and gearbox as necessary and lay to side. – Separate all connecting, coolant, vacuum and intake hoses from engine. Vehicles with manual gearbox
– Remove slave cylinder for hydraulic clutch. ⇒ 6-speed manual gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism; As‐ sembly overview - hydraulics . – Unbolt selector mechanism from gearbox ⇒ 6-speed manual gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism . Vehicles with four-wheel drive:
– Remove selector mechanism from gearbox ⇒ 6-speed man‐ ual gearbox 02Q, four-wheel drive; Rep. gr. 34 ; Repairing selector mechanism .
ProCarManuals.com
– Unbolt pendulum support -arrows-.
AG.
Continuation for all vehicles:
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– Remove front propshaft ⇒ Final drive 02D, 0AV; Rep. gr. 39 ; Assembly overview - repairing propshaft .
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– Separate pressure line for hydraulic clutch control.
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– Remove wiring harness from cable guide on longitudinal mem‐ ber and lay to side on engine.
Vehicles with particulate filter – Remove subframe ⇒ Running gear, axles, steering; Rep. gr. 40 ; Removing and installing subframe . – Remove right drive shaft ⇒ Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts . – Remove steering box ⇒ Running gear, axles, steering; Rep. gr. 48 ; Removing and installing steering box . Continuation for all vehicles: – Insert engine bracket -T10012- in engine and gearbox jack V.A.G 1383 A- . Note
Support pins must be secured to engine bracket -T10012- as shown. – Fit engine bracket -T10012- to cylinder block with M10 x 25/ 8.8 bolt and tighten to approx. 40 Nm. – Raise engine and gearbox slightly using engine and gearbox jack -V.A.G 1383 A- .
1. Removing and installing engine
7
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Note
To remove securing bolts, use stepladder -VAS 5085- .
– Unbolt assembly mounting on gearbox side from gearbox bracket -arrows-.
Note
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ProCarManuals.com
AG.
Rep. gr.10 - Removing and installing engine
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– Carefully lower engine with gearbox.
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.2
Removing engine (Touran)
Special tools and workshop equipment required ♦ Lifting tackle -2024 A♦ Engine bracket -T10012♦ Support clamp -VW 313♦ Engine and gearbox sup‐ port -VW 540♦ Workshop hoist -V.A.G 1202 A-
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s
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♦ Drip tray -V.A.G 1306-
1. Removing and installing engine
9
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ♦ Torque wrench -V.A.G 1331♦ Torque wrench -V.A.G 1332♦ Engine and gearbox jack V.A.G 1383 A♦ Spring-type clip pliers -VAS 5024♦ Stepladder -VAS 5085♦ Guide rods -T10093♦ Cable ties
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10
Rep. gr.10 - Removing and installing engine
AG.
♦ All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.
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♦ The engine is removed downwards together with the gearbox.
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♦ Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 WARNING
When doing any repair work, especially in the engine com‐ partment, pay attention to the following due to the cramped conditions: ♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant and refrigerant, brake lkswagen AG n AG. Voin fluid and vacuum) and electrical their original does po‐ agewiring ksw not l o sitions. gu yV b ed
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– Remove air filter housing with air mass meter and connecting pipe.
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– Remove plenum chamber bulkhead. ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
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– Remove engine cover. To do this, pull engine cover upwards abruptly at front -arrows A- and then pull forwards out of rear fastening -arrow B-.
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– Remove bolt -arrow A- and pull air filter housing upwards out of mounting. – Remove battery and battery tray. – Disconnect fuel supply and return lines as well as coolant line on cylinder head.
1. Removing and installing engine
11
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 WARNING
♦ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! ♦ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! ♦ Wear eye and hand protection when performing any type of repair work on the fuel system! – Remove noise insulation. ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . – Bring lock carrier into service position. ⇒ General body re‐ pairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier service position . – Drain coolant ⇒ page 123 Vehicles with air conditioner
To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent. To facilitate removing and installing engine without opening re‐ frigerant circuit: – Remove poly V-belt ⇒ page 25 . – Remove air conditioner compressor. ⇒ Heating, air condition‐ ing; Rep. gr. 87 ; Removing and installing compressor brack‐ et . AG. Volkswagen AG d oes not gu ara nte eo ra c
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Continuation for all vehicles
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– Remove connecting pipes between charge air cooler and en‐ gine. – Unbolt left and right-hand drive shafts from gearbox ⇒ Run‐ ning gear, axles, steering; Rep. gr. 40 ; Removing and in‐ stalling drive shaft . – Remove front exhaust pipe.
– Remove securing nuts -arrows- for engine control unit.
AG.
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Rep. gr.10 - Removing and installing engine
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– Release connector from engine control unit, disconnect con‐ nector.
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Note
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Open all cable guide fasteners -arrows-. – Remove wiring harness from cable guide on longitudinal mem‐ ber and lay to side on engine. – Pull off or disconnect all other electrical connections from en‐ gine and gearbox as necessary and lay to side. – Separate all connecting, coolant, vacuum and intake hoses from engine. – Remove slave cylinder for hydraulic clutch. ⇒ 6-speed manual gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism; As‐ sembly overview - hydraulics . – Unbolt selector mechanism from gearbox ⇒ 6-speed manual gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism . – Unbolt pendulum support -arrows-. Vehicles with particulate filter – Remove subframe ⇒ Running gear, axles, steering; Rep. gr. 40 ; Removing and installing subframe .
– Remove steering box ⇒ Running gear, axles, steering; Rep. gr. 48 ; Removing and installing steering box . . Volkswagen AG Continuation for all avehicles: gen AG do
-T10012- in
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Note
Support pins must be secured to engine bracket -T10012- as shown. – Fit engine bracket -T10012- to cylinder block with M10 × 25/ 8.8 bolt and tighten to approx. 40 Nm.
rrectness of i t to the co nform spec a t i h re o n in wit thi s
– Raise engine and gearbox slightly using engine and gearbox jack -V.A.G 1383 A- .
– Unbolt assembly mounting on engine side from engine bracket -arrows-.
To remove securing bolts, use stepladder -VAS 5085- .
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– Remove right drive shaft ⇒ Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts .
1. Removing and installing engine
13
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Unbolt assembly mounting on gearbox side from gearbox bracket -arrows-. – Carefully lower engine with gearbox. Note
Engine with gearbox must be guided carefully when lowered to prevent damage to bodywork.
1.3
Removing engine (Passat)
Special tools and workshop equipment required ♦ Lifting tackle -2024 A♦ Engine bracket -T10012-
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AG.
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Rep. gr.10 - Removing and installing engine
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14
rrectness of i t to the co nf o r m spec atio h re n in wit
♦ Drip tray -V.A.G 1306- or drip tray -VAS 6208-
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♦ Workshop hoist -V.A.G 1202 A- or workshop crane -VAS 6100-
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♦ Engine and gearbox sup‐ port -VW 540- or engine and gearbox support -VAS 6095-
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♦ Support clamp -VW 313-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ♦ Torque wrench (5... 50 Nm) -V.A.G 1331♦ Torque wrench (40... 200 Nm) -V.A.G 1332♦ Engine and gearbox jack V.A.G 1383 A♦ Spring-type clip pliers -VAS 5024-
rrectness of i t to the co nform spec a t i h re o n in wit thi s
Not illustrated:
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♦ Stepladder -VAS 5085-
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♦ Cable ties
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♦ Grease -G 000 100-
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♦ Engine bung set -VAS 6122-
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♦ Container for removed parts -V.A.G 1698-
1. Removing and installing engine
15
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Procedure
strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.
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♦
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d Note e nte is r o eo h ut ra a s Before carrying out further work, disconnect battery earth c s
♦ The engine is removed downwards together with the gearbox.
♦ It is advisable to remove the front wheels before beginning engine removal. The vehicle can then be lowered on hoist until the brake disc splash plates are just above the floor. This pro‐ vides the most ergonomic working position regarding acces‐ sibility of engine compartment components. ♦ All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.
♦ Some components cannot be removed, or removed only with difficulty, with the engine installed. Therefore, you should de‐ termine all defective components before removing engine and renew them while engine is removed.
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WARNING
AG.
When doing any repair work, especially in the engine com‐ partment, pay attention to the following due to the cramped conditions: ♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions. ♦ Ensure that there is sufficient clearance to all moving or hot components. – Read fault memories of all control units before removal ⇒ Di‐ agnosis tester VAS 5051; Guided fault finding; Vehicle system test or VAS 5052; Vehicle self-diagnosis . – With ignition switched off, disconnect earth strap from battery. One-piece engine cover For one-piece engine cover, pull engine cover abruptly upwards at front and right -arrows A-, then pull forwards out of rear fas‐ tening -arrow B-.
16
Rep. gr.10 - Removing and installing engine
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♦ To prevent damage to removed components, place them in the container for removed parts -V.A.G 1698- .
rrectness of i t to the co nform spec at i h re o n wit in t his
♦ Leave ignition key in ignition lock to prevent steering lock from engaging.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Two-piece engine cover
– Remove air filter housing together with air mass meter and connecting pipe. ht rig py Co t.
– Remove battery and battery tray.
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– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐ screen wiper system; Removing and installing wiper arms . agen lksw Vo by
– Remove plenum chamber cover ⇒ General body repairs, ex‐ terior; Rep. gr. 64 ; Removing and installing plenum chamber cover. AG.
ProCarManuals.com
– Remove bolt -arrow A- and pull air filter housing upwards out of mounting.
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n AG. Volkswagen AG do es n wage s k l otcover o For two-piece engine cover, first pull outer engine abruptly gu yV b ara d upwards at -arrows-, then pull inner engine cover abruptly e nte up‐ is r eo wards at -arrows-. tho ra au c s s
Vehicles without anti-theft alarm system – Release and disconnect connector from engine control unit ⇒ page 251 , Removing and installing engine control unit. Vehicles with anti-theft alarm system – Release and disconnect connector from engine control unit ⇒ page 240 , Removing and installing engine control unit with theft protection. Continuation for all vehicles – Remove feed-through for engine control unit wiring harness -arrow-.
1. Removing and installing engine
17
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Open all cable guide fasteners -arrows-. – Remove wiring harness from cable guide on longitudinal mem‐ ber and lay to side on engine.
WARNING
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♦ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
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♦ Wear eye and hand protection when performing any type of repair work on the fuel system!
– Remove wire from central electrics -arrow-.
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– Unscrew earth cable from longitudinal member. – Pull off or disconnect all other electrical connections from en‐ gine and gearbox as necessary and lay to side. – Separate all connecting, vacuum and intake hoses from en‐ gine. – Remove selector mechanism from gearbox ⇒ 5-speed man‐ ual gearbox 0A4; Rep. gr. 34 ; Repairing selector mechanism . – Remove hydraulic clutch slave cylinder ⇒ 5-speed manual gearbox 0A4; Rep. gr. 30 . – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Assembly overview - Body - front . – Bring lock carrier into service position ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐ sition . – Pull connector off oil level and oil temperature sender -G266- .
18
Rep. gr.10 - Removing and installing engine
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♦ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!
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– Pull off fuel hose -3-.
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– Pull retainer for oil level and oil temperature sender -G266connector off subframe. – Drain coolant ⇒ page 123 . es, in part or in w l purpos hole ercia , is n m ot com
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– Completely remove exhaust pipes from auxiliary heater ⇒ Heating, air conditioning; Rep. gr. 82 .
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AG. Volkswagen AG d agen oes ksw no l o V gu 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ Golf 2004 ➤ , Golf tPlus by ara d e nte is r 4-cylinder diesel o e o engine (1.9 l engine) - Edition 08.2010 h ut ra a c s s
– Pull off coolant hoses on coolant pipes to supplementary heater. – Separate all other coolant hoses from engine. – Unbolt left and right drive shafts from gearbox ⇒ Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts . – Unbolt pendulum support -arrows-.
– Remove poly V-belt ⇒ page 25 . ht rig py Co t.
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– Secure air conditioner compressor to lock carrier so that re‐ frigerant lines/hoses are free of stress. agen lksw Vo by
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ProCarManuals.com
– Remove air conditioner compressor from ancillary bracket ⇒ Heating, air conditioning; Rep. gr. 87 ; Removing and in‐ stalling compressor bracket .
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To facilitate removing and installing engine without opening re‐ frigerant circuit:
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 – Remove front exhaust pipe ⇒ page 255 . – Unscrew rear coolant pipe ⇒ page 120 . – Tighten engine bracket -T10012- on cylinder block with se‐ curing nut and M10 × 25/ 8.8 bolt to approx. 40 Nm. – Insert engine bracket -T10012- in engine and gearbox jack V.A.G 1383 A- . – Raise engine and gearbox slightly using engine and gearbox jack -V.A.G 1383 A- .
1. Removing and installing engine
19
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Unbolt assembly mounting on engine side from engine bracket -arrows-. Note
To remove securing bolts, use stepladder -VAS 5085- .
– Unbolt assembly mounting on gearbox side from gearbox bracket -arrows-. Note
To remove securing bolts, use stepladder -VAS 5085- .
Note
Engine with gearbox must be guided carefully when lowering to prevent damage to bodywork. AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra When working on the engine, a secure it to support clamp -VW 540c s s of the assembly stand using engine and gearbox support -VW
Securing engine to assembly stand
313- .
Procedure
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– Disconnect gearbox.
– Attach lifting tackle -2024 A- as shown and raise engine out of engine and gearbox jack -V.A.G 1202 A- using workshop crane -V.A.G 1383 A- . Belt pulley end: 2nd hole in hook rail at position 1 Flywheel end: 4th hole in hook rail at position 8 WARNING
The hooks and locating pins must be secured with locking pins.
♦ The holes marked with 1 … 4 of the support bar point to the belt pulley. c o p yri gh t. C op yi
♦ The holes in the hook rails are counted up from the hook.
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– Secure engine on support clamp -VW 540- using engine and gearbox jack -VW 313- .
20
Rep. gr.10 - Removing and installing engine
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1.4
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– Carefully lower engine with gearbox.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.5
Notes on installing
Installation is carried out in the reverse order. When installing, note the following: – Check clutch release bearing for wear and renew if necessary. – Lubricate splines of input shaft lightly with G 000 100. – Check whether dowel sleeves for centring engine and gearbox are in cylinder block and install if necessary. When installing engine, ensure correct position of assembly mounting: – On belt pulley side, ensure that there is a distance -a- of at least 10 mm between engine support and right longitudinal member. – The side surface of the engine support -2- should be located parallel to the support arm -1-. Dimension -x- must be identical at top and bottom.
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Note
♦ Specified torques for assembly mountings ⇒ page 22 ♦ Electrical connections and routing. ⇒ Electrical system; Rep. gr. 97 Procedure
– Install pendulum support. – Install drive shafts ⇒ Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts . – Install front exhaust pipe ⇒ page 255 . Vehicles with manual gearbox Prote cted by c o p yri gh t. C op yi
– Remove selector mechanism from gearbox ⇒ 6-speed man‐ ual gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .
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Vehicles with four-wheel drive:
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– Install slave cylinder for hydraulic clutch ⇒ 6-speed manual gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism; As‐ sembly overview - hydraulics .
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– Ensure that the edges of the support arm on the gearbox as‐ ss sembly mounting -2- and gearbox support -1- are parallel with one another. Dimension -x- must be identical at top and bot‐ tom.
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Note
– 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 .
1. Removing and installing engine
21
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r On vehicles with particulate filter install subframe ⇒ Running o eo h ra gear, axles, steering; Rep. gr. 40 s aut c s
Continuation for all vehicles: –
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– Install air conditioner compressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Removing and installing compressor bracket. – Install poly V-belt ⇒ page 26 .
– Install noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Assembly overview - Body - front . – Install engine control unit ⇒ page 239 . – Install plenum chamber bulkhead ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulk‐ head . – Fill coolant system with coolant ⇒ page 123 . – Carry out road test and then read fault memory ⇒ page 239 .
ProCarManuals.com
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.
22
10 Nm 20 Nm 45 Nm 60 Nm
Rep. gr.10 - Removing and installing engine
AG.
1.6
M6 M8 M10 M12
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Bolts, nuts
Specified torque
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Threaded connection
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Specified torques
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– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Removing and installing alternator and poly V- belt .
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Pendulum support Always note the size and strength rating of bolt. Different specified torques are valid. Caution
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s 02Q Heli Coil in‐ s
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From model year 08, in manual gearboxes serts are installed in the threaded connections to pendulum support. Difference ⇒ Rep. gr. 34
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For these and all other gearboxes bolts with strength rating 10.9 must be used. If Heli Coil inserts are not fitted in manual gearboxes 02Q, use bolts with strength rating 8.8 and the specified torques. Bolt -A-
M10 x 35 strength rating 8.8: turn 40 Nm + 90° further M10 x 35 strength rating 10.9: turn 50 Nm + 90° further Always renew after removing
M10 x 75 strength rating 8.8: turn 40 Nm + 90° further M10 x 75 strength rating 10.9: turn 50 Nm + 90° further
Do not tighten until pendulum support is bolted on gearbox
AG.
100 Nm + 90° turn
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Bolt -C-
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Always renew after removing
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Bolt -B-
Always renew after removing
1. Removing and installing engine
23
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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 Note
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
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
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6 - 25 Nm
Rep. gr.13 - Crankshaft group
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5 - Poly V-belt tensioning ele‐ ment ❑ Swing with ring spanner to slacken poly V-belt.
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4 - Bracket ❑ For alternator and air conditioner compressor.
AG.
3 - Alternator
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2 - 25 Nm
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1 - Belt pulley and vibration damper ❑ Can only be installed in one position, holes are offset.
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Assembly overview - poly V-belt drive
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1.1
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If large quantities of swarf or metal particles (caused, for example, by partial seizure of the crankshaft or conrod bearings) are found in the engine oil when performing repairs, clean the oil passages thoroughly and renew the engine oil cooler in order to prevent subsequent damage.
1.1.1
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Removing poly V-belt
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Special tools and workshop equipment required ♦ Locking pin -T10060 A-
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♦ 16 mm open-end spanner -T 10241-
– Remove noise insulation. ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . – Remove lower part of front right wheel housing liner ⇒ Gen‐ eral body repairs, exterior; Rep. gr. 66 ; Removing and in‐ stalling wheel housing liner . WARNING
♦ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! ♦ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! ♦ Wear eye and hand protection when performing any type of repair work on the fuel system! – Golf, Golf Plus, Touran: Pull fuel filter out of bracket and place it with hoses to one side.
1. Dismantling and assembling engine
25
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Only Passat: Separate push-fit couplings of fuel lines -arrows-. Note
Do this by lifting catch of push-on connectors. All other vehicles continued – –
– Lock tensioning element using locking pin -T10060 A- . r fo ng
– Remove poly V-belt.
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1.1.2
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The open-end spanner 16 mm -T 10241- is particularly well suited to relieve tension.
Installing poly V-belt
– Install in reverse order. Note ♦ Ensure, before installing poly V-belt, that all ancillaries (alter‐ nator, air conditioner compressor) are secured tightly. ♦ When fitting poly V-belt, check direction of belt rotation and ensure proper seating of belt in pulleys. ♦ Lastly, place poly V-belt over alternator. – Only Passat: Install fuel filter. Specified torque: 10 Nm. After completing repairs always:
26
Rep. gr.13 - Crankshaft group
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– Swing tensioning element in direction of arrow to remove ten‐ sion from poly V-belt.
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ (1.9 l engine) - Edition 08.2010
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diesel engine AG do n AG. Volkswagen4-cylinder es n wage s k l ot g o V ua by ran – Start engine and edcheck belt running. tee ris o h t or u air conditioner compressor Belt drive without ac a ss
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Belt drive with air conditioner compressor
1. Dismantling and assembling engine
27
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.2
Assembly overview - toothed belt drive
1 - Toothed belt guard upper part 2 - 100 Nm 3 - 25 Nm 4 - Camshaft pulley
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7 - Stud ❑ 15 Nm
8 - Rear toothed belt guard 9 - 25 Nm
10 - Sealing grommet ❑ Renew if damaged. 11 - 20 Nm + turn (45°)
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15 - Coolant pump ❑ Removing and installing ⇒ page 128
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14 - Idler roller
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13 - 20 Nm
16 - Crankshaft toothed belt pulley 17 - 120 Nm + turn (90°) ❑ Renew. ❑ Use counterhold tool -3099- to loosen and tighten. ❑ Do not additionally oil or grease thread and shoulder. ❑ Turning further can be done in several stages. 18 - 15 Nm 19 - Toothed belt guard lower part 20 - Belt pulley and vibration damper ❑ Can only be installed in one position, holes are offset. 21 - 10 Nm + turn (90°) ❑ Renew.
28
Rep. gr.13 - Crankshaft group
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12 - Tensioning roller ❑ Remove engine support in order to remove and install ⇒ page 29 .
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6 - 10 Nm ❑ Renew.
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5 - Hub ❑ With sender wheel n AG. Volkswagen AG do ❑ Use counterhold tool es n wage s k l ot g T10051- to loosen andy Vo ua b d ran tighten. ir se tee o h t or ❑ To remove, use u puller ac a T10052- . ss ❑ Removing and installing ⇒ page 97 , remov‐ ing and installing camshaft.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 22 - Cover 23 - Toothed belt ❑ Mark direction of rotation before removing. ❑ Check for wear. ❑ Do not kink. ❑ Removing, installing and tensioning ⇒ page 66 . 24 - 40 Nm + turn (180°) ❑ Renew. 25 - Toothed belt guard centre part 26 - Engine bracket
1.3
Removing and installing engine support
Special tools and workshop equipment required ♦ Support bracket -10 - 222 A♦
For two-piece engine cover, first pull outer engine cover abruptly upwards at -arrows-, then pull inner engine cover abruptly up‐ wards at -arrows-.
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Two-piece engine cover
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– To do this, pull engine cover upwards abruptly at front and right -arrows A- and then pull forwards out of rear fastening -arrow B-.
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–
n AG. Volkswagen AG do es n wage s k l ot g o Torque wrench -V.A.G 1331yV ua b d ran ir se tee o h Remove engine cover. t or u ac a ss
1. Dismantling and assembling engine
29
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Separate push-on connectors of fuel lines -arrows-. Note ♦ Do this by pressing in catch of push-on connectors. ♦ Ensure that no fuel escapes (use a cloth). – Lay fuel filter with hoses to side. – Disconnect coolant hose from top of expansion tank. – Remove expansion tank and lay it to side. – Remove charge air pipe between charge air cooler and tur‐ bocharger. – Carefully cover or seal open ends. Golf, Golf Plus and Touran:
– Remove securing bolts from assembly mounting/engine sup‐ port -arrows- and remove complete assembly mounting. Note
♦ The assembly mounting may only be removed if the engine is supported with support bracket 10-222A! ♦ The engine support must only be loosened when the assembly mounting has been removed. WARNING
30
Rep. gr.13 - Crankshaft group
AG.
– Remove front right wheel housing liner.
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– Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐ tion .
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When raising and lowering engine using support bracket -10-222A- , ensure that no components or hoses are damaged, strained or torn off.
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– Fit engine support bracket -10-222A- with adapters -10-222A/ 13- and take up weight of engine in installation position.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Raise engine with support bracket -10-222A- until both upper bolts of engine support can be loosened and removed. – Lower engine with support bracket -10-222A- until lower bolt can be loosened and removed. – Remove engine support upwards. Installing
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The tightening sequence and specified torques for the engine support securing bolts must always be followed. Otherwise the engine support can be stressed and it can break.
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– Insert new bolts and
– 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- . II: Engine support with greater clearance to engine Note
– Install assembly mounting between engine and body, renew securing bolts ⇒ page 22 .
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Before installing assembly mounting, tighten all engine support bolts to prescribed torque.
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I : Engine support with less clearance to engine
– 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. Dismantling and assembling engine
31
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.4
Assembly overview - crankcase
1 - Cylinder block ❑ Removing and installing sealing flange and fly‐ wheel ⇒ page 33 . ❑ Removing and installing crankshaft ⇒ page 48 . ❑ Dismantling and assem‐ bling pistons and con‐ rods ⇒ page 48 2 - Seal ❑ Renew.
4 - 15 Nm + turn (90°) ❑ Renew. ❑ First fit upper left and lower right bolts and then tighten all 4 bolts in diagonal sequence. 6 - 20 Nm
7 - Connection ❑ For thermostat. 8 - 15 Nm 9 - O-ring ❑ Renew.
10 - Thermostat ❑ Removing and installing ⇒ page 130 ❑ Observe installation position ⇒ page 130 , removing and installing thermostat. ❑ Checking: heat thermostat in water. ❑ Opening begins at approx. 85 °C. ❑ Ends at approx. 105 °C ❑ Opening lift at least 7 mm.
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5 - Bracket
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11 - Hexagon bolt ❑ Tightening sequence and torque specifications ⇒ Heating, air conditioning; Rep. gr. 87 ; Removing and installing compressor bracket .
14 - 25 Nm 15 - Oil sump ❑ Clean sealing surface before fitting. ❑ Install with silicone sealant -D 176 404 A2- . 16 - 15 Nm
32
Rep. gr.13 - Crankshaft group
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13 - Poly V-belt tensioning element
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12 - Bracket ❑ For alternator, if air conditioner compressor is fitted
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3 - Oil filter bracket ❑ Dismantling and assem‐ bling ⇒ page 109 .
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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 .
Assembly overview - sealing flanges and flywheel
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1 - Seal ❑ Do not additionally oil or grease the oil seal seal‐ ing lip. ❑ Before installing, re‐ move deposits from crankshaft journal using a clean cloth. ❑ Renewing crankshaft oil seal - belt pulley end ⇒ page 36 .
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3 - Cylinder block ❑ Removing and installing crankshaft ⇒ page 48 . ❑ Dismantling and assem‐ bling pistons and con‐ rods ⇒ page 48
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2 - Sealing flange ❑ Must seat on dowel sleeves. ❑ Removing and installing ⇒ page 38 ❑ Install with silicone sealant -D 176 404 A2⇒ page 38 .
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Repairing clutch ⇒ 6-speed manual gearbox 02S; Rep. gr. 30 ; Repairing clutch .
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Note
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2.1
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4 - 60 Nm + turn (90°) ❑ Renew. 5 - Flywheel ❑ To remove and install flywheel, counterhold with 3067. ❑ Removing and installing dual-mass flywheel ⇒
2. Removing and installing sealing flange and flywheel
33
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 page 34 . 6 - Intermediate plate ❑ Must sit on dowel sleeves ❑ Do not damage or bend when assembling. 7 - 15 Nm ❑ Renew. 8 - Sealing flange with oil seal ❑ Renew complete with oil seal and sender wheel only. ❑ Removing and installing ⇒ page 40 9 - Removing and installing engine speed sender -G28- ⇒ page 46 . ❑ Loosen and tighten using commercially available ball-ended hexagon key socket ❑ Specified torque: 5 Nm.
2.2
Removing and installing dual-mass fly‐ wheel
Special tools and workshop equipment required
ProCarManuals.com
♦ Counterhold -3067-
Removing
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Caution
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To prevent damage to the dual-mass flywheel when removing, the bolts -B- must not be removed with an impact wrench or similar. The bolts may only be removed by hand. – Mark position of dual-mass flywheel in relation to engine. – Rotate the dual-mass flywheel -A- so that the bolts -B- align centrally with the holes -arrows-. – When unscrewing bolts -B-, ensure that none of the bolt heads come into contact with the dual-mass flywheel -arrows-. The flywheel will otherwise be damaged when the bolts are un‐ screwed further.
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Rep. gr.13 - Crankshaft group
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34
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– Remove moving and installing gearbox .
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Insert counterhold -3067- in hole on cylinder block -B-. AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a reverse sorder. When installing, c s
– Unscrew dual-mass flywheel.
Specified torque ⇒ Item 4 (page 33) .
– Use new bolts for securing.
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– Insert counterhold -3067- in hole on cylinder block -A-.
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Installation is carried out in the note the following:
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Installing
2. Removing and installing sealing flange and flywheel
35
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
Renewing crankshaft oil seal - belt pulley end
♦ Assembly tool -T10053+3-
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ProCarManuals.com
♦ Torque wrench V.A.G 1332-
– Remove toothed belt. ⇒ page 66 – Remove crankshaft toothed belt pulley. To do this, lock toothed belt pulley using counterhold -3099- . Note
When bolting on counterhold, place two washers between toothed belt pulley and counterhold. – To guide oil seal extractor -3203- , screw central bolt by hand into crankshaft to stop. – Unscrew inner part of oil seal extractor two turns (approx. 3 mm) out of outer part and lock with knurled screw. – Oil threaded head of oil seal extractor.
36
Rep. gr.13 - Crankshaft group
AG.
Removing
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2.3.1
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♦ Torque wrench V.A.G 1331-
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♦ Oil seal extractor -3203-
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♦ Counterhold tool -3099-
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2.3
– Loosen knurled screw and turn inner part against crankshaft until oil seal is pulled out.
2.3.2
Installing
Note
The oil seal sealing lip must not be additionally oiled or greased.
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– Slide oil seal over guide sleeve onto crankshaft journal.
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– Place guide sleeve -T10053/1- onto crankshaft journal.
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– Remove oil residue from crankshaft journal using clean cloth.
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– Using great ble into seal.
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– Press oil seal in to stop using assembly tool -T10053- and centre bolt. – Install and tighten toothed belt ⇒ page 66 .
2. Removing and installing sealing flange and flywheel
37
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
2.4
Removing and installing sealing flange - pulley end
Special tools and workshop equipment required ♦ Counterhold tool -3099♦ Assembly tool -T10053♦ Torque wrench V.A.G 1331♦ Torque wrench V.A.G 1332♦ Hand drill with plastic brush attachment ♦ Silicone sealant -D 176 404 A-
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– Remove toothed belt. ⇒ page 66
– Remove crankshaft toothed belt pulley. To do this, lock toothed belt pulley using counterhold -3099- .
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Note
When bolting on counterhold, place two washers between toothed belt pulley and counterhold. – Drain engine oil. – Remove sump ⇒ page 105 . – Pull off front sealing flange. – Remove sealing flange; if necessary, loosen by applying light blows with a rubber-headed hammer. – Remove sealant residue from cylinder block with a flat scraper.
38
Rep. gr.13 - Crankshaft group
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ProCarManuals.com
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2.4.1
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♦ Flat scraper
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove residual sealant from sealing flange using a plastic rotary brush (wear eye protection). – Clean sealing surfaces. They must be free of oil and grease.
2.4.2
Installing
Note
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– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3 mm). Note
♦ The sealant bead must not be thicker than 2… 3 mm, other‐ wise excess sealant can enter sump and block the strainer in oil pump suction pipe, as well as drip onto the sealing surface of crankshaft oil seal. ♦ Before applying sealant bead, cover sealing surface of oil seal with a clean cloth. – Apply silicone sealant bead as shown to the clean sealing sur‐ face of sealing flange.
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– Install sealing flange immediately and tighten all bolts lightly.
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When fitting sealing flange with oil seal installed use guide sleeve -T10053/1- . AG.
ProCarManuals.com
♦ The sealing flange must be installed within 5 minutes of ap‐ plying the silicone sealant.
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♦ Observe expiry
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– 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. Removing and installing sealing flange and flywheel
39
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
2.5
Renewing crankshaft sealing flange flywheel end
Special tools and workshop equipment required ♦ Assembly tool -T10134-
♦ Torque wrench -V.A.G 1331♦ Socket -V.A.G 1332/11♦ 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 es n w ot g removed. olks yV
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– Remove intermediate plate.
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– Remove flywheel.
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– Set engine to TDC No. 1 cylinder ⇒ page 66 , Removing and installing toothed belt. – Remove sump ⇒ page 105 .
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– Remove engine speed sender -G28- -arrow- using a commer‐ cially available ball-ended hex key socket ⇒ page 46 . – Unscrew sealing flange securing bolts. Note
Sealing flange and sender wheel are pressed off the crankshaft together using three M 6 x 35 mm bolts.
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Rep. gr.13 - Crankshaft group
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♦ Vernier gauge
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Screw three M 6 x 35 mm bolts into threaded holes -arrowsof sealing flange. – Screw bolts alternately (max. 1/2 turn 180° for each bolt) into sealing flange and press sealing flange together with sender wheel off crankshaft.
2.5.2
Pressing in sealing flange with sender wheel
Note
♦ 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 olksw en AGinVthe agen AG doe to the crankshaft by a guide pin inserted into aaghole s no ksw l o t gu V crankshaft. by a
B - Hexagon nut
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C - Assembly housing D - Locating pin
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
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G - Guide pin for petrol engines (red knob)
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A - Clamping surface
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♦ 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.
2. Removing and installing sealing flange and flywheel
41
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
2.5.3
A - Assembling seal with sender wheel on assembly tool -T10134-
– Screw in hexagon nut -B- to just before clamping surface -Aof threaded spindle.
– Clamp assembly device -T10134- in a vice on clamping sur‐ face -A- of threaded spindle. – Press assembly housing -C- downwards until it lies on hexagon nut -B- -arrow-.
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 n AG. Volkswagen AG do es n wage twisted. o olks
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– Locating hole -A- on sender wheel -C- must align with marking -B- on sealing flange.
– Place sealing flange with front side downwards on a clean flat surface.
AG.
Rep. gr.13 - Crankshaft group
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42
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Note
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
Ensure sealing flange lies flat on assembly tool.
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Note
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– Place sealing flange with front side on assembly tool -T10134so that locating pin -B- can be inserted in sender wheel hole -A-. ht rig py Co t.
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– Upper edge of sender wheel and front edge of sealing flange must align -arrows-.
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– Push sealing lip support ring -A- downwards in direction of ar‐ row until it lies on flat surface.
– Push sealing flange and support ring for sealing lip -B- against surface of assembly tool -T10134- whilst tightening the three knurled screws -A- so that locating pin cannot slide out of sender wheel hole. Note
When installing sealing flange, ensure that sender wheel remains fixed in assembly device.
2.5.4
B - Attaching assembling tool -T10134with sealing flange on crankshaft flange
•
Crankshaft flange must be free of oil and grease.
•
Engine positioned at TDC No. 1 cylinder.
2. Removing and installing sealing flange and flywheel
43
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Screw hexagon nut -B- to end of threaded spindle. AG. – Press threaded spindle of assembly tool -T10134- in sdirection agen k w l o V of arrow, until hexagon nut -B- lies against assembly housing by ed -A-. ris
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au side of crankcase – Align flat side of assembly housing on sump ss sealing surface.
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– Secure assembly tool -T10134- to crankshaft flange using hexagon socket head bolts -A-. Note
– Push assembly housing -C- by hand in direction of arrow until sealing lip support ring -B- contacts crankshaft flange -A-. – Push guide pin for diesel engines (black knob) -D- into hole in crankshaft. This ensures that the sender wheel reaches its fi‐ nal installation position. Note
The guide pin for petrol engines (red knob) -F- must not be in‐ serted in threaded hole of crankshaft. – Hand-tighten both hexagon socket head bolts of assembly tool. – Screw hexagon nut -E- onto threaded spindle by hand until it lies on assembly housing -C-.
44
Rep. gr.13 - Crankshaft group
AG.
C - Bolting assembly tool -T10134- onto crankshaft flange
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– To guide sealing flange, screw two M 7 × 35 mm bolts -A- into cylinder block.
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Screw hexagon socket head bolts -A- into crankshaft flange (ap‐ prox. 5 full turns).
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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2.5.6
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– Tighten hexagon nut of assembly tool -T10134- to 35 Nm us‐ ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G 1332/11- .
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Note
After hexagon nut is tightened to 35 Nm, a small air gap must still be present between cylinder block and sealing flange.
2.5.7
E - Checking sender wheel installation position on crankshaft
– Screw hexagon nut -E- to end of threaded spindle.
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– Remove assembly tool -T10134- .
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– Screw the three knurled screws -B- out of sealing flange.
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– Remove the two bolts -A- from cylinder block.
– The sender wheel is in the correct installation position on the crankshaft if a gap -a- = 0.5 mm exists between crankshaft flange -A- and sender wheel -B-.
– Set vernier gauge on crankshaft flange. – Measure distance -a- between crankshaft flange and sender wheel. If measurement -a- is too small: – Press sender wheel further. ⇒ page 46 If dimension -a- is attained: – Tighten new securing bolts for sealing flange to 15 Nm using alternate and diagonal sequence.
2. Removing and installing sealing flange and flywheel
45
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Install engine speed sender -G28- -arrow- and tighten secur‐ ing bolt to 5 Nm. – Install sump ⇒ page 105 . – Install intermediate plate. – Install flywheel using new bolts. Tighten securing bolts to 60 Nm + turn 90° further.
2.5.8
F - Re-pressing sender wheel
– Secure assembly tool -T10134- to crankshaft flange using hexagon socket head bolts -A-. – Hand tighten both hexagon socket head bolts.agen AG. Volkswagen AG do
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– Screw hexagon nut -E- onto threaded spindle by hand until it lies on assembly housing -C-.
– Tighten hexagon nut for assembly tool -T10134- to 45 Nm. – Check installation position of sender wheel on crankshaft again. ⇒ page 45
2.6
Removing and installing engine speed sender -G28-
Special tools and workshop equipment required
46
Rep. gr.13 - Crankshaft group
AG.
If dimension -a- is too small again:
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– Check installation position of sender wheel on crankshaft again. ⇒ page 45
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ♦ Hexagon key extension, 4 mm -T10370-
♦ Or commercially available ball-ended hexagon key socket, 5 mm . Volkswag Note
– Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐ tion . – Clamp off coolant hoses at engine oil cooler using hose clip and pull off hoses. – Remove oil filter bracket. – Remove securing bolt -arrow- and pull out engine speed sender -G28- . Installation is performed in the reverse order, observing the fol‐ lowing: specified torque for engine speed sender -G28- securing bolt: 5 Nm.
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2. Removing and installing sealing flange and flywheel
47
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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
2 - 65 Nm + turn (90°) ❑ Renew. ❑ To measure radial clear‐ ance, tighten to 65 Nm but not further.
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3 - Bearing cap ❑ Bearing cap 1: pulley end. ❑ Bearing cap 3 with re‐ cesses for thrust wash‐ ers. ❑ Bearing shell retaining lugs in cylinder block and bearing caps must align.
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4 - Bearing shell 3 ❑ For bearing cap without oil groove. ❑ For cylinder block with oil groove. 5 - Thrust washer ❑ For bearing cap 3. ❑ Note fixing arrange‐ ment.
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6 - Crankshaft ❑ Axial clearance new: 0.07 … 0.17 mm wear limit: 0.37 mm ❑ Check radial clearance with Plastigage new: 0.03…0.08 mm, wear limit: 0.17 mm ❑ Do not rotate crankshaft when checking radial clearance. ❑ Crankshaft dimensions ⇒ page 48 .
(Dimensions in mm)
48
Rep. gr.13 - Crankshaft group
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Crankshaft dimensions
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7 - Thrust washer ❑ For cylinder block, bearing 3
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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).
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Honing dimen‐ sion
Main journal ∅
Basic dimension 54.00
3.1.2
-0.022 -0.042
Conrod journal ∅ 47.80
-0.022 -0.042
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- .
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- This gearbox can be identified by the gearbox oil cooler.
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7-speed dual clutch gearbox: Always renew needle bearing when removing engine or gearbox.
3. Crankshaft
49
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 1 - -1- Kukko 21/2 2 - Centring mandrel -3176-
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3 - Drift -VW 207 C-
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Rep. gr.13 - Crankshaft group
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Pulling needle bearing out:
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Pull out needle roller bearing using Kukko 21/2, adapter T10055/3- and puller -T10055- .
7-speed dual clutch gearbox
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Special tools, testers, measuring instruments and auxiliary items required
3. Crankshaft
51
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 1 - -1- Kukko 21/2 and -4Kukko 22/1 2 - Centring mandrel -31763 - Drift -VW 207 C-
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Gearbox is separated from engine
Pulling needle bearing out: – Pull out using commercially available puller -A-, e.g. Kukko 21/2 and Kukko 22/1. Installing
52
Rep. gr.13 - Crankshaft group
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – 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.
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Driving depth: Dimension -a- = 1.5 to 1.8 mm.
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3. Crankshaft
53
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
4
Pistons and conrodsolkswagen AG
. Volkswagen AG
Checking piston projection at TDC ⇒ page 56 . Piston and cylinder dimensions ⇒ page 57 .
Assembly overview - pistons and conrods
1 - Piston rings ❑ Offset gaps by 120°. ❑ Use piston ring pliers to remove and install. ❑ „TOP“ faces towards piston crown. ❑ Checking ring gap ⇒ page 57 . ❑ Checking ring-to-groove clearance ⇒ page 58 .
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2 - Piston ❑ With combustion cham‐ ber. ❑ Mark installation posi‐ tion and cylinder num‐ ber. ❑ Installation position and allocation of piston to cylinder ⇒ page 58 . ❑ Arrow on piston crown points to belt pulley end. ❑ Install using piston ring clamp. ❑ If piston skirt is cracked, renew piston. ❑ Checking piston projec‐ tion at TDC ⇒ page 56 . 3 - Piston pin ❑ If difficult to remove, heat piston to 60 °C. ❑ Remove and install us‐ ing drift -VW 222- . 4 - Circlip
5 - Conrod ❑ Mark cylinder allocation -A- with coloured pen. ❑ Installation position: Marking -B- faces towards pulley end. ❑ With industrially cracked conrod cap. 6 - Bearing shell ❑ Note installation position.
54
Rep. gr.13 - Crankshaft group
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4.1
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Piston rings, cylinder bore and piston installation position ⇒ page 57
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⇒ page 54 .
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yV db Assembly overview - pistons and conrods ise r tho au55 . Separating new conrod ⇒ page s s
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐ cation: Black line on bearing surface in area of joint. ❑ Do not interchange used bearing shells. ❑ Insert bearing shells centrally. ❑ Check for secure seating. ❑ Axial clearance, wear limit: 0.37 mm. ❑ Check radial clearance with Plastigage: Wear limit: 0.08 mm, do not rotate crankshaft when checking radial clearance 7 - Cylinder block ❑ Checking cylinder bores ⇒ page 58 . ❑ Piston and cylinder dimensions ⇒ page 57 .
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11 - Conrod bolt, 30 Nm + turn (90°) ❑ Renew. ❑ Oil threads and contact surface. ❑ Use old bolt for measuring radial clearance.
4.2
Separating new conrod
– Lightly clamp the conrod in a vice using aluminium vice clamps, as shown in the illustration.
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♦ To prevent damage to the conrod, only clamp conrod in lightly.
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– Mark cylinder allocation of conrod ⇒ Item 5 (page 54)
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10 - 25 Nm ❑ Insert without sealant.
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Note
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9 - Oil spray jet ❑ For piston cooling.
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♦ Clamp conrod in below the marked line. – Unscrew the two bolts -arrows- approx. 5 turns.
4. Pistons and conrods
55
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Using a plastic hammer, carefully knock against conrod bear‐ ing cap -arrow- until it is loose.
4.3
Checking piston projection at TDC
Special tools and workshop equipment required
Test procedure Note
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♦ Dial gauge
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♦ End dimension plate -VW 385/17-
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Rep. gr.13 - Crankshaft group
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If different values are determined during the projection measure‐ ment, use the largest dimension for selecting the gasket.
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♦ Measuring bridge -VW 382/7-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Piston projection at TDC must be measured when installing new pistons or a short engine. Install the appropriate cylinder head gasket depending upon piston projection, according to following table: Note
Turn engine clockwise to measure piston projection at TDC. Piston projection
Identification Holes/notches
0.91 mm … 1.00 mm 1.01 mm … 1.10 mm 1.11 mm … 1.20 mm
1 2 3
Cylinder head gasket identification ♦ Part No. = arrow 1 ♦ Production control code = arrow 2 (can be disregarded)
4.4
Piston and cylinder dimensions
Honing dimension
79.72 79.97
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79.76 80.01
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Piston rings, cylinder bore and piston in‐ stallation position
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Basic dimen‐ sion Stage I Stage II
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♦ Holes = arrow 3
4. Pistons and conrods
57
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Push piston ring squarely from above down to approx. 15 mm from bottom end of cylinder. Piston ring dimensions in mm 1. compression ring 2. compression ring Oil scraper ring
New
Wear limit
0.20 ... 0.40 0.20 ... 0.40 0.25 ... 0.50
1.0 1.0 1.0
Checking ring-to-groove clearance
Special tools and workshop equipment required ♦ Feeler gauges – Clean ring groove before checking. Piston ring dimensions in mm
Wear limit
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Checking cylinder bores
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Special tools and workshop equipment required ♦ Inside caliper 50 … 100 mm – Take measurements at 3 positions in both transverse -A- and longitudinal -B- directions, as illustrated. Difference between actual and nominal diameter max. 0.10 mm. Note
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Piston installation position and allocation of piston to cylinder Piston in cylinders 1 and 2: Larger inlet valve recess -arrows- towards flywheel. Piston in cylinders 3 and 4: Larger inlet valve recess -arrows- towards belt pulley end.
58
Rep. gr.13 - Crankshaft group
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Cylinder bores must not be measured when cylinder block is mounted on a repair stand with engine support bracket -VW 540- , as measurements may then be incorrect.
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1. compression ring 2. compression ring Oil scraper ring
New
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note ♦ New piston allocation to cylinders is shown by a coloured marking on piston crown. ♦ Piston for cylinders 1 and 2: marked 1/2
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♦ Piston for cylinders 3 and 4: marked 3/4
4. Pistons and conrods
59
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
15 –
Cylinder head, valve gear
1
Cylinder head Note
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♦ If the cylinder head is replaced, all the coolant in the system must also be renewed.
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Rep. gr.15 - Cylinder head, valve gear
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♦ The plastic packing pieces for protecting the open valves must not be removed until immediately before fitting cylinder head.
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 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
3 - 10 Nm ❑ Renew. 4 - 25 Nm 5 - 100 Nm 6 - Camshaft pulley
9 - Sealing grommet ❑ Renew if damaged.
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8 - Rear toothed belt guard
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7 - Hub ❑ With sender wheel ❑ Use counterhold tool T10051- to loosen and tighten. ❑ To remove, use puller T10052- . ❑ Removing and in‐ stalling.
11 - Stud ❑ 15 Nm
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10 - Hall sender -G40❑ For camshaft position ❑ To remove, unbutton sealing grommet ⇒ Item 9 (page 61) from rear toothed belt guard.
12 - Cylinder head bolt ❑ Observe sequence when loosening and tightening ⇒ page 83 . ❑ Before installing, place washers in cylinder head ⇒ Item 4 (page 92) .
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2 - Toothed belt ❑ Mark direction of rota‐ tion before removing. ❑ Check for wear. ❑ Do not kink. ❑ Removing, installing and tensioning ⇒ page 66 .
1. Cylinder head
61
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 13 - Fuel return line 14 - Fuel supply line 15 - Coolant line 16 - Cylinder head cover ❑ Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth. 17 - Pressure regulating valve ❑ For crankcase ventilation. 18 - To turbocharger. 19 - Cap ❑ Renew seal if damaged. 20 - Seal ❑ Renew if damaged. 21 - 10 Nm ❑ Observe tightening sequence ⇒ page 64 .
23 - 20 Nm 24 - Lifting eye
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25 - Unit injector ❑ Removing and installing ⇒ page 230
28 - From brake servo
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27 - Central connector ❑ For unit injector
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26 - 10 Nm
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29 - Tandem pump ❑ For fuel and vacuum supply ❑ Check ⇒ page 195 . ❑ Removing and installing ⇒ page 198 ❑ Must not be dismantled.
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Rep. gr.15 - Cylinder head, valve gear
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32 - Seal ❑ Renew.
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31 - Return hose ❑ To fuel filter ❑ Blue or with blue marking. ❑ Check for secure seating. ❑ Secure with spring-type clips.
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30 - Supply hose ❑ From fuel filter. ❑ White or with white marking. ❑ Check for secure seating. ❑ Secure with spring-type clips.
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22 - Gasket for cylinder head cover ❑ Renew together with cylinder head cover only. olkswa64 gen AG ⇒. Vpage ❑ Before fitting, seal transitions with „AMV 174 004g01“ en AG d
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 33 - Bracket 34 - 20 Nm 35 - Cylinder head ❑ Removing and installing ⇒ page 83 ❑ After renewing, renew entire coolant. 36 - Cylinder head gasket ❑ Renew. ❑ Note marking ⇒ page 63 . ❑ After renewing, renew entire coolant. 37 - Glow plug olkswagen AG en AG. V does ❑ 15 Nm olkswag not V gu y ara d b⇒ page 269 . ❑ Check e n is
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t or 38 - Tensioning roller ac au ss ❑ Remove engine support in order to remove and install ⇒ page 29 .
Special tools and workshop equipment required ♦ Straight edge ♦ Feeler gauges
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Note
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Max. permissible distortion: 0.1 mm.
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39 - 20 Nm + turn (45°)
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
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♦ Different thicknesses of cylinder head gasket are fitted de‐ pending on the piston projection. When renewing gasket, install new gasket with same identification. ♦ Piston projection at TDC must be determined when installing new pistons or a short engine. ⇒ page 56
Special tools and workshop equipment required ♦ 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-.
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Rep. gr.15 - Cylinder head, valve gear
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♦ Torque wrench -V.A.G 1331-
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Removing and installing cylinder head cover
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Two-piece engine cover For two-piece engine cover, first pull outer engine cover abruptly upwards at -arrows-, then pull inner engine cover abruptly up‐ wards at -arrows-. – Remove upper toothed belt guard. – Disconnect crankcase breather hose at union on rear of charge air pipe. – Unbolt bracket from exhaust gas recirculation valve.
Engine codes BLS, BXJ: to remove cylinder head cover, addi‐ tionally remove: ♦ -2- intake hose ♦ -3- intake manifold flap Renew seal. ♦ -4- bolt, 8 Nm Continuation for all vehicles – Remove cylinder head cover.
Cylinder head cover, engine codes: BLS, BXJ Installing for all engine codes
Install in reverse order. In the process, note the following: Note
♦ Renew cylinder head cover gasket and seal for bolts if dam‐ aged. r fo ng
♦ Renew seal for intake manifold flap. Engine codes BLS, BXJ
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Cylinder head cover, engine codes: AVQ, BJB, BKC, BRU, BXE, BXF n AG. Volkswagen AG do e wage
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♦ -1- upper toothed belt guard
1. Cylinder head
65
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Place a drop of sealant -AMV 174 004 01- (∅ approx. 5 mm) -arrows- on edges of both sealing surfaces of bearing cap and cylinder head at front of engine.
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Cylinder head cover, engine codes: BJB, BKC, BRU, BXE, BXF – Screw on cylinder head cover by hand in sequence -1 … 13-.
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– Tighten bolts in sequence -1 … 13- to 10 Nm. Prote cted by
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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Removing, installing and tensioning toothed belts
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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.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 . Volkswagen AG gen AG does not gu ara nte eo ra c
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Removing and installing toothed belt (vehicles with engine support bolted close to engine)
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♦ Pin wrench -T10020- or hexagon wrench
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♦ Locking pin -3359-
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♦ Locking pin -T10115♦ Crankshaft stop -T10050♦ Torque wrench V.A.G 1331♦ Torque wrench V.A.G 1332-
1. Cylinder head
67
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
♦ Counterhold tool -T10172with pins -T10172/4un le
ProCarManuals.com Removing Note
Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature. – Remove engine cover. ⇒ page 5 – Remove coolant expansion tank, coolant hoses remain con‐ nected. – Remove poly V-belt ⇒ page 25 . – Remove tensioning element for poly V-belt.
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Rep. gr.15 - Cylinder head, valve gear
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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.
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Note
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♦ Crankshaft stop -T10100(on vehicles with oval crankshaft belt pulley)
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♦ Support bracket -10-222Awith adapters -10-222A/1-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove front right wheel housing liner. – Remove charge air pipe between charge air cooler and tur‐ bocharger. ⇒ page 218 – Carefully cover or seal open ends. – Remove belt pulley with vibration damper. – Remove lower and centre parts of toothed belt guard. Golf, Golf Plus, Touran – Set up support bracket -10-222A- with adapters -10-222A/22and support enginen AinGinstallation . Volkswagen Aposition.
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– Set up support bracket -10-222A- with adapters -10-222A/1and support engine in installation position.
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Passat: If the toothed belt has to be taken off for removal of the cylinder head.
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Note
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Both lifting eyes for the support are located on the cylinder head, so an additional spindle -A- with bracket to support the engine must be secured on the cylinder block. AG.
ProCarManuals.com
Passat:
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If toothed belt is to be removed in order to remove cylinder head, set up support bracket -10-222A- with higher adapters -10-222A/ 13- . This will provide the space necessary for removing the cylin‐ der head.
– Set up support bracket -10-222A- with adapters -10-222A/1and support engine in installation position with spindles -Band -C-. Note ♦ Spindle -A- hangs loose. ♦ Unscrew filler neck for window wash system. ♦ Unbolt coolant expansion tank and lay to side (hoses remain connected). – Pull fuel filter out of bracket. – Unscrew filler neck for window wash system.
1. Cylinder head
69
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Unbolt fuel filter bracket from engine mounting -arrows-. – Unbolt coolant expansion tank and lay to side (hoses remain connected). Continuation for all vehicles
– Remove securing bolts between assembly mounting and en‐ gine bracket and between assembly mounting and body -arrows- and remove complete assembly mountings. Note
♦ The engine bracket must be loosened only when the assembly mounting has been removed. WARNING
n AG. Volkswagen AG do es n wage s k l ot g Vo y ua b When raising and lowering engine using support bracket ran ed s i tee r -10-222A- , ensure that no components or hoses are damaged, o h t or u strained or torn off. ac a ss es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng
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– Raise engine with support bracket -10-222A- until both upper bolts of engine bracket can be loosened.
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– Lower engine with support bracket -10-222A- until both lower bolts of engine bracket can be loosened. – Remove refrigerant line securing clamp from longitudinal member. – Remove engine support.
– Turn crankshaft to TDC No. 1 cylinder. Note
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Gradual introduction of oval crankshaft toothed belt pulleys. When installing this toothed belt pulley, the crankshaft stop T10100- must be installed to determine the TDC position instead of crankshaft stop -T10050- . Observe identification characteris‐ tics -arrows-. ht rig py Co t.
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♦ The assembly mounting may only be removed if the engine is supported with support bracket -10-222A- !
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Characteristics of crankshaft toothed belt pulley A = round belt pulley, lock using crankshaft stop -T10050- , TDC marking at 12 o'clock B = oval belt pulley, lock using crankshaft stop -T10100- . TDC marking at 1 o'clock Vehicles with round crankshaft pulley – Turn crankshaft to TDC No. 1 cylinder.
Turn crankshaft until marking on crankshaft pulley and tooth seg‐ ment of camshaft pulley is on top. The marking on the rear toothed belt guard must align with the marking on the camshaft sender wheel -arrow-. – Lock hub using locking pin -3359- . To do this, slide locking pin through the free elongated hole on left into hole in cylinder head. – Lock crankshaft toothed belt pulley with crankshaft stop T10050 - . To do this, push crankshaft stop into teeth of belt pulley from face side.
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crankshaft stop must engage in the drilling of sealing flange. Vehicles with oval crankshaft pulley
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– Turn crankshaft to TDC No. 1 cylinder.
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Note
1. Cylinder head
71
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note
Turn crankshaft until marking on crankshaft pulley and tooth seg‐ ment of camshaft pulley is on top. The marking on the rear toothed belt guard must align with the marking on the camshaft sender wheel -arrow-. – Lock hub using locking pin -3359- . To do this, slide locking pin through the free elongated hole on left into hole in cylinder head. – Lock crankshaft toothed belt pulley with crankshaft stop T10100- . To do this, push crankshaft stop into teeth of belt pulley from face side. Note
The marks on the crankshaft toothed belt pulley and the crankshaft stop must align. When doing this, the pin of the crankshaft stop must engage in the drilling of sealing flange. olkswagen AG en AG. V does not V gu y b ara d nte ise r eo Loosen securing bolts -1-utof ho camshaft pulley until the camshaft ra a pulley can be moved within the elongated holes. c s s
wag – Mark direction of rotation of toothed olksbelt.
– Loosen tensioning roller securing nut.
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– Turn pin wrench -T10020- anti-clockwise until toothed belt tensioning roller can be locked with locking pin -T10115- . Note
A hexagon key can be used to tension or relieve tension on the tensioner.
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Rep. gr.15 - Cylinder head, valve gear
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Continuation for all vehicles
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Now turn pin wrench -T10020- clockwise to stop and tighten securing nut -1- hand tight. – Remove toothed belt first from coolant pump and then from remaining pulleys. AG. Volkswagen AG d agen oes ksw not l o gu yV b ara Camshaftislocked with locking pin -3359- . ed nte r o eo th r a or The scrankshaft is locked with crankshaft stop -T10050au c s crankshaft stop -T10100- .
Installing •
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Tensioning roller locked with locking pin -T10115- and se‐ cured to right stop. Note
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•
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.
– Fit toothed belt onto crankshaft toothed belt pulley, tensioning roller, camshaft toothed belt pulley and idler roller.
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– Then fit toothed belt on coolant pump toothed belt pulley.
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– Turn camshaft pulley in its elongated holes to centre position -arrows-.
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
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 AG. Volkswagen A
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– In this position, tighten camshaft toothed belt pulley securing bolts -1- to 25 Nm. – Remove locking pin -3359- and crankshaft stop -T10050- .
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– Turn crankshaft two rotations in engine direction of rotation until crankshaft is just before TDC No. 1 cylinder. Vehicles with round crankshaft pulley
– Lock hub with locking pin -3359- whilst turning engine in di‐ rection of rotation. – Check whether crankshaft can be locked with crankshaft stop -T10050- .
Vehicles with oval crankshaft pulley
74
Rep. gr.15 - Cylinder head, valve gear
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AG.
– Now turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange whilst turning.
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– Turn crankshaft slightly against engine direction of rotation until the pin of the crankshaft stop is positioned just before the hole in the sealing flange -arrow-.
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– Loosen securing bolts -1- for camshaft toothed belt pulley.
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If crankshaft cannot be locked:
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Lock hub with locking pin -3359- whilst turning engine in di‐ rection of rotation. – Check whether crankshaft can be locked with crankshaft stop -T10100- .
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– Turn crankshaft slightly against engine direction of rotation until the pin of the crankshaft stop is positioned just before the hole in the sealing flange -arrow-.
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– Now turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange whilst turning. AG.
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Continuation for all vehicles
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– Loosen securing bolts -1- for camshaft toothed belt pulley.
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If crankshaft cannot be locked:
– Fit counterhold -T10172- with pins -T10172/4- as shown. Press counterhold -T10172- in direction of arrow, keeping camshaft toothed belt pulley under tension. – In this position, tighten camshaft toothed belt pulley securing bolts -1- to 25 Nm. – Remove locking pin -3359- and crankshaft stop -T10050- . – Turn crankshaft two rotations in engine direction of rotation until crankshaft is just before TDC No. 1 cylinder. – Repeat check.
1. Cylinder head
75
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Set engine bracket against cylinder block and tighten securing bolts -A- to 40 Nm + (180°) turn further. Note
Before installing assembly mounting, tighten all engine bracket bolts to specified torque. – Install assembly mounting between engine and body (renew securing bolts). Tightening torque of M 8 bolts: 20 Nm + (90°) turn further Tightening torque of M 10 bolts: 40 Nm + (90°) turn further – Bolt engine assembly mounting to engine bracket by bringing contact surfaces together using support bracket -10-222A- . Specified torque: 60 Nm + turn (90°) further – Install centre and lower parts of toothed belt guard. – Install belt pulley vibration damper (renew securing bolts). Tightening torque: 10 Nm + (90°) turn further – Install upper toothed belt guard. – Install front right wheel housing liner. – Install coolant expansion tank.
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–
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– Fit engine cover.
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– Bolt on filler neck for window wash system.
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– Install poly V-belt ⇒ page 26 .
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.3.2
Removing and installing toothed belt (vehicles with engine support bolted further away from engine)
Note ♦ A revised engine support has been introduced gradually and it is no longer necessary to remove the engine support and to support the engine for the procedure „removing, installing and tensioning toothed belt“. ♦ To change the tensioning roller, for both versions the engine support must be removed. Special tools and workshop equipment required ♦ Diesel injection pump lock‐ ing pin -3359♦ Locking pin -T10060 A♦ Crankshaft stop -T10100♦ Counterhold tool -T10172-
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– Remove engine cover. ⇒ page 5 To do this, pull engine cover upwards abruptly at front -arrows A- and then pull forwards out of rear fastening -arrow B-. AG.
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♦ Special wrench, long reach -T10264-
1. Cylinder head
77
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove two-piece engine cover panel ⇒ page 5 . WARNING
♦ In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector en‐ gine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. ♦ Wear protective gloves. ♦ Wear eye protection.
– Pull fuel supply hose -1- and fuel return hose -2- off fuel lines. – Pull off coolant line -3-.
– Remove connecting pipe between charge air cooler and intake connecting pipe, to do this, lightly lift retaining clips -arrows-.
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– Disconnect fuel supply line -3- and return line -2- by pulling release tabs. – Remove fuel filter »screwed filter« and lay it with hoses to side -arrow-.
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– Remove bolt -1-.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Pull fuel filter »inserted filter« out of bracket -arrow-. – Unscrew bolt at filler neck -2- for windscreen washer system reservoir. – Unscrew bracket -3- for fuel filter.
– Disconnect electrical connector on coolant expansion tank -1-. – Remove coolant expansion tank, coolant hoses remain con‐ nected. Place it on engine. – Remove poly V-belt ⇒ page 25 .
– Remove upper toothed belt guard, to do this, loosen retaining clips -arrows-. – Remove front right wheel housing liner. – –
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–
AG. Volkswagen AG d agen oes ksw not l o Remove belt pulley with vibration damper. V gu by ara d e nte is r o Remove lower and centre parts of toothed belt guard. eo h ut ra a c s Turn crankshaft to TDC No. 1 cylinder. s
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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.
AG.
The marks on the crankshaft toothed belt pulley and the crankshaft stop must align. When doing this, the pin of the crankshaft stop must engage in the drilling of sealing flange.
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– Lock crankshaft toothed belt pulley with crankshaft stop T10100- . To do this, push crankshaft stop into teeth of belt pulley from face side. ht rig py Co t.
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– Remove tensioning element for poly V-belt.
1. Cylinder head
79
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Mark direction of rotation of toothed belt.
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s
– Loosen tensioning roller securing nut -1-.
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– Now turn tensioning roller eccentric clockwise -arrow- onto stop and tighten securing nut -1- hand-tight. Prote cted by c o p yri gh t. C op yi
– Remove toothed belt first from coolant pump and then from remaining toothed belt pulleys.
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Installing •
Camshaft locked with locking pin -3359- .
•
Crankshaft locked with crankshaft stop -T10100- .
•
Tensioning roller locked with locking pin -T10265- and se‐ cured to right stop with securing nut. Note
Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature. – Turn camshaft pulley in its elongated holes to centre position -arrows-. – Guide toothed belt through gap between engine support and engine. – Fit toothed belt onto crankshaft toothed belt pulley, tensioning roller, camshaft toothed belt pulley and idler roller. – Then fit toothed belt on coolant pump toothed belt pulley.
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Rep. gr.15 - Cylinder head, valve gear
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– Turn eccentric of tensioning roller anti-clockwise -arrow- using socket -T10264- , until the tensioning roller can be locked with locking tool -T10265- .
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– Loosen securing bolts -1- of camshaft pulley until the camshaft pulley can be moved within the elongated holes.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note
Ensure that tensioning roller seats correctly in rear toothed belt guard -arrow-. – Remove locking pin -T10265- from tensioning roller. – Loosen tensioning roller securing nut -1-.
– Turn eccentric of tensioning roller clockwise -arrow- using special wrench, long reach -T10264- until indicator -2- is in middle of gap in base plate. Note
Ensure that securing nut does not turn as well.
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–
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d Fit counterhold -T10172- with pin -T10172/4as shown in il‐ e nte is r o eo lustration, and keep the toothed belt under tension on pulling h ut ra a side, by pressing in -direction ofssarrow-. c
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– Tighten bolts -1- of camshaft toothed belt pulley to 25 Nm. – Remove locking pin -3359- and crankshaft stop -T10100- . – Turn crankshaft two rotations in engine direction of rotation until the crankshaft is just before TDC again.
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– Lock hub of camshaft with locking pin -3359- whilst turning engine in direction of rotation.
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– Hold tensioning roller in this position and tighten tensioning roller nut to 20 Nm + turn 45° further.
1. Cylinder head
81
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Check whether crankshaft can be locked with crankshaft stop -T10100- .
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– Now turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange whilst turning.
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– Fit counterhold -T10172- with pins -T10172/4- as shown. Press counterhold -T10172- in direction of arrow, keeping camshaft toothed belt pulley under tension. – In this position, tighten camshaft toothed belt pulley securing bolts -1- to 25 Nm. – Remove locking pin -3359- and crankshaft stop -T10100- . – Turn crankshaft two rotations in engine direction of rotation until crankshaft is just before TDC No. 1 cylinder. – Repeat check and adjustment if necessary. – Install centre and lower parts of toothed belt guard. – Install belt pulley vibration damper (renew securing bolts).
82
Rep. gr.15 - Cylinder head, valve gear
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– Turn crankshaft slightly against engine direction of rotation until the pin of the crankshaft stop is positioned just before the hole in the sealing flange -arrow-.
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ProCarManuals.com
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– Loosen securing bolts -1- for camshaft toothed belt pulley.
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If crankshaft cannot be locked:
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Tightening torque: 10 Nm + (90°) turn further – Install poly V-belt ⇒ page 26 . – Install upper toothed belt guard. – Install connecting pipe between charge air cooler and intake connecting pipe. – Install front right wheel housing liner. – Install coolant expansion tank. – Bolt fuel filter -arrows-.
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– Engage fuel filter in bracket.
1.4
Removing and installing cylinder head
Note
♦ From 05.05 a modified engine support has been introduced, it is no longer necessary to support the engine for the procedure „removing and installing the cylinder head“. r fo ng
♦ -1-: Engine support ► 05.05 (support necessary) ♦ -2-: Engine support 06.05 ► ( (support not necessary)
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– Fit engine cover.
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– Bolt on filler neck for window wash system.
1. Cylinder head
83
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Special tools and workshop equipment required ♦ Drip tray -V.A.G 1306- or drip tray -VAS 6208♦ Torque wrench V.A.G 1331♦ Torque wrench V.A.G 1332♦ Hand vacuum pump with accessories -V.A.G 1390♦ Water drainage container V.A.G 1390/1-
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♦ Retainer -T10014- (only ve‐ hicles ► 05.05)
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Special tools and workshop equipment required
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Rep. gr.15 - Cylinder head, valve gear
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♦ Support bracket -10-222A- with adapters -10-222A/13- (only vehicles ► 05.05)
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note ♦ From 05.05 a modified engine support has been introduced, it is no longer necessary to support the engine for the procedure „removing and installing the cylinder head“. ♦ -1-: Engine support ► 05.05 (support necessary) ♦
WARNING
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cylinder head is installed.
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♦
AG. Volkswagen AG d agen oes ksw not l o V gu -2-: Engine support 06.05 ► ( (support not necessary) by ara d e nte is r o eo All cable ties which are opened or cut through when cylinder h ut ra a head is removed must be replaced in the same position when c s s
When doing any repair work, especially in the engine com‐ partment, pay attention to the following due to the cramped conditions:
♦ Ensure that there is sufficient clearance to all moving or hot components.
AG.
Before removing cylinder head, extract fuel using hand-operated vacuum pump with accessories -V.A.G 1390- and water drainage container -V.A.G 1390/1- .
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Note
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Removing
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1.4.1
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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions.
– Remove engine cover panel ⇒ page 5 . Golf, Golf Plus, Touran – Remove plenum chamber bulkhead. ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead . All other vehicles continued – Remove air filter housing with air mass meter and connecting pipe. – Remove bolt -arrow A- and pull air filter housing upwards out of mounting. – Remove noise insulation. ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . – Drain coolant ⇒ page 123 – Disconnect fuel supply and return lines as well as coolant line on cylinder head. – Before removing cylinder head, extract fuel from tandem pump using hand-operated vacuum pump with accessories -V.A.G 1390- and water drainage container -V.A.G 1390/1- ⇒ page 195 . – Pull fuel filter module upwards out of bracket and lay it with hoses to side. 1. Cylinder head
85
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove front exhaust pipe ⇒ page 255 . – Remove turbocharger support and oil return from turbocharg‐ er. – Remove oil supply line and lay it to side ⇒ page 112 . Note
From 05.05 a modified engine support has been introduced, it is no longer necessary to remove the engine support and supporting the engine for the procedure „removing, installing and tensioning toothed belt“ ⇒ page 66 – Remove toothed belt. ⇒ page 66 – Remove toothed belt tensioning roller.
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– Install hub for camshaft pulley ⇒ page 97 , Removing installing camshaft.
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– Remove rear toothed belt guard securing bolts -2- and -4-.
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– Unscrew Hall sender -G40- -3-.
– Pull off or disconnect all other electrical connections as nec‐ essary from cylinder head and lay to one side. – Separate all connection, coolant, vacuum and intake hoses from cylinder head. Golf, Golf Plus Touran: Vehicles ► 05.05 Note
Both lifting eyes for the support are located on the cylinder head, so an additional bracket for supporting the engine must be se‐ cured on the cylinder block.
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.
86
Rep. gr.15 - Cylinder head, valve gear
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Passat: Vehicles ► 05.05
AG.
– Unhook spindle -B- and push it to side.
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– Lift engine slightly using spindle -A- until spindle -B- is relieved.
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– Screw retainer -T10014- into threaded hole above coolant pump and tighten to 20 Nm.
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ProCarManuals.com
– Remove exhaust gas recirculation connecting pipe.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Screw retainer -T10014- into threaded hole above coolant pump and tighten to 20 Nm. – Lift up engine slightly via spindle -A-.
– Once spindles -B- and -C- are no longer under tension, unhook them and slide them to one side. – Remove tensioning roller securing nut for toothed belt Continuation for all vehicles – Remove cylinder head cover. ⇒ page 64
– Maintain
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h sequence ut when loosening cylinder head bolts. ra a c s s
Note
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The cylinder head must be guided carefully to prevent damage.
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– Lift cylinder head slightly and remove from engine laterally past toothed belt guard.
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For vehicles 06.05 ►
1. Cylinder head
87
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.4.2
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.
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 1-
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Tighten initially with torque wrench:y Volksw
Turn further with rigid spanner:
Stage III = + (90°) turn further Stage IV = + (90°) turn further Note
After repair work it is not necessary to retighten the cylinder head bolts.
r fo ng
Further installation is carried out in the reverse order. In the pro‐ cess, note the following:
AG.
Rep. gr.15 - Cylinder head, valve gear
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88
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Stage II = 60 Nm
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Stage I = 35 Nm
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ProCarManuals.com
– Fit cylinder head gasket.
– Install hub for camshaft toothed belt pulley ⇒ page 97 , Removing and installing camshaft. – Install toothed belt ⇒ page 66 . – Install poly V-belt ⇒ page 26 . – Install oil supply line ⇒ page 112 . – Install noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Assembly overview - Body - front . – Install plenum chamber bulkhead ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulk‐ head . – Fill coolant system with coolant ⇒ page 123 .
Note
AG.
ProCarManuals.com
Checking compression
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1.5
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– Carry out road test and then read fault memory ⇒ page 239 .
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– After tightening cylinder head, turn camshaft so that cams for No. 1 cylinder point equally upwards. Before fitting toothed belt, turn crankshaft in engine direction of rotation ⇒ page 66 , removing, installing and tightening toothed belt.
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AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte s i r Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 o e o ➤ , Touran 2003 ➤ h ut ra a 4-cylinder diesel engine (1.9 l engine) c - Edition 08.2010 s s
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
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Special tools and workshop equipment required ♦ Jointed spanner -3220♦ Torque wrench V.A.G 1331♦ Adapter -V.A.G 1381/12♦ Compression tester V.A.G 1763-
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Engine oil temperature min. 30 °C.
c o p yri gh t . C op yi
Test procedure
– Pull off central connector for unit injectors.
Prote cted by
– Remove all glow plugs or ceramic glow plugs using jointed extension and socket -3220- .
90
Rep. gr.15 - Cylinder head, valve gear
AG.
If ceramic glow plugs are fitted, always observe notes on remov‐ ing and installing ceramic glow plugs ⇒ page 269 .
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Test prerequisite
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Golf
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d 2004 ➤ ri,seGolf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ nte o e o 08.2010 h t 4-cylinder diesel engine (1.9 l engine) - Edition u r ac a ss
– Screw in adapter -V.A.G 1381/12- in place of glow plugs or ceramic glow plugs.
– Check compression using compression tester -V.A.G 1763- .
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Note
Using the compression tester ⇒ Operating instructions. – Operate starter until tester shows no further pressure in‐ crease. Compression pressures:
New: 25 … 31 bar, wear limit: 19 bar
Maximum permissible difference between all cylinders: 5 bar
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AG.
Specified torque: 15 Nm.
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– Remove glow plugs or ceramic glow plugs using jointed ex‐ tension and socket -3220- .
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If ceramic glow plugs are fitted, always observe notes on remov‐ ing and installing ceramic glow plugs ⇒ page 269 .
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Note
– 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
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
2
Valve gear
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h Cylinder heads with cracks ut between the valve seats may be used ra a c s without reducing engine s life, provided the cracks are small and
Note
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not more than 0.5 mm wide.
Assembly overview - valve gear ⇒ page 92 .
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Checking valve guides ⇒ page 94 . Renewing valve stem seals ⇒ page 95 . Removing and installing camshaft ⇒ page 97 . Removing and installing camshaft seal ⇒ page 101 .
Assembly overview - valve gear
2 - Rocker arm shaft ❑ Do not interchange.
AG.
4 - Washer ❑ For cylinder head bolts. ❑ Insert in cylinder head before installing bearing caps 5 - Bucket tappet ❑ Do not interchange. ❑ With hydraulic valve clearance compensa‐ tion. ❑ Store with cam contact surface downwards. ❑ Before installing, check camshaft axial clear‐ ance ⇒ page 93 . ❑ Oil contact surfaces. ❑ Before removing, remove camshaft bearing caps
92
Rep. gr.15 - Cylinder head, valve gear
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3 - Cylinder head bolt ❑ Renew. ❑ Note sequence when loosening and tighten‐ ing ⇒ page 83 , Remov‐ ing and installing cylin‐ der head. ❑ Before installing, insert washers ⇒ Item 4 (page 92) in cylinder head.
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1 - 20 Nm + turn (90°) ❑ Renew. ❑ Note sequence when loosening and tighten‐ ing ⇒ page 97 , Re‐ moving and installing camshaft.
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2.1
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d spring platese nte i r o eo h ut ra valve spring a c s s
6 - Valve cotter 7 - Valve
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8 - Outer ❑ Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder head installed ⇒ page 95 , Renewing valve stem seals. rrectness of i t to the co nform spec at i h re o n wit in t his
9 - Inner valve spring ❑ Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder head installed ⇒ page 95 , Renewing valve stem seals. 10 - Valve stem seal ❑ Renewing ⇒ page 95 . 11 - Valve guide ❑ Check ⇒ page 94 . 12 - Unit injector ❑ Removing and installing ⇒ page 230
14 - Seal ❑ Do not additionally oil or grease the oil seal sealing lip. ❑ Before installing, remove residual oil from camshaft journal using a clean cloth. ❑ To install, tape over groove in taper of camshaft (e.g. using Sellotape). ❑ Removing and installing ⇒ page 101 ht rig py Co t.
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15 - Valves ❑ Valve dimensions ⇒ page 94 .
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13 - Cylinder head ❑ See note ⇒ page 92 .
16 - Bearing shell ❑ Do not interchange used bearing shells (mark). ❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head 17 - Camshaft ❑ Checking axial clearance ⇒ page 93 . ❑ Removing and installing ⇒ page 97 ❑ Check radial clearance with Plastigage, wear limit: 0.11 mm. ❑ Runout: max. 0.01 mm. 18 - Bearing cap ❑ Installation sequence ⇒ page 97 , removing and installing camshaft ❑ To install, seal parting surfaces of bearing caps 1 and 5 with sealant -AMV 174 004 01- ⇒ page 94 19 - 8 Nm + turn (90°) ❑ Renew. Checking camshaft axial clearance
2. Valve gear
93
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Special tools and workshop equipment required ♦ Universal dial gauge bracket -VW 387♦ Dial gauge Check with bucket tappets removed and with first, third and last n AG. Volkswagen AG do bearing caps fitted. es wage -AMV
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Seal parting surfaces of bearing caps 1 174 004 01-
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Wear limit: max. 0.15 mm
Be careful that no sealant gets into grooves -arrows-.
Valve dimensions
Valves must not be reworked. Only lapping-in is permitted.
31.45 6.956 89.95 45
Checking valve guides
Special tools and workshop equipment required ♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge
94
Rep. gr.15 - Cylinder head, valve gear
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35.95 6.980 89.95 45
AG.
2.2
mm mm mm ∠°
Exhaust valve
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Inlet valve
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Dimension
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Note
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Note
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– Apply sealant -AMV 174 004 01- thinly and evenly on the sur‐ faces -1-.
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– Insert new valve into guide. The end of the valve stem must be flush with the guide. On account of differing stem diame‐ ters, only use inlet valve in inlet guide and exhaust valve in exhaust guide. – Determine rock. Wear limit: max. 1.3 mm – Cylinder head must be renewed if rock exceeds wear limit.
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♦ Valve lever -VW 541/1A-
AG.
♦ Fitting tool -3129-
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♦ Puller -3047 A-
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♦ Assembly tool -2036-
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Special tools and workshop equipment required
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Renewing valve stem seals
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2.3
♦ Thrust piece -VW 541/5-
2.3.1
Removing
(With cylinder head installed) – Remove camshaft. ⇒ page 97
2. Valve gear
95
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove bucket tappets and place them with the contact sur‐ face downwards. When doing this, ensure that the tappets are not interchanged. – Set piston of respective cylinder to top dead centre (TDC). – Insert valve assembly device -2036- and adjust mounting to height of studs. – Remove valve springs using valve lever -VW 541/1A- and press tool -VW 541/5- .
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The valves are supported by the piston
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Installing
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2.3.2
– Place the plastic sleeve -A- supplied on the respective valve stem. This will prevent the new valve stem seal -B- being damaged. c o p yri gh t . C op yi
– Insert new valve stem seal in fitting tool -3129- .
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Rep. gr.15 - Cylinder head, valve gear
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96
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– Lubricate sealing lip of valve stem seal and carefully push on valve guide.
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– Pull off valve stem seals using puller -3047 A- .
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Note
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
2.4
Removing and installing camshaft
Special tools and workshop equipment required ♦ Counterhold tool -T10051♦ Puller -T10052♦ Torque wrench (5... 50 Nm) -V.A.G 1331♦ Torque wrench (40... 200 Nm) -V.A.G 1332-
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♦ Sealant -AMV 174 004 01-
Removing
– Remove toothed belt. ⇒ page 66 – Remove securing bolts for camshaft toothed belt pulley -1-. – Pull camshaft toothed belt pulley off hub.
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2.4.1
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2. Valve gear
97
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Loosen hub securing bolt -1-. – To do this, use counterhold -T10051- . – Loosen hub securing bolt about 2 turns.
– Apply
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r puller -T10052and screw securing bolts -1into hub. o eo h ut ra a s tension s to hub by evenly tightening puller until hub sep‐ c
When doing this, hold puller with 30 mm spanner.
– Remove cylinder head cover. – Mark rocker arm shafts using a permanent felt tip marker to prevent interchanging. This will prevent having to perform ba‐ sic settings of unit injectors -arrows-. – Remove rocker arm shafts. Note
First loosen both outer and then inner securing bolts respectively. Prote cted by c o p yri gh t. C op yi
– Remove tandem pump ⇒ page 195 .
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– First remove bearing caps 5, 1 and 3. Then loosen bearing caps 2 and 4 alternately and diagonally. – Remove camshaft.
98
Rep. gr.15 - Cylinder head, valve gear
AG.
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– Remove hub from taper of camshaft.
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Note
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– Apply arates from taper of camshaft.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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.
♦ Seal parting surfaces of bearing caps 1 and 5 with sealant AMV 174 004 01- ⇒ page 94 . es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng
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♦ Bearing cap 5 must be flush with outer edge of cylinder head, 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 further. – Install camshaft oil seal. ⇒ page 101 – Install injector rocker arm shafts with new securing bolts and tighten, first the inner -2- and then the outer -1-, evenly and in diagonal sequence to 20 Nm + (90°) turn further.
AG.
– To do this, use counterhold -T10051- .
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– Tighten hub securing bolt -1- to 100 Nm.
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– Fit hub onto camshaft.
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Note
AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s
2. Valve gear
99
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Push camshaft toothed belt pulley onto hub. Note
The toothed segment -arrow- of the camshaft belt pulley must be on top. – Align camshaft toothed belt pulley at centre of elongated holes. – Hand tighten securing bolts -1- to camshaft toothed belt pulley so that there is no play. – Lock hub using locking pin -3359- . – Install and tighten toothed belt ⇒ page 66 . – Screw new adjustment screws into rocker arms hand-tight and fit lock nut. – Fit dial gauge onto adjustment screw of unit injector as shown.
– Remove dial gauge.
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– Hold adjuster screw in this position and tighten lock nut to 30 Nm. – Install tandem pump ⇒ page 195 . – Install cylinder head cover. Note
AG.
Rep. gr.15 - Cylinder head, valve gear
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100
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When new bucket tappets have been installed the engine must not be started for about 30 minutes. The hydraulic compensation elements must settle (otherwise valves will strike pistons).
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– Turn adjustment screw 180° back off stop.
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– 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.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
2.5
Removing and installing camshaft oil seal
Special tools and workshop equipment required ♦ Fitting sleeves -10-203♦ Oil seal extractor -3240♦ Torque wrench -V.A.G 1331♦ Torque wrench -V.A.G 1332♦ Bolt M12×1.5 × 65
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– Remove camshaft toothed belt pulley and hub ⇒ page 97 , Removing and installing camshaft.
AG.
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– Lubricate threaded head of oil seal extractor -3240- , place it in position and exerting firm pressure, screw it as far as pos‐ sible into oil seal.
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– Unscrew inner part of oil seal extractor -3240- two turns (ap‐ prox. 3 mm) out of outer part and lock with knurled screw.
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– Remove toothed belt. ⇒ page 66
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Removing
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2.5.1
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– Loosen knurled screw and turn inner part against camshaft until oil seal is pulled out.
2. Valve gear
101
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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. – Install and tighten toothed belt ⇒ page 66 .
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Rep. gr.15 - Cylinder head, valve gear
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102
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AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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 Checking engine oil level ⇒
Oil capacities
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With oil filter change: 3.8 l
Engine codes BLS and BXJ With oil filter change: 4.3 l
Without oil filter change: 3.8 l
1.2
Checking engine oil level
Check which dipstick is installed. 1 - Max. mark 2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with engine oil! r fo ng
b - Oil level within hatched field: Can be topped up with engine oil. c - Area from min. mark up to hatched field: Must be topped up, max. 0.5 l of engine oil! AG.
Checking engine oil level
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1.3
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Without oil filter change: 3.3 l
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Engine codes AVQ BJB, BKC, BRU, BXE and BXF
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
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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 Thoroughly clean oil channels.
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Assembly overview - oil pump, sump ⇒ page 104 Removing and installing sump ⇒ page 105 .
5 - Piston fitting tool 6 - Guide tube 7 - Dowel sleeves 8 - O-ring ❑ Renew.
104
Rep. gr.17 - Lubrication
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4 - Oil dipstick ❑ The oil level must not be above the max. mark! ❑ Markings ⇒ page 103 .
AG.
3 - Chain tensioner with ten‐ sioning rail, 15 Nm ❑ When installing, preten‐ sion spring and fit.
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2 - Sealing flange ❑ With seal. ❑ Must sit on dowel sleeves ❑ Removing and installing ⇒ page 38 ❑ Install with silicone sealant -D 176 404 A2⇒ page 38 . ❑ Do not additionally oil or grease the oil seal seal‐ ing lip. ❑ Before installing, re‐ move oil residue from crankshaft journal using a clean cloth. ❑ Renewing crankshaft oil seal - belt pulley end ⇒ page 36 .
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1 - 15 Nm
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Assembly overview - oil pump, sump
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Renew oil filter element
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Renew engine oil cooler
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 9 - 15 Nm 10 - Suction line AG. Volkswagen AG d agen oes kifsw not l o ❑ Clean strainer soiled. gu yV b ed
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14 - Oil sump ❑ Clean sealing surface before fitting. ❑ Install with silicone sealant -D176404A2- . ❑ Removing and installing ⇒ page 105 15 - Oil drain plug, 30 Nm ❑ Renew. 16 - 10 Nm 17 - Oil level and oil temperature sender -G266❑ Black 3-pin connector
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19 - Oil pump ❑ With 12 bar pressure relief valve. ❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted. ❑ Renew if running surfaces and gears are scored. ht rig py Co t.
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20 - Chain sprocket for oil pump
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21 - Bracket ❑ For oil level/temperature sender wiring harness. AG.
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18 - Seal ❑ Renew.
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
Special tools and workshop equipment required
2. Parts of lubrication system
105
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ♦ Torque wrench -V.A.G 1331-
♦ Hand drill with plastic brush attachment ♦ Silicone sealant -D176404A2♦ Hand drill with plastic brush attachment ♦ Flat scraper
2.2.1
Removing
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♦ Eye protection
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– Drain engine oil. Note
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– Remove noise insulation. ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview .
Observe environmental regulations for disposal.
– Pull 3-pin connector off oil level and oil temperature sender G266- . – Remove sump.
– Remove sealant residue from cylinder block with a flat scraper.
AG.
Rep. gr.17 - Lubrication
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106
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– Loosen sump with light blows of a rubber headed hammer if necessary. ht rig py Co t.
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♦ Hexagon key extension, 5 mm -3249-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
–
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Note
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2.2.2
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– Clean sealing surfaces. They must be free of oil and grease.
Installing
♦ Observe expiry date of sealing compound.
AG.
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♦ 2 ... 2…3 mm thick.
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– Apply silicone sealing compound, as shown, to clean sealing surface on sump. Sealant bead must be:
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– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3 mm).
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♦ The sump must be installed within 5 minutes of applying sili‐ cone sealing compound.
♦ 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
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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Rep. gr.17 - Lubrication
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Further assembly is basically the reverse of the dismantling se‐ quence.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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
11 - Oil pressure switch -F1❑ 0.7 bar switch: brown. ❑ Tighten to 20 Nm. ❑ If seal is leaking, nip open and renew. ❑ Check ⇒ page 110 .
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10 - Plug, 10 Nm ❑ If seal is leaking, nip open and renew.
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9 - Oil filter element ❑ Ensure "Top" is upper‐ most when fitting
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8 - Seal ❑ Renew.
AG.
7 - Cap, 25 Nm
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6 - Oil supply line, 22 Nm ❑ To turbocharger. ❑ Removing and installing ⇒ page 112
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5 - Union, 35 Nm
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4 - Seal ❑ Renew.
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3 - Seal ❑ Renew.
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2 - 15 Nm + turn (90°) ❑ Renew. ❑ First fit upper left and lower right bolts and then tighten all four bolts diagonally.
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
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ❑ See note ⇒ page 104 . ❑ Checking engine oil cooler for leaks ⇒ page 134 15 - Seal ❑ Renew. 16 - Bracket 17 - 10 Nm
3.2
Checking oil pressure and oil pressure switch
Special tools and workshop equipment required ♦ Oil pressure tester V.A.G 1342♦ Voltage tester V.A.G 1527 B-
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110
Rep. gr.17 - Lubrication
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Functional check and repair of optical and acoustic oil pressure warning: ⇒ Current flow diagrams, Electrical fault finding and Fit‐ ting locations Guided fault finding with VAS 5051.
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Note
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Test procedure
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♦ Auxiliary measuring set V.A.G 1594 A-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove oil pressure switch -F1- and screw into tester. – Screw tester into oil filter bracket in place of oil pressure switch. – Connect brown wire of tester to earth (-). – Connect voltage tester -V.A.G 1527 B- to battery positive (+) and oil pressure switch using cable from auxiliary measuring set -V.A.G 1594 A- . LED must not light up. – Start engine and increase speed slowly. – At 0.55 … 0.85 bar, the LED must light up; otherwise renew oil pressure switch. – Increase engine speed further. At 2000 rpm and an oil tem‐ perature of 80 °C the oil pressure should be at least 2.0 bar. At higher engine speeds, oil pressure must not exceed 7.0 bar. If necessary renew oil filter bracket.
3.3
Assembly overview - oil supply line to turbocharger
1 - Retaining clamp 3 - Oil supply line ❑ To turbocharger. 4 - 10 Nm 5 - Bracket 7 - 10 Nm
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8 - Union nut, 22 Nm
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6 - Union nut, 22 Nm
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2 - 25 Nm
3. Oil filter bracket, oil pressure, engine oil cooler and oil supply line
111
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
3.4
Removing and installing oil supply line to turbocharger
Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331-
3.4.1
Removing
– Remove engine cover. ⇒ page 5
– Remove bolt -arrow A- and pull air filter housing upwards out of mounting. – Remove noise insulation. ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . – Loosen securing bolts for retaining clips. . Volkswage
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The procedure must be adhered to, this will ensure that the oil supply line is installed tension-free.
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– Remove air filter housing with air mass meter and connecting pipe.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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– Tighten union nut -8- on oil filter bracket hand tight.
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– 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.
3. Oil filter bracket, oil pressure, engine oil cooler and oil supply line
113
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
19 –
Cooling
1
Parts of cooling system WARNING
When doing any repair work, especially in the engine com‐ partment, pay attention to the following due to the cramped conditions: ♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions. olkswagen AG en AG. V ag lksw
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♦ When the engine is warm, the cooling system is under pres‐ sure. If necessary, release pressure before beginning repair work.
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♦ Hoses are secured with spring-type clips. In case of repair, only use spring-type clips. ♦ Spring-type clip pliers -VAS 5024- or hose clip pliers V.A.G 1921- are recommended for fitting spring-type clips.
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Rep. gr.19 - Cooling
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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).
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Perform leakage test of cooling system using cooling system tester -V.A.G 1274- and adapters adapter -V.A.G 1274/8- and adapter -V.A.G 1274/9- . Parts of cooling system, body side (radiator with two radiator fans) ⇒ page 115 . Parts of cooling system, body side (radiator with one radiator fan) ⇒ page 117 Removing and installing fan support with fans (Golf, Golf Plus, Touran) ⇒ page 117 Removing and installing fan support with fans (Passat) ⇒ page 119 Parts of cooling system - engine side ⇒ page 120 . Coolant hose schematic diagram ⇒ page 122 . Draining and filling with coolant ⇒ page 123 . Removing and installing radiator (Golf, Golf Plus, Touran) ⇒ page 126 Removing and installing radiator (Passat) ⇒ page 127 Removing and installing coolant pump ⇒ page 128 . Checking cooling system for leaks ⇒ page 132 . Checking pressure relief valve in filler cap ⇒ page 133 . . Volkswagen AG
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1 - Upper coolant hose ❑ Coolant hose schematic
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Removing and installing thermostat ⇒ page 130 .
1. Parts of cooling system
115
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 diagram ⇒ page 122 . 2 - O-ring ❑ Renew if damaged. 3 - Cooler ❑ Removing and installing ⇒ page 126 ❑ After renewing, renew entire coolant. 4 - Cap ❑ Check using cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/9- . ❑ Test pressure 1.4 … 1.6 bar 5 - Connector 6 - 5 Nm 7 - Expansion tank ❑ Check using cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/8- . 8 - 5 Nm 9 - 10 Nm 11 - Additional fan ❑ Vehicles with optional equipment only. 12 - Radiator fan 13 - Connector
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16 - Radiator outlet coolant temperature sender -G83-
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15 - Retaining clip ❑ Check for secure seating.
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14 - Lower coolant hose ❑ Coolant hose schematic diagram ⇒ page 122 .
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10 - Fan support
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.2
Assembly overview - parts of cooling system, body side (radiator with one radiator fan)
1 - Upper coolant hose ❑ Coolant hose schematic diagram ⇒ page 122 . 2 - O-ring ❑ Renew if damaged.
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12 - Radiator fan 13 - Fan support 14 - 5 Nm 15 - 5 Nm
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8 - Expansion tank ❑ Check using cooling system tester V.A.G 1274- and adapter V.A.G 1274/8- .
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6 - Connector
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5 - Cap ❑ Check using cooling system tester V.A.G 1274- and adapter V.A.G 1274/9- .
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3 - Radiator ❑ Removing and installing ⇒ page 126 ❑ After renewing, renew entire coolant.
16 - Connector 17 - Lower coolant hose ❑ Coolant hose schematic diagram ⇒ page 122 . 18 - Retaining clip ❑ Check for secure seating. 19 - Radiator outlet coolant temperature sender -G83-
1.3
Removing and installing fan support with fans (Golf, Golf Plus, Touran)
Special tools and workshop equipment required
1. Parts of cooling system
117
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ♦ Torque wrench (5... 50 Nm) -V.A.G 1331-
Removing The procedure for the single fan is identical. – Remove noise insulation ⇒ General body repairs, exterior;olksw agen AG Rep. gr. 50 ; Assembly overview - Body - front s. wagen AG. V does k Vol by d e ris ho t⇒ u Bring lock carrier into service position General body repairs, a ss Lock carrier - service po‐ exterior; Rep. gr. 50 ; Body - front;
– Remove air intake duct from air filter. un le
– Separate connector -1- and remove fan support securing bolts -arrows-. – Remove fan support with fans upwards.
– Separate connection -2- and free wiring. – Unclip connector -1- from fan support and free wiring.
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– Remove securing nuts -arrows- and remove fans.
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Nm 5
Radiator fan to fan support (double fan) Fan support to radiator
10 5
118
Rep. gr.19 - Cooling
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.4
Removing and installing fan support with fans (Passat)
Special tools and workshop equipment required ♦ Torque wrench (5... 50 Nm) -V.A.G 1331-
Removing The procedure for the single fan is identical.
– Remove air intake duct from air filter. – Separate connector -1- and remove fan support securing bolts -arrows-. G. Volkswagen agen ksw Vol y b ed ris o h t au
– Remove fan support with fans upwards.
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– Separate connection -2- and free wiring. – Unclip connector -1- from fan support and free wiring. – Remove securing nuts -arrows- and remove fans. Installing
The procedure for the single fan is identical. Installation is carried out in the reverse order. When installing, note the following:
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Radiator fan to fan support (double fan) Fan support to radiator
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Component Radiator fan to fan support (single fan)
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Specified torques: ⇒ Item 15 (page 117)
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– Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Assembly overview - Body - front .
Nm 5 10 5
1. Parts of cooling system
119
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.5
Parts of cooling system, engine side
1 - To top of expansion tank ❑ Coolant hose schematic diagram ⇒ page 122 . 2 - Upper coolant pipe ❑ Bolted to cylinder head cover AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s
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4 - O-ring ❑ Renew.
6 - Coolant temperature sender -G62❑ With coolant tempera‐ ture display sender -G27 - To exhaust gas recircula‐ tion cooler. ❑ Coolant hose schematic diagram ⇒ page 122 . 9 - 10 Nm
10 - To heat exchanger ❑ Coolant hose schematic diagram ⇒ page 122 .
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13 - To bypass flap ❑ Coolant hose schematic diagram ⇒ page 122 .
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5 - Retaining clip ❑ Check for secure seat‐ ing.
14 - T-piece 15 - To top of radiator ❑ Coolant hose schematic diagram ⇒ page 122 . 16 - 15 Nm 17 - To bottom of expansion tank ❑ Coolant hose schematic diagram ⇒ page 122 . 18 - Coolant pipe 19 - To bottom of radiator ❑ Coolant hose schematic diagram ⇒ page 122 . 20 - Connection ❑ For thermostat. 21 - Thermostat ❑ Removing and installing ⇒ page 130 ❑ Observe installation position ⇒ page 130 , removing and installing thermostat.
120
Rep. gr.19 - Cooling
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ❑ ❑ ❑ ❑
Checking: heat thermostat in water. Opening begins at approx. 85 °C. Ends at approx. 105 °C. Opening lift at least 7 mm.
22 - To heat exchanger ❑ Coolant hose schematic diagram ⇒ page 122 23 - Rear coolant pipe 24 - 10 Nm 25 - To auxiliary heater ❑ Coolant hose schematic diagram ⇒ page 122 26 - Coolant pipe 27 - To exhaust gas recirculation cooler. ❑ Coolant hose schematic diagram ⇒ page 122
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29 - Coolant pump ❑ Check for ease of movement. ❑ Note installation position. ❑ Removing and installing ⇒ page 128
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28 - Engine oil cooler ❑ Removing and installing ⇒ page 109
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1.6
Coolant hose schematic diagram
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1 - Expansion tank 2 - Rear coolant pipe 3 - Bypass flap 4 - Exhaust gas recirculation cooler 5 - Cylinder head/cylinder block 6 - Heat exchanger for heater unit 7 - Connection 8 - Front coolant pipe
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9 - Gearbox oil cooler ❑ if fitted ❑ Only on vehicles with automatic gearbox. 11 - Radiator
12 - Lower coolant hose 13 - Engine oil cooler 14 - Coolant pump and ther‐ mostat 15 - Upper coolant pipe 16 - Circulation pump -V55❑ if fitted 17 - Auxiliary heater ❑ Vehicles with optional equipment only.
Note
Coolant hose schematic diagram for vehicles with optional equip‐ ment ⇒ Heating, ventilation, air conditioning system; Rep. gr. 82 ; Connection diagram for coolant hoses in vehicles with auxil‐ iary heater
122
Rep. gr.19 - Cooling
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1.7
Draining and filling coolant
Special tools and workshop equipment required ♦ Refractometer -T10007♦ Drip tray -V.A.G 1306♦ Spring-type clip pliers VAS 5024 A♦ Cooling system charge unit -VAS 6096-
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– Open cap on coolant expansion tank.
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– Open cap on coolant expansion tank.
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♦ Adapter -V.A.G 1274/8-
– Remove noise insulation. ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . If drain plug is fitted:
1. Parts of cooling system
123
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – To drain coolant from radiator, open drain plug -arrow-. If drain plug is not fitted:
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Rep. gr.19 - Cooling
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Observe environmental regulations for disposal.
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– To drain coolant from engine, also remove coolant hose from engine oil cooler -arrow-.
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.7.2
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‐ AG. Volkswagen AG d damage, cording to TL VW 774 F“ prevent agenfrost and corrosion oes kswpoint of coolant. Therefore, not the l o scaling and also raise boiling V gu y b ar d cooling system must isebe filled all year round with coolant ad‐ante r o eo h ditive and corrosion protection additive. ut r sa
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♦ If for climatic reasons greater frost protection is required, the amount of coolant additive can be increased, but only up to 60 % (frost protection to about -40 °C). Otherwise frost protection and cooling effectiveness are reduced again. ♦ The refractometer -T10007- is recommended for determining the current anti-freeze concentration.
Recommended mixture ratios:
40 % 50 %
3.2 l 4.0 l
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♦ If radiator, heat exchanger, cylinder head or cylinder head gasket is renewed, do not reuse old coolant.
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♦ The coolant concentration must not be reduced by adding wa‐ ter even in warmer seasons and in warmer countries. The coolant additive concentration must be at least 40 %.
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♦ Frost protection is required down to about -25 °C (in countries with arctic climates: down to about -35 °C).
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♦ Because of itsshigher boiling point, the coolant improves en‐ gine reliability under heavy loads, particularly in countries with tropical climates.
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 6096Operating instructions for cooling system charge unit -VAS 6096are enclosed with unit.
1. Parts of cooling system
125
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Fill coolant expansion tank of -VAS 6096- with at least 8 litres of pre-mixed coolant in correct mixture ratio. Note
Exhaust air takes a slight quantity of coolant along with it; this should be collected -2-.
Removing and installing radiator (Golf, Golf Plus, Touran)
Special tools and workshop equipment required ♦ Refractometer -T10007♦ Drip tray -V.A.G 1306-
♦ Adapter -V.A.G 1274/8-
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Rep. gr.19 - Cooling
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1.8
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.8.1
Removing (Golf, Golf Plus, Touran)
– Bring lock carrier into service position. ⇒ General body re‐ pairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier service position . – Drain coolant ⇒ page 123 AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e Separate connector for radiator fan. nte is r o eo h ut ra a Remove radiator securing bolts. c s s
– Pull coolant hoses off radiator. –
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– Remove radiator downwards.
1.8.2
Installing (Golf, Golf Plus, Touran)
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Installation is carried out in the reverse order. When installing, note the following: – Fill with coolant. ⇒ page 123
1.9
Removing and installing radiator (Passat)
♦ Refractometer -T10007♦ Torque wrench -V.A.G 1331/-
♦ Hose clip pliers -VAS 6340-
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Special tools and workshop equipment required
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1. Parts of cooling system
127
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Removing – Drain coolant ⇒ page 123 . – Pull coolant hoses off radiator. – Pull off connector for radiator fan. – Remove cowling together with fans ⇒ page 119 . – Remove bolts -arrow up- -arrow down- and lift radiator up and out. Installing Installation is carried out in the reverse order. When installing, note the following: – Replenish coolant ⇒ page 123 .
Removing and installing coolant pump
Special tools and workshop equipment required ♦ Refractometer -T10007♦ Drip tray -V.A.G 1306♦ Torque wrench V.A.G 1331♦ Spring-type clip pliers VAS 5024 A♦ Adapter -V.A.G 1274/8-
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♦ Cooling system charge unit -VAS 6096-
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1.10
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.10.1
Removing
Note
Always renew seals and gaskets. – Drain coolant ⇒ page 123 . – Remove poly V-belt ⇒ page 25 . – Remove toothed belt ⇒ page 66 .
1.10.2
Installing
Installation is carried out in the reverse order. When installing, note the following: agen – Moisten new O-ring -3- with coolant. lksw
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– Insert coolant pump bolts -1- to 15 Nm.
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The coolant pump plug faces downwards. – Install toothed belt ⇒ page 66 . – Install poly V-belt ⇒ page 26 . – Fill coolant system with coolant ⇒ page 123 .
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– Remove securing bolts -1- for coolant pump -2- and carefully remove coolant pump.
1. Parts of cooling system
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1.11
Removing and installing thermostat
Special tools and workshop equipment required ♦ Refractometer -T10007♦ Drip tray -V.A.G 1306♦ Torque wrench V.A.G 1331♦ Spring-type clip pliers VAS 5024 A♦ Adapter -V.A.G 1274/8-
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1.11.1
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♦ Cooling system charge unit -VAS 6096-
Removing
Note
– Drain coolant ⇒ page 123
Rep. gr.19 - Cooling
AG.
130
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– Pull coolant hose off connection.
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– Remove alternator. ⇒ Electrical system; Rep. gr. 27 ; Re‐ moving and installing alternator with poly V-belt .
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Always renew seals and gaskets.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove securing bolts -1- of connection -2- and remove con‐ nection -2- with thermostat -4-. – Turn thermostat -4- 1/4 turn (90°) anticlockwise and remove it from connection -2-.
Installing
Installation is carried out in the reverse order. When installing, note the following: – Moisten new O-ring -3- with coolant. olkswagen AG AG. Vconnection 1 – Insert thermostat geninto doeand -2a-4s no turn /4 turn (90°) ksw l o t gu yV clockwise. ar db
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The brace on the thermostat must be almost vertical.
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– Insert connection -2- with thermostat -4- in cylinder block. – Tighten securing bolts -1- to 15 Nm. – Replenish coolant. ⇒ page 123
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1.11.2
1. Parts of cooling system
131
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Checking cooling system for leaks
Special tools and workshop equipment required un le es, in part or in w l purpos hole ercia , is n m ot com
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Test sequence: WARNING
Hot steam may escape when expansion tank is opened. Place cloth over cap and open with caution. – Open cap on coolant expansion tank.
132
Rep. gr.19 - Cooling
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Test prerequisite
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♦ Adapter for cooling system tester -V.A.G 1274/9-
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♦ Adapter for cooling system tester -V.A.G 1274/8-
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♦ Cooling system tester V.A.G 1274-
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1.12
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Attach cooling system tester -V.A.G 1274- with cooling system tester adapter -V.A.G 1274/8- to expansion tank. – Use hand pump on tester to create a pressure of about 1.0 bar. If pressure drops:
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Checking pressure relief valve in filler cap
– Attach cooling system tester -V.A.G 1274- with cooling system tester adapter -V.A.G 1274/9- to cap. – Use hand pump on cooling system tester to create a pressure of max. 1.6 bar. The pressure relief valve must not open. – Renew sealing cap.
– Increase pressure to over 1.6 bar. The pressure relief valve must open.
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– Renew sealing cap.
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If the pressure relief valve opens prematurely:
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1.12.1
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– Find leaks and rectify.
1. Parts of cooling system
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1.13
Checking engine oil cooler for leaks
Special tools and workshop equipment required ♦ Refractometer -T10007♦ Hose clamps up to 25 mm -3094♦ Cooling system tester V.A.G 1274♦ Adapter for cooling system tester -V.A.G 1274/8-
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♦ Drip tray -VAS 6208-
♦ Expansion tank -1K0 121 407 A- or -6Q0 121 407 A- or -1J0 121 407 B♦ Plug -191 211 343-
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Rep. gr.19 - Cooling
AG.
Not illustrated:
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♦ Torque wrench -V.A.G 1331-
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Special tools and workshop equipment required
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♦ Spring-type clip pliers -VAS 5024A-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ♦ Cap -1J0 121 324♦ Coolant hose -251 265 056♦ Screw clamp Test prerequisite: •
Engine cold
Test procedure – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐ tion . – Clamp supply line and return line off engine oil cooler using hose clips to ∅ 25 mm -3094- . – Loosen spring-type clips -arrows- using spring-type clip pliers -VAS 5024A- . Note
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– Push sealing cap -5- to rear connection of engine oil cooler -4-. – Secure sealing plug -2- to breather connection of expansion tank -1-. – Secure coolant hose -3- to oil cooler and expansion tank. – Fill expansion tank up to „Max“ marking. – Attach cooling system tester -V.A.G 1274- with cooling system tester adapter -V.A.G 1274/8- to expansion tank. Use hand pump on tester to create a pressure of about 1.6 bar. Watch pressure drop on pressure gauge. A pressure drop within 10 minutes is not permitted. If pressure drops:
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Assembly is carried out in the reverse order, note the following: – Check coolant level, if necessary replenish coolant.
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– Renew engine oil cooler.
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– Pull coolant hoses off engine oil cooler.
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Collect escaping
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1. Parts of cooling system
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20 –
Fuel supply system
1
Safety precautions
1.1
Safety precautions when working on fu‐ el supply system WARNING
When doing any repair work, especially in the engine com‐ partment, pay attention to the following due to the cramped conditions: ♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions.
♦ 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!
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♦ Wear eye and hand protection when of repair work on the fuel system!
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When removing and installing fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel tank, observe the following:
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♦ Even before work commences, the extraction hose of an ac‐ tivated fume extraction system has to be placed in the vicinity of the assembly opening of the fuel tank to extract any escap‐ ing fumes. If no exhaust extraction system is available, a radial fan with a displacement greater than 15 m3/h can be used providing that motor is not in air flow. ♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
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Rep. gr.20 - Fuel supply system
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♦ Ensure that there is sufficient clearance to all moving or hot components.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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
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♦ Carefully cover opened components or seal if repairs cannot be carried out immediately.
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♦ Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.).
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♦ Also ensure that no diesel fuel comes into contact with the coolant hoses. Should this occur, the hoses must be cleaned immediately. Damaged hoses must be renewed.
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♦ When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely nec‐ essary.
2. Rules for cleanliness
137
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Fuel tank, vehicles with front-wheel drive ⇒ page 138 . Fuel tank, vehicles with four-wheel drive ⇒ page 142 . Emptying fuel tank ⇒ page 148 .
Removing and installing fuel delivery unit ⇒ page 150 . Removing and installing fuel gauge sender ⇒ page 151 . Checking fuel pump ⇒ page 152 .
Assembly overview - fuel filter ⇒ page 156 . Removing and installing fuel cooler ⇒ page 158 .
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♦ Hose connections are secured with either spring-type or clamp-type clips. ♦ Always renew clamp-type clips with spring-type clips.
138
Rep. gr.20 - Fuel supply system
AG.
♦ Spring-type clip pliers -VAS 5024/- or hose clip pliers -V.A.G 1921/- are recommended for installation of spring-type clips.
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Fuel tank, vehicles with front-wheel drive
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Rules for cleanliness ⇒ page 137 .
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
3.1.1
Assembly overview - fuel tank
1 - Cap 2 - 1.5 Nm 3 - Earth connection ❑ Check for secure seat‐ ing. 4 - 10 Nm 5 - Cable guide
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8 - Clamping washer
9 - Securing strap ❑ Note installation posi‐ tion. 10 - Heat shield ❑ For fuel tank.
11 - Seal ❑ Renew if damaged. ❑ Moisten with fuel when installing
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12 - Fuel delivery unit ❑ With fuel gauge sender (G). ❑ Note installation posi‐ tion of flange on fuel tank ⇒ page 162 . ❑ Removing and installing ⇒ page 150 ❑ Checking fuel pump ⇒ page 152 . ❑ Removing and installing fuel gauge sender ⇒ page 170 .
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7 - 25 Nm ❑ Renew.
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6 - Fuel tank ❑ When removing, sup‐ port using engine and gearbox jack -V.A.G 1383/A- . ❑ Removing and installing ⇒ page 140
13 - Locking ring ❑ Remove and install using wrench -T10202- . ❑ Specified torque: 110 Nm 14 - Supply line ❑ To fuel filter ❑ Clipped onto fuel tank. ❑ Check for secure seating. ❑ Black ❑ To pull off flange, press release button on connecting piece. 15 - Return line ❑ From fuel cooler ❑ Blue or with blue marking.
3. Parts of fuel supply system (Golf, Golf Plus)
139
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ❑ Clipped onto fuel tank. ❑ Check for secure seating. ❑ To pull off flange, press release button on connecting piece. 16 - Tank flap unit ❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit .
3.1.2
Removing and installing fuel tank
Special tools and workshop equipment required
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Removing
– Note safety precautions before beginning work ⇒ page 136 . Prote cted by c o py rig ht . C op yi
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Note
♦ Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary. ♦ When lowering fuel tank, guide it carefully to prevent damage. – Disconnect earth strap from battery with ignition switched off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and recon‐ necting battery . – Remove rear seat bench (Golf Plus: rear right seat) ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats; Removing and installing seat bench .
140
Rep. gr.20 - Fuel supply system
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♦ Engine and gearbox jack -V.A.G 1383/A-
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♦ Torque wrench -V.A.G 1331/-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove cover from fuel delivery unit. – Pull connector off flange. – Remove fuel flap unit. ⇒ General body repairs, exterior; Rep. gr. 55 ; Fuel flap unit – Emptying fuel tank ⇒ page 148 . – Remove rear right wheel housing liner: ⇒ General body re‐ pairs, exterior; Rep. gr. 66 ; Removing and installing wheel housing liner .
– Disconnect fuel lines at front right of fuel tank. Note
Press buttons on hose couplings to do this. – If vehicle has supplementary heating, separate connector to wagen AG. Volkswagen AG doe s no ks metering pump and unclip wire. ⇒ Supplementary heating; t gu Vol by ara d Rep. gr. 82 ; Removing and installing metering pump -V54 n ise
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uttank. – Remove bolts -A- and remove heat shield for fuel sa s
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– Support fuel tank using engine and gearbox jack -V.A.G 1383/ A- .
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– Remove securing bolts -arrows- for the fuel tank. – Slowly lower fuel tank and pull it forwards. – Tilt fuel tank to get it past rear axle. Installing
Install in reverse order. In the process, note the following: ♦ Install breather and fuel hoses free of kinks. ♦ Ensure that fuel hose connections are tight.
♦ Do not interchange supply line and return line (return line blue or with blue marking, supply line black). ♦ Clip supply and return lines onto fuel tank.
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3. Parts of fuel supply system (Golf, Golf Plus)
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– Remove bolts from filler neck -arrows-.
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3.2
Fuel tank, vehicles with four-wheel drive
3.2.1
Assembly overview - fuel tank
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5 - Locking ring, 110 Nm ❑ Check for secure seat‐ ing. ❑ Remove and install us‐ ing wrench -T10202- .
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4 - Fuel delivery unit ❑ Removing and installing ⇒ page 150 ❑ Checking fuel pump ❑ Note installation posi‐ tion on fuel tank ⇒ page 143 . ❑ With fuel gauge sender -G- . ❑ Removing and installing fuel gauge sender ⇒ page 170 .
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3 - Seal ❑ Renew. ❑ When installing, fit dry in fuel tank opening. ❑ Moisten with fuel only when installing flange.
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2 - Return line ❑ blue ❑ Check for secure seat‐ ing.
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1 - Supply line ❑ Black ❑ Check for secure seat‐ ing.
6 - Tank flap unit ❑ With rubber cup. ❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and installing fuel tank flap unit . 7 - Cap ❑ Renew if damaged. 8 - Securing bolt ❑ Tighten to 1.5 Nm. 9 - Earth connection ❑ Check for secure seating. 10 - 10 Nm 11 - Suction-jet pump ❑ Clipped onto fuel gauge sender 2 -G169❑ Removing and installing ⇒ page 147
142
Rep. gr.20 - Fuel supply system
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 12 - Fuel gauge sender 2 -G16913 - Fuel tank ❑ When removing, support using engine and gearbox jack -V.A.G 1383 A- . ❑ Removing and installing ⇒ page 143 14 - Securing strap ❑ Note installation position. 15 - 25 Nm ❑ Renew. 16 - Heat shield ❑ Riveted to exhaust pipe mounting Installation position of flange for fuel delivery unit and fuel gauge sender 2 -G169The marking on the flange must align with the marking on the fuel tank -arrow-.
The marking on the fuel tank is not clearly visible.
Removing and installing fuel tank es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n
3.2.2
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Special tools and workshop equipment required ♦ Torque wrench (5... 50 Nm) -V.A.G 1331-
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♦ Engine and gearbox jack -V.A.G 1383 A-
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Note
– Note safety precautions before beginning work ⇒ page 136 .
3. Parts of fuel supply system (Golf, Golf Plus)
143
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– First check whether a coded radio is fitted. If so, obtain antitheft coding. es, in part or in w l purpos hole ercia , is n m ot com
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– Disconnect earth strap from battery with ignition switched off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and recon‐ necting battery .
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Note
If necessary, drain fuel tank using fuel extractor -VAS 5190- . ⇒ page 148 – Remove rear right wheel. – Remove rear right wheel housing liner. ⇒ General body re‐ pairs, exterior; Rep. gr. 66 ; Removing and installing wheel housing liner; Rear wheel housing liner . – Unscrew securing bolts and remove tank flap unit. ⇒ General body repairs, exterior; Rep. gr. 55 ; Fuel flap unit r te o iva r rp fo g n
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– Remove covers and separate electrical connectors -arrows-. – Remove centre and rear silencers.
– Secure exhaust system to underbody using wire. – Remove rear propshaft ⇒ Manual gearbox; Rep. gr. 39 ; Final drive, differential, differential lock WARNING
Fuel supply line is pressurised. Wear eye protection and pro‐ tective clothing to avoid possible injury and skin contact. Be‐ fore loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
144
Rep. gr.20 - Fuel supply system
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– Remove bench seat ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing seat bench .
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– Unscrew filler neck from body -arrows- and unclip electrical wire from filler neck.
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drive control unit -J492- .
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– Pull off adapter cable
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– Support fuel tank using engine and gearbox jack -V.A.G 1383 A- and unscrew tensioning straps and securing bolts.
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The filler neck must be „guided out“ between body and rear axle. To do this, take the fuel tank off engine and gearbox jack -V.A.G 1383 A- with the assistance of a 2nd mechanic.
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– Slowly lower fuel tank.
– Clip in cable for four-wheel drive control unit -J492- on fuel tank.
– With the aid of a 2nd mechanic, guide the filler neck in between rear axle and body. Then place the fuel tank on the engine and gearbox jack -V.A.G 1383 A- .
– Raise fuel tank slowly up to installation position and secure it in place.
3. Parts of fuel supply system (Golf, Golf Plus)
145
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Fit adapter cable on four-wheel drive control unit -J492- . The remaining installation steps are carried out in the reverse se‐ quence. In the process, note the following: ♦ Install breather and fuel lines free of kinks. ♦ Do not interchange supply line and return line (return line blue or with blue marking, supply line black). ♦ Ensure that fuel line connections are tight. ♦ Check earth connection on fuel tank and body to filler neck.
3.2.3 •
Removing and installing fuel gauge sender 2 -G169-
The fuel tank should be no more than half full Note
♦ If necessary, drain fuel tank using fuel extractor -VAS 5190- . ⇒ page 148 ♦ Note safety precautions before beginning work ⇒ page 136 . ♦ Observe rules for cleanliness ⇒ page 137 . Removing: – First check whether a coded radio is fitted. If so, obtain antitheft coding. – Disconnect earth strap from battery with ignition switched off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and recon‐ necting battery . G. Volkswagen nA wage
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– Disconnect electrical connectors. – Open locking ring using wrench -T10202- .
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– Remove left cover (ass auseen facing direction of normal travel) s from fuel gauge sender 2 -G169- .
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♦ Ensure that the fuel gauge sender is not bent.
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When installing do not bend fuel gauge sender 2 -G169- float arm.
– Fit suction-jet pump on sender on inside of fuel tank. Locating lugs must engage. – Place a new flange seal dry into aperture in fuel tank and moisten only inside (contact to flange) with fuel. – Note installation position of fuel gauge sender 2 -G169- ⇒ page 143
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– Tighten locking ring using wrench -T10202- . Specified torque: 110 Nm. AG.
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– Install cover.
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– Fit connectors.
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– Check correct position of seal.
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– Place fuel gauge sender 2 -G 169- in fuel tank.
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Installing:
– 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 .
3. Parts of fuel supply system (Golf, Golf Plus)
147
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Pull return hose of suction-jet pump out of fuel delivery unit -arrow-. – Separate quick-release coupling of supply line from suctionjet pump on Y-piece of fuel delivery unit. – Remove fuel gauge sender 2 -G 169- ⇒ page 146 . – Now the suction-jet pump can be pulled out from the side of the fuel gauge sender 2 -G169- (left side of vehicle). – Check that the fuel lines on suction-jet pump are fitted securely and are not damaged. – Additionally check suction-jet pump for possible soiling.
3.3
Emptying fuel tank
Special tools and workshop equipment required
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♦ Fuel tank sender unit tool -T10202-
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– Note safety precautions before beginning work ⇒ page 136 .
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Emptying fuel tank if it is more than 3/4 full ⇒ page 148 .
Caution
Secure earth wire of fuel extractor -VAS 5190- to a bare metal part of the body.
148
Rep. gr.20 - Fuel supply system
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Emptying fuel tank if it is more than 3/4 full
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3.3.1
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Emptying fuel tank if it is less than 3/4 full ⇒ page 149 .
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♦ Torque wrench (40... 200 Nm) -V.A.G 1332-
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♦ Fuel extractor -VAS 5190-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ (1.9 l engine) - Edition 08.2010
–
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– Remove filler cap from fuel tank filler neck. – Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel filler neck.
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Note
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– Push extraction hose into fuel tank until marking on hose -arrow- coincides with shaft end.
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–
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A ball valve -2- is located at the bottom of the filler neck in the fuel tank -1-; it must not be damaged by the extraction hose -3-. Therefore push hose into filler neck only as far as marking -arrow-. – Empty fuel tank as far as possible. – Carefully pull out extraction hose. Note ♦ When no more fuel is extracted, the tank is emptied just enough for the sender flange to be opened without danger. ♦ If the fuel tank has to be drained fully, proceed as follows: ⇒ page 149
3.3.2
Emptying fuel tank if it is less than 3/4 full
– Remove bench seat ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats; Removing and installing bench seat . – Remove cover from fuel delivery unit. WARNING
Fuel supply line is pressurised. Wear eye protection and pro‐ tective clothing to avoid possible injury and skin contact. Be‐ fore loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
3. Parts of fuel supply system (Golf, Golf Plus)
149
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Pull connector and fuel lines off flange. Note
Press buttons on hose couplings to do this. – Open locking ring using fuel tank sender wrench -T10202- . – Lift sender flange. – Insert extraction hose of fuel extractor -VAS 5190- as deeply as possible into fuel tank and extract fuel. If fuel tank needed only to be emptied, reinstall sender flange.
Removing and installing fuel delivery unit
Special tools and workshop equipment required
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Observe safety precautions ⇒ page 136 .
Observe rules for cleanliness ⇒ page 137 . r fo ng
– First check whether a coded radio is fitted. If so, obtain antitheft coding.
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Rep. gr.20 - Fuel supply system
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150
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– Disconnect earth strap from battery with ignition switched off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and recon‐ necting battery .
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Removing
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♦ Torque wrench -V.A.G 1332-
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♦ Wrench -T10202-
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3.4
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove rear seat bench (Golf Plus: rear right seat) ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats; Removing and installing seat bench . – Remove cover from fuel delivery unit. – Pull 5-pin connector and fuel lines off flange. Note
Press buttons on hose couplings to do this. WARNING
♦ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! ♦ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!
– Remove union nut with wrench -T10202- . – Pull fuel delivery unit and seal out of the opening in fuel tank. Note
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– Installing the fuel delivery unit is carried out in reverse order of removal.
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♦ Do not bend fuel gauge sender when installing. ♦ Insert seal for flange or fuel delivery unit dry into opening of fuel tank. ♦ Moisten seal with fuel only when installing flange or fuel de‐ livery unit. ♦ Ensure that fuel hose connections are tight. ♦ After installing fuel delivery unit, check that the supply, return and breather lines are still clipped onto the fuel tank.
Removing and installing fuel gauge sender
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– Remove fuel delivery unit ⇒ page 150 .
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Removing
3. Parts of fuel supply system (Golf, Golf Plus)
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♦ Note installation position of fuel delivery unit flange: mark on flange must align with mark on fuel tank -arrows-.
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♦ Wear eye and hand protection when performing any type of repair work on the fuel system!
151
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Release connector lugs on lines -3- and -4- and pull off. – Lift retaining tabs -1- and -2- using a screwdriver and pull fuel gauge sender off downwards -arrows-. Installing – Insert fuel sender into guides on fuel delivery unit and press upwards until it engages.
3.6
Checking fuel pump Note
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Special tools and workshop equipment required ♦ Pressure gauge -VAS 6550♦ Vehicle diagnosis tester Test prerequisite: •
Fuses must be OK.
•
Battery voltage at least 12 V
•
All electrical consumers, e.g. lights and rear window heating, must be switched off.
– Separate quick-release coupling -A- (completely black or with black marking) of fuel supply line.
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– 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 .
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Rep. gr.20 - Fuel supply system
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– Open shut-off taps „A“ and „B“ of pressure tester and close shut-off tap „C“.
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– Switch on pressure tester -VAS 6550- by pressing On/Off button.
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– Connect pressure tester -VAS 6550- with cables -VAS 6550/1and -VAS 6550/2- to open ends of fuel supply line.
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Checking delivery pressure of fuel pump
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3.6.1
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Check fuel filter connections for correct arrangement, before starting to check the fuel pump ⇒ page 156
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
3.6.2
Checking fuel pump delivery rate
Special tools and workshop equipment required ♦ Pressure gauge -VAS 6550♦ Container > 3 litre with measuring scale ♦ Vehicle diagnosis tester Test prerequisite: Fuses must be OK.
•
Battery voltage at least 12 V
•
All electrical consumers, e.g. lights and rear must be switched off.
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The delivered fuel may be cloudy. This is normal and can be ig‐ nored.
– Connect -VAS 6550/1- pressure tester line to fuel supply -A-. – Guide open end of line into measuring container. – Connect vehicle diagnosis tester and perform guided function „checking electric fuel pump(s)“. Note
– After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s.
– If necessary, renew defective line and repeat test.
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– Check fuel supply line between fuel pump and engine com‐ partment for kinks, crushes or damage.
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If the specification is not attained:
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The fuel pump is now activated for 30 seconds.
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– Separate quick-release coupling -A- (completely black or with black marking) of fuel supply line.
– If it is not kinked, crushed or damaged, remove rear seat bench ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats . – Detach carpet under seats and fold it back. ⇒ General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor – Remove cover from fuel delivery unit. Note
Press in securing ring to release fuel line.
3. Parts of fuel supply system (Golf, Golf Plus)
153
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– Pull fuel supply line (black or ery unit.
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– Connect -VAS 6550/1- pressure tester line to fuel supply -A-. – Guide open end of line into measuring container.
Note
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– Connect diagnosis tester and perform the guided function „Checking electric fuel pump(s)“.
The fuel pump is now activated for 30 seconds. – After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s. If the specification is not attained:
– Check voltage supply ⇒ page 154 and current draw ⇒ page 155 of fuel pump.
Checking voltage supply of fuel pump
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♦ Test instrument adapter/DSO (5-pin) -VAS 5565-
Test prerequisites •
Fuses must be OK.
•
The battery voltage must be at least 12 V, if necessary connect a battery charger.
•
All electrical consumers, e.g. lights and rear window heating, must be switched off.
– Remove seat bench ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats . – Detach carpet under seats and fold it back. ⇒ General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor – Remove cover from fuel delivery unit. – Switch on ignition. The fuel pump must be heard to run for about 2 seconds. – Switch off ignition. If the fuel pump does not start: – Pull connector off fuel delivery unit flange.
154
Rep. gr.20 - Fuel supply system
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♦ Pickup clamp -V.A.G 1526B/2-
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♦ Hand-held multimeter -V.A.G 1526D-
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Special tools and workshop equipment required
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3.6.3
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Connect test instrument adapter/DSO (5-pin) -VAS 5565- be‐ tween connector and flange. – Connect hand-held multimeter -V.A.G 1526D- to contacts -1and -5- of adapter. – Connect vehicle diagnosis tester and perform guided function „checking electric fuel pump(s)“. Note
The fuel pump is now activated for 30 seconds. – Read voltage value on hand-held multimeter -V.A.G 1526D- : Specification = battery voltage. If no voltage is present: – Check activation of fuel pump relay and wiring for an open or short circuit ⇒ Vehicle diagnostic, testing and information sys‐ tem VAS 5051. Voltage supply OK: – Check that electrical wiring between flange and fuel pump is connected and has continuity. If no open circuit can be found: – Renew fuel delivery unit.
3.6.4
Checking current draw of fuel pump
Special tools and workshop equipment required
♦
♦ Vehicle diagnosis tester
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The battery voltage and the diesel fuel temperature have a great influence on the current draw of the fuel pump. For this reason ensure that the battery voltage is at least 12 V whilst checking and the diesel fuel temperature does not fall to the freezing point. Test prerequisites •
Battery voltage at least 12 V
•
Diesel fuel temperature above (10 ) C
– Remove seat bench ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats .
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– Remove cover from fuel delivery unit.
3. Parts of fuel supply system (Golf, Golf Plus)
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– Remove fuel delivery unit ⇒ page 180 .
155
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– Pull connector -C- off flange.
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– Connect test instrument adapter/DSO (5-pin) -VAS 5565- to connector and fuel delivery unit. – Connect pick-up clamp -A- to red terminal with lettering „pickup clamp“ for test instrument adapter/DSO (5-pin) -VAS 5565- .
ProCarManuals.com
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Note
The fuel pump is now activated for 30 seconds. – Read current draw on hand-held multimeter -V.A.G 1526D- . Specification: max. 7.5 amps. – If the measured value is not within specifications: – Renew fuel delivery unit ⇒ page 180 .
3.7
Assembly overview - fuel filter Note
Note that there are different versions of fuel filter upper part ⇒ page 158 .
156
Rep. gr.20 - Fuel supply system
AG.
– Connect vehicle diagnosis tester and perform guided function „checking electric fuel pump(s)“.
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– Switch on ignition.
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Pickup clamp of hand-held multimeter -V.A.G 1715- can also be connected to red terminal with lettering „pickup clamp“ of test in‐ strument adapter/DSO (5-pin) -VAS 5565- .
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Note
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 1 - Supply line ❑ From fuel tank. ❑ White or with white marking. ❑ Check for secure seat‐ ing. 2 - 5 Nm
5 - Seal ❑ Renew.
6 - Supply line ❑ To tandem pump
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7 - Return line ❑ From tandem pump ❑ Blue or with blue mark‐ ing. ❑ Check for secure seat‐ ing.
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9 - Fuel temperature sender -G81-
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8 - Upper part of fuel filter
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4 - Plug for water extraction ❑ Remove and extract about 100 cm3 liquid us‐ ing hand-operated vac‐ uum pump with acces‐ sories -V.A.G 1390- and water drainage contain‐ er -V.A.G 1390/1- .
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3 - Return line ❑ To fuel cooler ❑ Check for secure seat‐ ing. ❑ Blue or with blue mark‐ ing.
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. Parts of fuel supply system (Golf, Golf Plus)
157
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
3.7.1
Upper part of fuel filter
Type A ⇒ page 158 Type B ⇒ page 158 Upper part of fuel filter, type A 1 - 8 Nm 2 - Plug for water extraction (remove and extract about 100 cm3 liquid using hand-operated vacuum pump with accessories V.A.G 1390- and water drainage container -V.A.G 1390/1- , renew seal) 3 - Fuel supply line from fuel tank, white or white marking. Check for secure seating. 4 - Fuel return line to fuel tank, blue or blue marking. Check for secure seating. 5 - Fuel supply line to engine, white or white marking. Check for secure seating.
secure seating.
3 - Fuel supply line from fuel tank, white or white marking. Check for secure seating.
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4 - Fuel return line from engine, blue or blue marking. Check for secure seating. 5 - Fuel supply line to engine, white or white marking. Check for secure seating.
3.8
Removing and installing fuel cooler
Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331/-
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– Note safety precautions before beginning work ⇒ page 136 . Observe rules for cleanliness ⇒ page 137 .
158
Rep. gr.20 - Fuel supply system
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6 - Fuel return line from engine, blue or blue marking. Check for secure seating.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
– Remove underbody panel. – Separate fuel lines at fuel cooler. – Remove securing nuts -arrows-. Installing
Install in reverse order. In the process, note the following:
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♦ Tighten fuel cooler securing nuts to 15 Nm.
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3. Parts of fuel supply system (Golf, Golf Plus)
159
♦ Hose connections are secured with either spring-type or clamp-type clips. ♦ Always renew clamp-type clips with spring-type clips. ♦ Spring-type clip pliers -VAS 5024/- or hose clip pliers -V.A.G 1921/- are recommended for installation of spring-type clips.
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Rep. gr.20 - Fuel supply system
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Note
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Parts of fuel supply system (Touran)
2003 ➤
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Vol 137 . Rules for cleanliness ⇒ page by d ise
r Assembly overview ho- fuel tank with attachments ⇒ ut sa
Removing and installing fuel tank ⇒ page 165 . Assembly overview - fuel filter ⇒ page 167 .
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s Emptying fuel tank ⇒ page 162 .
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Removing and installing fuel cooler ⇒ page 168 . Removing and installing fuel delivery unit ⇒ page 169 . Removing and installing fuel gauge sender ⇒ page 170 . Checking fuel pump ⇒ page 171 .
4.1
Assembly overview - fuel tank with attachments
1 - Cap
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4 - Earth connection ❑ Check for secure seat‐ ing.
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2 - 1.5 Nm
5 - 10 Nm 6 - Pressure retention valve with connecting hose 7 - Gravity/overflow valve 8 - Fuel tank ❑ When removing, sup‐ port using engine and gearbox jack -V.A.G 1383/A- . ❑ Removing and installing ⇒ page 165 . 9 - Heat shield ❑ For fuel tank. 10 - Securing strap 11 - 20 Nm + turn (90°) 12 - Fuel delivery unit ❑ With fuel gauge sender (G). ❑ Note installation posi‐ tion of flange on fuel tank ⇒ page 162 . ❑ Removing and installing ⇒ page 169 ❑ Checking fuel pump ⇒ page 152 . ❑ Removing and installing fuel sender ⇒ page 170 . ❑ Clean strainer if soiled.
4. Parts of fuel supply system (Touran)
161
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 13 - Seal ❑ Renew. ❑ Moisten with fuel when installing. 14 - Union nut, 80 Nm ❑ Remove and install using union nut tool -3217- . 15 - Supply line ❑ To fuel filter ❑ Clipped onto fuel tank. ❑ Check for secure seating. ❑ Black ❑ To pull off flange, press release button on connecting piece.
Installation position of fuel delivery unit Marking on flange must align with marking on fuel tank -arrows-. Black supply line -1- to connection marked -V-. Return line -2- (blue or with blue marking) to connection marked -R-. Note
After installing fuel delivery unit flange, check that supply, return n AG. Volkswagen A G do es n wage and breather lines are still clipped onto fuel tank. o olks
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♦ Fuel extractor -VAS 5190-
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16 - Return line ❑ From fuel cooler ❑ Blue or with blue marking. ❑ Clipped onto fuel tank. ❑ Check for secure seating. ❑ To pull off flange, press release button on connecting piece.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ♦ Union nut tool -3217-
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– Note safety precautions before beginning work ⇒ page 136 . Emptying fuel tank if it is more than 3/4 full ⇒ page 163 . Emptying fuel tank if it is less than 3/4 full ⇒ page 164 .
4.2.1
Emptying fuel tank if it is more than 3/4 full Caution
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– At distance -a- = 1,200 mm from end, mark extraction hose with insulating tape -arrow-.
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♦ Torque wrench (40... 200 Nm) -V.A.G 1332-
4. Parts of fuel supply system (Touran)
163
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove filler cap from fuel tank filler neck. – Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel filler neck. – Push extraction hose into fuel tank until marking on hose -arrow- coincides with shaft end.
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel tank -1-; it must not be damaged by the extraction hose -3-. Therefore push hose into filler neck only as far as marking -arrow-. – Drain fuel tank as much as possible through fuel filler neck.
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♦ When no more fuel is extracted, the tank is emptied just enough for the sender flange to be opened without danger. The tank may be removed while containing remaining fuel. ♦ If work must be performed on fuel pump or fuel tank sender, proceed as follows:
4.2.2
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Emptying fuel tank if it is less than 3/4 full
– Fold rear seats forwards.
– Detach carpet under seats and fold it back. ⇒ General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor
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.
Press buttons on hose couplings to do this.
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Rep. gr.20 - Fuel supply system
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– Pull connector and fuel lines off flange.
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– Carefully pull out extraction hose.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Open locking ring using union nut tool -3217- . – Raise fuel delivery unit. – Insert extraction hose of fuel extractor -VAS 5190- as deeply as possible into fuel tank and extract fuel. If fuel tank needed only to be emptied, install fuel delivery unit again ⇒ page 169 .
4.3
Removing and installing fuel tank
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♦ Torque wrench -V.A.G 1331/-
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Special tools and workshop equipment required
♦ Engine and gearbox jack -V.A.G 1383/A-
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Removing – Note safety precautions before starting work ⇒ page 136 . Observe rules for cleanliness ⇒ page 137 . Note ♦ Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary. ♦ When lowering fuel tank, guide it carefully to prevent damage. – Disconnect earth strap from battery with ignition switched off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and recon‐ necting battery . – Fold rear seats forwards. 4. Parts of fuel supply system (Touran)
165
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Detach carpet under seats and fold it back. ⇒ General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor – Remove cover from fuel delivery unit. – Pull connector off flange. – Remove fuel flap unit. ⇒ General body repairs, exterior; Rep. gr. 55 ; Fuel flap unit – Draining fuel tank ⇒ page 162 – Remove rear right wheel housing liner: ⇒ General body re‐ lkswagen o pairs, exterior; Rep. gr. 66 ; Removing and installing wheel yV db e housing liner . is or un le
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– Disconnect fuel lines at front right of fuel tank. Note
Press buttons on hose couplings to do this.
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– Remove securing bolts -B- and remove retaining strap. – Slowly lower fuel tank and pull it forwards. – Tilt fuel tank to get it past rear axle. Installing Install in reverse order. In the process, note the following: ♦ Install breather and fuel hoses free of kinks. ♦ Ensure that fuel hose connections are tight. ♦ Do not interchange supply line and return line (return line blue or with blue marking, supply line black). ♦ Clip supply and return lines onto fuel tank.
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Rep. gr.20 - Fuel supply system
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– Support fuel tank using engine and gearbox jack -V.A.G 1383/ A- .
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– Remove bolts -A- and remove heat shield for fuel tank.
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– If vehicle has supplementary heating, separate connector to metering pump and unclip wire. ⇒ Supplementary heating; Rep. gr. 82 ; Removing and installing metering pump -V54
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– Remove bolts from filler neck -arrows-.
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4.4
Assembly overview - fuel filter
1 - Upper part of fuel filter ❑ Observe various types ⇒ page 167 2 - Fuel temperature sender G81❑ Installed in engine re‐ turn line 3 - Seal ❑ Renew. 4 - Filter insert ❑ Observe change inter‐ vals. 5 - Seal ❑ Renew. 6 - Fuel filter lower part 8 - Bracket 9 - Seal ❑ Renew. 10 - Retaining clip AG. Volkswagen AG d ❑ Check for secure seat‐ agen oes ksw not l ing. o V g by ed
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4.4.1
Upper part of fuel filter
Type A ⇒ page 167 Type B ⇒ page 168 Upper part of fuel filter, type A 1 - 8 Nm
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4 - Fuel return line to fuel tank, blue or blue marking. Check for secure seating. agen lksw Vo by
5 - Fuel supply line to engine, white or white marking. Check for secure seating. AG.
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7 - 8 Nm
4. Parts of fuel supply system (Touran)
167
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 6 - Fuel return line from engine, blue or blue marking. Check for secure seating. Upper part of fuel filter, type B 1 - 5 Nm 2 - Fuel return line to fuel tank, blue or blue marking. Check for secure seating. 3 - Fuel supply line from fuel tank, white or white marking. Check for secure seating. 4 - Fuel return line from engine, blue or blue marking. Check for secure seating. 5 - Fuel supply line to engine, white or white marking. Check for secure seating.
4.5
Removing and installing fuel cooler
Special tools and workshop equipment required
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Removing
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– Note safety precautions before starting work ⇒ page 136 . Observe rules for cleanliness ⇒ page 137 . Note
The fuel cooler is located in the return line to fuel tank. It is located on the vehicle underbody. – Remove underbody panel. – Remove securing nuts -arrows-. Prote cted by c o p yri gh t. C op yi
Installing
Install in reverse order. In the process, note the following:
Rep. gr.20 - Fuel supply system
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♦ Tighten fuel cooler securing nuts to 15 Nm.
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♦ Torque wrench -V.A.G 1331/-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
4.6
Removing and installing fuel delivery unit
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♦ Union nut tool -3217-
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Observe safety precautions ⇒ page 136 .
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♦ Torque wrench -V.A.G 1332-
– First check whether a coded radio is fitted. If so, obtain antitheft coding. – Disconnect earth strap from battery with ignition switched off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and recon‐ necting battery . – Fold rear seats forwards. – Detach carpet under seats and fold it back. ⇒ General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor – Remove cover from fuel delivery unit. – Pull 5-pin connector and fuel lines off flange. Note
Press buttons on hose couplings to do this.
4. Parts of fuel supply system (Touran)
169
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 WARNING
♦ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! ♦ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! ♦ Wear eye and hand protection when performing any type of repair work on the fuel system!
– Unscrew union nut with union nut tool -3217- wrench . – Pull fuel delivery unit and seal out of the opening in fuel tank. Note
If delivery unit is to be renewed, drain old delivery unit before dis‐ posal.
– Installing the fuel delivery unit is carried out in reverse order of removal. Note ♦ Do not bend fuel gauge sender when installing. ♦ Insert seal for flange or fuel delivery unit dry into opening of fuel tank. ♦ Moisten seal with fuel only when installing flange or fuel de‐ n AG. Volkswagen AG do livery unit. e wage
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♦ Note installation position of fuel delivery unit flange: mark on flange must align with mark on fuel tank -arrows-.
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4.7
Removing and installing fuel gauge sender
Removing
– Remove fuel delivery unit ⇒ page 169 .
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Installing
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Release connector lugs on lines -3- and -4- and pull off. – Lift retaining tabs -1- and -2- using a screwdriver and pull fuel gauge sender off downwards -arrows-. Installing – Insert fuel sender into guides on fuel delivery unit and press upwards until it engages.
4.8
Checking fuel pump Note
Check fuel filter connections for correct arrangement, before starting to check the fuel pump ⇒ page 158
Checking delivery pressure of fuel pump
Special tools and workshop equipment required ♦ Pressure gauge -VAS 6550♦ Vehicle diagnosis tester Test prerequisite: •
Fuses must be OK.
•
Battery voltage at least 12 V
•
All electrical consumers, e.g. lights and rear window heating, must be switched off.
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– Switch on pressure tester -VAS 6550- by pressing On/Off button.
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– Open shut-off taps „A“ and „B“ of pressure tester and close shut-off tap „C“. – Start engine and run at idling speed. – Read pressure on pressure tester -VAS 6550- . Specification: min. 0.5 bar. – Place pressure tester -VAS 6550- onto windscreen so that it can be read from inside vehicle. – Increase idling speed to 2500 rpm and read the pressure on pressure tester -VAS 6550- , specification min 0.25 bar. – If the delivery pressure temporarily drops, renew fuel delivery unit ⇒ page 180 .
– If the tandem pump values are OK, check fuel pump delivery rate ⇒ page 172 .
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– If the specifications are attained, check tandem pump to en‐ sure the fuel filter is not blocked ⇒ page 195 .
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4.8.1
171
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
4.8.2
Checking fuel pump delivery rate
Special tools and workshop equipment required ♦ Pressure gauge -VAS 6550♦ Container > 3 litre with measuring scale ♦ Vehicle diagnosis tester Test prerequisite: •
Fuses must be OK.
•
Battery voltage at least 12 V
•
All electrical consumers, e.g. lights and rear window heating, must be switched off. Note
The delivered fuel may be cloudy. nored.
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– Connect -VAS 6550/1- pressure tester line to fuel supply -A-. – Guide open end of line into measuring container. – Connect vehicle diagnosis tester and perform guided function „checking electric fuel pump(s)“. Note
The fuel pump is now activated for 30 seconds. – After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s. If the specification is not attained: – Check fuel supply line between fuel pump and engine com‐ partment for kinks, crushes or damage. – If it is not kinked, crushed or damaged, remove rear seat bench ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats .
Note
Press in securing ring to release fuel line.
172
Rep. gr.20 - Fuel supply system
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– Remove cover from fuel delivery unit.
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– Detach carpet under seats and fold it back. ⇒ General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor
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– If necessary, renew defective line and repeat test.
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– Separate quick-release coupling -A- (completely black or with black marking) of fuel supply line.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Pull fuel supply line (black or black marking) -A- off fuel deliv‐ ery unit. . Volkswagetester n AG d line to fuel supply -A-. n AGpressure – Connect -VAS 6550/1oes wage
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The fuel pump is now activated for 30 seconds.
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th or function – Connect vehicle diagnosis tester and perform guided ac au s s „checking electric fuel pump(s)“.
– After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s. If the specification is not attained:
– Check voltage supply ⇒ page 173 and current draw ⇒ page 174 of fuel pump.
4.8.3
Checking voltage supply of fuel pump
♦ Hand-held multimeter -V.A.G 1526Dr fo ng
♦ Pickup clamp -V.A.G 1526B/2♦ Test instrument adapter/DSO (5-pin) -VAS 5565-
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Special tools and workshop equipment required
Test prerequisites •
Fuses must be OK.
•
The battery voltage must be at least 12 V, if necessary connect a battery charger.
•
All electrical consumers, e.g. lights and rear window heating, must be switched off.
– Remove seat bench ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats . – Detach carpet under seats and fold it back. ⇒ General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor – Remove cover from fuel delivery unit. – Switch on ignition. The fuel pump must be heard to run for about 2 seconds. – Switch off ignition. If the fuel pump does not start: – Pull connector off fuel delivery unit flange. 4. Parts of fuel supply system (Touran)
173
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Connect test instrument adapter/DSO (5-pin) -VAS 5565- be‐ tween connector and flange. – Connect hand-held multimeter -V.A.G 1526D- to contacts -1and -5- of adapter. – Connect vehicle diagnosis tester and perform guided function „checking electric fuel pump(s)“. Note
The fuel pump is now activated for 30
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If no voltage is present:
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– Read voltage value on hand-held multimeter -V.A.G 1526D- : Specification = battery voltage.
Voltage supply OK:
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– Check activation of fuel pump relay and wiring for an open or short circuit ⇒ Vehicle diagnostic, testing and information sys‐ tem VAS 5051.
– 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.
4.8.4
Checking current draw of fuel pump
Special tools and workshop equipment required
Note
The battery voltage and the diesel fuel temperature have a great influence on the current draw of the fuel pump. For this reason ensure that the battery voltage is at least 12 V whilst checking and the diesel fuel temperature does not fall to the freezing point. Test prerequisites •
Battery voltage at least 12 V
•
Diesel fuel temperature above (10 ) C
– Remove seat bench ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats . – Detach carpet under seats and fold it back. ⇒ General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor – Remove cover from fuel delivery unit.
174
Rep. gr.20 - Fuel supply system
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♦ Vehicle diagnosis tester
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♦ Test instrument adapter/DSO (5-pin) -VAS 5565-
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– Remove fuel delivery unit ⇒ page 180 .
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Pull connector -C- off flange.
– Connect test instrument adapter/DSO (5-pin) -VAS 5565- to connector and fuel delivery unit. – Connect pick-up clamp -A- to red terminal with lettering „pickup clamp“ for test instrument adapter/DSO (5-pin) -VAS 5565- .
Pickup clamp of hand-held multimeter -V.A.G 1715- can also be connected to red terminal with lettering „pickup clamp“ of test in‐ strument adapter/DSO (5-pin) -VAS 5565- . – Switch on ignition. – Connect vehicle diagnosis tester and perform guided function „checking electric fuel pump(s)“. Note agen30 The fuel pump is now AG. Volkswfor AGseconds. genactivated d
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– If the measured value is not within specifications: – Renew fuel delivery unit ⇒ page 180 .
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Note
4. Parts of fuel supply system (Touran)
175
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
5
Parts of fuel supply system (Passat)
Safety precautions ⇒ page 136 .
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Rules for cleanliness ⇒ page 137 .
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Checking fuel pump ⇒ page 185 .
Assembly overview - fuel filter ⇒ page 189 .
Fuel tank, vehicles with front-wheel drive
5.1.1
Assembly overview - fuel tank
5 - Elbow 6 - 10 Nm 7 - Fuel tank ❑ When removing, sup‐ port using engine and gearbox jack -V.A.G 1383/A- . ❑ Removing and installing ⇒ page 178 ❑ Emptying fuel tank ⇒ page 183 . 8 - Securing strap ❑ Note installation posi‐ tion. 9 - Heat shield ❑ For fuel tank. 10 - Lock washer, 2.5 Nm 11 - 25 Nm ❑ Renew.
176
Rep. gr.20 - Fuel supply system
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4 - Earth connection ❑ Check for secure seat‐ ing.
AG.
3 - Tank flap unit ❑ With rubber cup. ❑ Removing and installing ⇒ General body re‐ pairs, exterior; Rep. gr. 55 ; Tank flap unit
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2 - 1.5 Nm
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Removing and installing fuel cooler ⇒ page 191 .
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Emptying fuel tank, vehicles with front-wheel drive ⇒ page 183
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 12 - Metering pump -V54For supplementary heater ❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 82 . 13 - Seal ❑ Renew. ❑ When installing, fit dry in fuel tank opening. ❑ Moisten with fuel only when installing flange. 14 - Fuel delivery unit ❑ With fuel gauge sender (G). ❑ Removing and installing ⇒ page 180 ❑ Checking fuel pump ⇒ page 185 . ❑ Removing and installing fuel gauge sender ⇒ page 183 . 15 - Suction-jet pump ❑ Clean strainer if soiled. ❑ Not necessarily installed
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19 - Return line ❑ From fuel cooler. ❑ Blue or with blue marking. ❑ Clipped onto fuel tank. ❑ Check for secure seating. ❑ To pull off flange, press release button on connecting piece.
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20 - Supply line ❑ To fuel filter ❑ Clipped onto fuel tank. ❑ Check for secure seating. ❑ Black ❑ To pull off flange, press release button on connecting piece.
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18 - Supply line ss ❑ For auxiliary heater. ❑ To metering pump -V54- . ❑ Clipped onto fuel tank. ❑ Check for secure seating. ❑ To pull off flange, press release button on connecting piece.
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16 - Flange ❑ For fuel delivery unit ❑ Note installation position of flange on fuel tank ⇒ page 178 .
5. Parts of fuel supply system (Passat)
177
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Installation position of fuel delivery unit Marking -4- on flange points opposite direction of travel. Note
The fuel delivery unit flange can be installed only in this position. G. Volkswage
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Connect black
A agen ksw Vol y b supply line -1- with »arrow« to ed union on flange. ris o h t (blue or with blue marking) au to connection marked ss
Black supply line -3- to metering pump -V54- for auxiliary heater.
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Note
After installing fuel delivery unit flange, check that fuel lines are still clipped onto fuel tank.
5.1.2
Removing and installing fuel tank
♦ Torque wrench (5... 50 Nm) -V.A.G 1331-
♦ 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.
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Rep. gr.20 - Fuel supply system
AG.
Note
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Removing
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♦ Engine and gearbox jack -V.A.G 1383/A-
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Special tools and workshop equipment required
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Note safety precautions before beginning work ⇒ page 136 . Observe rules for cleanliness ⇒ page 137 . Note ♦ Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary. ♦ When lowering fuel tank, guide it carefully to prevent damage. – With the ignition switched off, disconnect battery earth strap. – Remove rear bench seat ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing bench A seat G. Vo.lkswagen – Pull 5-pin connector -5- off fuel
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– Open fuel tank filler flap.
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– Remove cover from fuel delivery unit.
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– Empty fuel tank ⇒ page 183 . – Remove right rear wheel.
– Remove rear right wheel housing liner ⇒ General body re‐ pairs, exterior; Rep. gr. 66 ; Removing and installing wheel housing liner . – Remove bolts from filler neck -arrows-.
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– Unclip ABS sensor wiring on fuel tank filler neck -arrows-.
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– Unscrew securing bolt and remove tank flap unit with rubber cup ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit .
– Remove underbody panel. WARNING
♦ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! ♦ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! ♦ Wear eye and hand protection when performing any type of repair work on the fuel system!
5. Parts of fuel supply system (Passat)
179
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– Separate return line -1- and supply line -2- at connections. ss
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– Separate fuel line -3- for metering pump -V54- at connections.
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Note
Press in securing ring to release fuel lines.
– Pull connector -arrow- off metering pump -V54- . – Support rear axle using engine and gearbox jack -V.A.G 1383 A- . – Remove securing bolts -arrows- and lower rear axle.
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Install in reverse order. In the process, note the following: – Tighten bolts of rear axle to body ⇒ Running gear, axles, steering; Rep. gr. 42 . ♦ Fuel lines are to be installed free of kinks. ♦ Do not interchange supply line and return line (return line blue or with blue marking, supply line black). ♦ Ensure that line connections are tight. ♦ Connections for fuel lines must engage audibly when joined. ♦ Check earth connection between body and filler neck for prop‐ er seating. ♦ Clip fuel lines onto fuel tank.
5.1.3
Removing and installing fuel delivery unit
Special tools and workshop equipment required
180
Rep. gr.20 - Fuel supply system
AG.
Installing
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– Slowly lower fuel tank. When doing this, pull fuel tank forwards, turn and guide filler neck between rear axle and body.
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– Remove securing strap bolts.
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– Then support fuel tank using engine and gearbox jack -V.A.G 1383 A- .
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ♦ Fuel tank sender unit tool -T10202-
Removing
Observe rules for cleanliness ⇒ page 137 . – First check whether a coded radio is fitted. If so, obtain antitheft coding. – With the ignition switched off, disconnect battery earth strap. – The fuel tank must not be more than 1/2 full when removing the suction-jet pump. Empty fuel tank if necessary ⇒ page 183 . – Remove rear bench seat ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing bench seat . – Remove cover from fuel delivery unit. – Pull supply line -1-, return line -2-, supply line -3- to metering pump -V54- and 5-pin connector -5- off fuel delivery unit flange. agen lksw Vo by
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Press in securing ring to release fuel lines.
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Note
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– Note safety precautions before beginning work ⇒ page 136 .
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♦ Torque wrench (40... 200 Nm) -V.A.G 1332-
5. Parts of fuel supply system (Passat)
181
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Open locking ring using fuel tank sender wrench -T10202- . – Lift sender flange.
– Pull fuel line -1- off suction-jet pump (if fitted). Note
Press in securing ring to release fuel line.
– Pull fuel delivery unit along with suction-jet pump out of open‐ ing in fuel tank. Note
Installing
Note
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– Installing the fuel delivery unit is carried out in reverse order of removal.
♦ For fuel delivery units of the new generation the suction-jet pump is no longer available. If the fuel delivery unit is to be renewed, remove suction-jet pump. ♦ When inserting fuel delivery unit, ensure that fuel gauge sender is not bent. ♦ Insert seal for flange or fuel delivery unit dry into opening of fuel tank. ♦ Moisten seal with fuel only when installing flange or fuel de‐ livery unit. c o p yri gh t. C op yi
♦ Do not interchange supply line and return line (return line blue or with blue marking, supply line black).
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♦ Ensure that fuel hose connections are tight. Prote cted by
♦ Connections for fuel lines must engage audibly when joined. ♦ After installing fuel delivery unit, check that fuel lines are still clipped onto fuel tank.
♦ Observe installation position of fuel delivery unit ⇒ page 178 .
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Rep. gr.20 - Fuel supply system
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♦ Fuel lines are to be installed free of kinks.
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If delivery unit is to be posal.
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– Press tab -2- of suction-jet pump in -direction of arrow- and unclip from fuel delivery unit
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
5.1.4
Removing and installing fuel gauge sender
Removing – Remove fuel delivery unit ⇒ page 180 . – Release connector tabs of wires -arrows- and pull them off. – Lift up retaining tabs -1- using a screwdriver and pull off fuel gauge sender upwards in direction of -arrow-. Installing – Insert fuel gauge sender into guides on fuel delivery unit and press downwards until it engages. – Install fuel delivery unit ⇒ page 180 .
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Emptying fuel tank, vehicles with frontwheel drive
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♦ Fuel extractor -VAS 5190-
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♦ Fuel tank sender unit tool -T10202-
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Special tools and workshop equipment required
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5.2
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♦ Torque wrench (40... 200 Nm) -V.A.G 1332-
5. Parts of fuel supply system (Passat)
183
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Emptying fuel tank if more than 3/4 full ⇒ page 184 Emptying fuel tank if less than 3/4 full ⇒ page 184
5.2.1
Emptying fuel tank if it is more than 3/4 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. Note
Note
When no more fuel is extracted, the tank is emptied just enough for the sender flange to be opened without danger. The tank may be removed while containing remaining fuel.
5.2.2
Emptying fuel tank if it is less than 3/4 full
Procedure
Note safety precautions before beginning work ⇒ page 136 . c o p yri gh t . C op yi
– Remove rear bench seat ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing bench seat . agen lksw Vo by
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– Remove cover from fuel delivery unit. WARNING
♦ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! ♦ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! ♦ Wear eye and hand protection when performing any type of repair work on the fuel system!
184
Rep. gr.20 - Fuel supply system
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– Then carefully remove extraction hose.
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– Empty fuel tank as far as possible.
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♦ A flap is located on the lower end of the fuel filler neck, this must not be damaged by the extraction hose. Therefore, push the extraction hose into the fuel filler neck only up to previously made marking.
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Pull supply line -1-, return line -2-, supply line -3- to metering pump -V54- and 5-pin connector -5- off fuel delivery unit flange. AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h in securing ring to release fuel lines. ut ra a c s s
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– Open locking ring using fuel tank sender wrench -T10202- . – Lift sender flange. – Insert extraction hose of fuel extractor -VAS 5190- as deeply as possible into fuel tank and extract fuel.
Checking fuel pump
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5.3
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Check fuel filter connections for correct arrangement, before starting to check the fuel pump ⇒ page 158
5.3.1
AG.
ProCarManuals.com
If fuel tank needed only to be emptied, reinstall sender flange ⇒ page 180 .
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Press
Checking delivery pressure of fuel pump
Special tools and workshop equipment required ♦ Pressure gauge -VAS 6550♦ Vehicle diagnosis tester Test prerequisite: •
Fuses must be OK.
•
Battery voltage at least 12 V
•
All electrical consumers, e.g. lights and rear window heating, must be switched off.
– Separate quick-release coupling -A- (completely black or with black marking) of fuel supply line. – Connect pressure tester -VAS 6550- with cables -VAS 6550/1and -VAS 6550/2- to open ends of fuel supply line. – Switch on pressure tester -VAS 6550- by pressing On/Off button. – Open shut-off taps „A“ and „B“ of pressure tester and close shut-off tap „C“. – Start engine and run at idling speed. – Read pressure on pressure tester -VAS 6550- . Specification: min. 0.5 bar.
5. Parts of fuel supply system (Passat)
185
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Place pressure tester -VAS 6550- onto windscreen so that it can be read from inside vehicle. – Increase idling speed to 2500 rpm and read the pressure on pressure tester -VAS 6550- , specification min 0.25 bar. – If the delivery pressure temporarily drops, renew fuel delivery unit ⇒ page 180 . – If the specifications are attained, check tandem pump to en‐ sure the fuel filter is not blocked ⇒ page 195 . – If the tandem pump values are OK, check fuel pump delivery rate ⇒ page 186 .
5.3.2
Checking fuel pump delivery rate
Special tools and workshop equipment required ♦ Pressure gauge -VAS 6550♦ Container > 3 litre with measuring scale ♦ Vehicle diagnosis tester un le
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•
Fuses must be OK.
•
Battery voltage at least 12 V
•
All electrical consumers, e.g. lights and rear window heating, must be switched off. Note
The delivered fuel may be cloudy. This is normal and can be ig‐ nored. – Separate quick-release coupling -A- (completely black or with black marking) of fuel supply line. – Connect -VAS 6550/1- pressure tester line to fuel supply -A-. – Guide open end of line into measuring container.
If the specification is not attained: – Check fuel supply line between fuel pump and engine com‐ partment for kinks, crushes or damage. – If necessary, renew defective line and repeat test. – If it is not kinked, crushed or damaged, remove rear seat bench ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats . – Detach carpet under seats and fold it back. ⇒ General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor
186
Rep. gr.20 - Fuel supply system
AG.
– After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s.
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The fuel pump is now activated for 30 seconds.
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– Connect vehicle diagnosis tester and perform guided function „checking electric fuel pump(s)“.
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Test prerequisite:
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove cover from fuel delivery unit. Note
Press in securing ring to release fuel line. – Pull fuel supply line (black or black marking) -A- off fuel deliv‐ ery unit. AG. Volkswagen
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au tester and perform guided function – Connect vehicle diagnosis ss „checking electric fuel pump(s)“.
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The fuel pump is now activated for 30 seconds.
If the specification is not attained: – Check voltage supply ⇒ page 187 . Measure current draw ⇒ page 188 of fuel pump.
5.3.3
Checking voltage supply of fuel pump
Special tools and workshop equipment required ♦ Hand-held multimeter -V.A.G 1526D♦ Pickup clamp -V.A.G 1526B/2ht rig py Co t.
♦ Test instrument adapter/DSO (5-pin) -VAS 5565-
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– After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s.
Test prerequisites •
Fuses must be OK.
•
The battery voltage must be at least 12 V, if necessary connect a battery charger.
•
All electrical consumers, e.g. lights and rear window heating, must be switched off.
– Remove seat bench ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats . – Detach carpet under seats and fold it back. ⇒ General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor
5. Parts of fuel supply system (Passat)
187
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove cover from fuel delivery unit. – Switch on ignition. The fuel pump must be heard to run for about 2 seconds. – Switch off ignition. If the fuel pump does not start: – Pull connector off fuel delivery unit flange. – Connect test instrument adapter/DSO (5-pin) -VAS 5565- be‐ tween connector and flange. – Connect hand-held multimeter -V.A.G 1526D- to contacts -1and -5- of adapter. – Connect vehicle diagnosis tester and perform guided function „checking electric fuel pump(s)“. Note
The fuel pump is now activated for 30 seconds.
If no voltage is present: – Check activation of fuel pump relay and wiring for an open or short circuit ⇒ Vehicle diagnostic, testing and information sys‐ tem VAS 5051. Voltage supply OK: – Remove fuel delivery unit ⇒ page 180 . – Check that electrical wiring between flange and fuel pump is connected and has continuity. If no open circuit can be found:
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– Renew fuel delivery unit.
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Checking current draw of fuel pump
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Special tools and workshop equipment required
♦ Hand-held multimeter -V.A.G 1526D- or pickup clamp -V.A.G 1526B/2♦ Test instrument adapter/DSO (5-pin) -VAS 5565♦ Vehicle diagnosis tester Note
– Remove seat bench ⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats .
188
Rep. gr.20 - Fuel supply system
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Diesel fuel temperature above (10 ) C
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•
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Battery voltage at least 12 V
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•
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Test prerequisites
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The battery voltage and the diesel fuel temperature have a great influence on the current draw of the fuel pump. For this reason ensure that the battery voltage is at least 12 V whilst checking and the diesel fuel temperature does not fall to the freezing point.
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– Read voltage value on hand-held multimeter -V.A.G 1526D- : Specification = battery voltage.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ (1.9 l engine) - Edition 08.2010
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– Remove cover from fuel delivery unit. – Pull connector -C- off flange.
– Connect test instrument adapter/DSO (5-pin) -VAS 5565- to connector and fuel delivery unit.
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–
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Pickup clamp of hand-held multimeter -V.A.G 1715- can also be connected to red terminal with lettering „pickup clamp“ of test in‐ strument adapter/DSO (5-pin) -VAS 5565- . AG.
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– Connect pick-up clamp -A- to red terminal with lettering „pickup clamp“ for test instrument adapter/DSO (5-pin) -VAS 5565- .
– Switch on ignition. – Connect vehicle diagnosis tester and perform guided function „checking electric fuel pump(s)“. Note
The fuel pump is now activated for 30 seconds. – Read current draw on hand-held multimeter -V.A.G 1526D- . Specification: max. 7.5 amps. – If the measured value is not within specifications: – Renew fuel delivery unit ⇒ page 180 .
5.4
Assembly overview - fuel filter Note
Note that there are different versions of fuel filter upper part ⇒ page 191 .
5. Parts of fuel supply system (Passat)
189
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 1 - Return line ❑ To fuel cooler ❑ Check for secure seat‐ ing. ❑ Blue or with blue mark‐ ing. 2 - 6 Nm 3 - Washer
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13 - Connection for fuel temperature sender -G8114 - Retaining clip ❑ Check for secure seating. 15 - O-ring ❑ Renew.
190
Rep. gr.20 - Fuel supply system
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12 - 10 Nm
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11 - Lower part of fuel filter
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10 - Filter insert ❑ Observe change intervals.
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9 - Seal ❑ Renew.
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8 - Fuel temperature sender G81-
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7 - Upper part of fuel filter
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6 - Supply line ❑ To tandem pump. ❑ White marking ❑ Check for secure seat‐ ing.
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5 - Return line ❑ From tandem pump. ❑ Blue marking ❑ Check for secure seat‐ ing.
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4 - Supply line ❑ From fuel tank. ❑ White or with white marking. ❑ Check for secure seat‐ ing.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
5.4.1
Upper part of fuel filter
Type A ⇒ page 191 Type B ⇒ page 191 Upper part of fuel filter, type A 1 - 8 Nm 2 - Plug for water extraction (remove and extract about 100 cm3 liquid using hand-operated vacuum pump with accessories V.A.G 1390- and water drainage container -V.A.G 1390/1- , renew seal) 3 - Fuel supply line from fuel tank, white or white marking. Check for secure seating. 4 - Fuel return line to fuel tank, blue or blue marking. Check for secure seating. . Volkswag AG agen
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2 - Fuel return line to fuel tank, blue or blue marking. Check for secure seating. 3 - Fuel supply line from fuel tank, white or white marking. Check for secure seating. 4 - Fuel return line from engine, blue or blue marking. Check for secure seating. 5 - Fuel supply line to engine, white or white marking. Check for secure seating.
5.5
Removing and installing fuel cooler
Special tools and workshop equipment required ♦ Torque wrench (5... 50 Nm) -V.A.G 1331-
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Upper part of fuel filter, type B
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Removing Note safety precautions before beginning work ⇒ page 136 . Observe rules for cleanliness ⇒ page 137 .
5. Parts of fuel supply system (Passat)
191
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note
The fuel cooler is located in the return line to fuel tank. It is located on the vehicle underbody. – Remove underbody panel. – Pull fuel lines -1- and -2- off fuel cooler. – Remove securing nuts -arrows-. Installing Install in reverse order. In the process, note the following:
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Rep. gr.20 - Fuel supply system
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192
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♦ Tighten fuel cooler securing nuts to 15 Nm.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
6
Accelerator mechanism
6.1
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2 - Accelerator position sender -G79❑ Not adjustable. ❑ The accelerator position sender passes the posi‐ tion of the accelerator on to the engine control unit. ❑ -A- openings for release tool ❑ Remove footwell cover to remove sender.
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4 - Cap
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3 - 10 Nm
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1 - Connector ❑ Black, 6-pin.
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Removing and installing accelerator mechanism ⇒ page 193 .
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Assembly overview - accelerator mech‐ anism
Removing and installing accelerator module
Special tools and workshop equipment required ♦ Release tool -T 10269- (for right-hand drive vehicles T10297- ).
6. Accelerator mechanism
193
– Lever off cap ⇒ Item 4 (page 193) using a screwdriver.
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Golf, Golf Plus and Passat:
– To remove accelerator module, push release tool -T 10269(for right-hand drive models -T10297- ) into openings provided to stop. Continuation for all vehicle types: – Pull connector off accelerator module. – Pull wiring guide off accelerator pedal module. – Pull out accelerator pedal module vertically. Installing Installation is carried out in the reverse order. When installing, note the following: – Attach connector and wiring guide to accelerator pedal mod‐ ule. – Press accelerator pedal module onto securing pins. – Insert centring pin into hole in vehicle underbody. – Secure accelerator module with securing bolt -3-. Specified torque: 9 Nm. – Attach cap. – Install steering column cover.
194
Rep. gr.20 - Fuel supply system
AG.
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– To remove accelerator module, push release tool -T 10238(for right-hand drive models -T10240- ) into openings provided to stop.
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– Remove securing bolt beneath it.
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
7
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
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♦ Banjo bolt with seals -VAS 5187/1A-
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♦ Tandem pump tester -VAS 5187-
♦ Torque wrench -V.A.G 1331-
Test prerequisites •
Coolant temperature must be at least 85 °C.
•
Unit injectors OK.
•
Fuel filter and fuel lines must not be blocked.
7. Tandem pump
195
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Procedure – Remove air filter housing. – Remove screw plug -arrow-.
– Connect tandem pump tester -VAS 5187- if necessary, with adapter -VAS 5187/7- or banjo bolt with seal -VAS 5187/1Aas shown. – Install air filter housing again. – Start engine and raise engine speed to 4000 rpm. Specification: at least 7.5 bar, tandem pump OK. If the specification is not attained: – Renew fuel filter. – Repeat check. If the specifications are still not attained:
– Using a hose clip, clamp-off return line between fuel filter and tandem pump. Prote cted by c o p yri gh t. C op yi
If specification is now obtained: – Tandem pump is OK. Renew unit injector O-rings.
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– Repeat check.
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– Observe pressure indicated on pressure gauge.
– 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. Special tools and workshop equipment required
196
Rep. gr.20 - Fuel supply system
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ♦ 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:
– Connect test connection -5- to fuel supply union of tandem pump using a commercially available compressed air connec‐ AG. Volkswagen AG d agen oes tion and a section of fuel hose. Use a spring-typeolclip ksw to secure. no
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To turn the pressure regulating valve -2- the knob must be pulled upwards.
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– Connect compressed air hose -1- (compressed air source) to charge air system tester -V.A.G 1687- . Note
If there is water in the sight glass, drain at water drain screw -6-. – Open valve -3-.
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– Open valve -4- and wait until the test circuit is filled. If neces‐ sary readjust pressure to 1.0 bar.
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– Unscrew pressure regulating valve -2- and close valves -3and -4-.
– 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
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
7.2
Removing and installing tandem pump DANGER!
The tandem pump may, under no circumstances, be disman‐ tled as the vacuum part could otherwise malfunction. This would result in the failure of the brake servo.
Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331♦ Hand vacuum pump with accessories -V.A.G 1390♦ Water drainage container V.A.G 1390/1-
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Rep. gr.20 - Fuel supply system
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♦ Spring-type clip pliers -VAS 5024 A-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
7.2.1
Removing
– Pull supply hose -1- (white marking) and return hose -2- (blue marking) off fuel filter. – Connect hand vacuum pump with accessories -V.A.G 1390and water drainage container -V.A.G 1390/1- to return hose AG. Volkswagen AG d -2-. agen oes ksw n ol yV
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ut fuel comes – Operate lever of hand vacuum pump until no more sa s out of return hose.
– Remove air filter housing ⇒ page 238 .
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– Disconnect fuel supply hose -2- from tandem pump. – Disconnect fuel return hose -1- (blue marking) from fuel pipe.
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– Pull vacuum hose -arrow- off tandem leading to brake servo.
– Unscrew bolts -arrows-. – Remove tandem pump from cylinder head.
7.2.2
Installing
Installation is carried out in the reverse order. When installing, note the following:
7. Tandem pump
199
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note ♦ Renew tandem pump gaskets. ♦ Ensure proper seating of tandem pump actuator in camshaft. ♦ Secure all hose connections with the correct type of hose clips (same as original equipment) ⇒ Electronic parts catalogue . olkswagen AG AG. Vbolts – Install tandem pump and tighten upperswsecuring to does agen k not l 20 Nm. Vo gu by
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– Attach supply hose (white marking) to supply connection of tandem pump.
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– Reconnect vacuum line to tandem pump leading from brake servo. – Connect hand vacuum pump with accessories -V.A.G 1390and water drainage container -V.A.G 1390/1- to return hose -2- (blue marking) of fuel filter. – Operate hand vacuum pump until fuel comes out of return hose. Be careful that no fuel is sucked into hand vacuum pump. – Attach return hose (blue marking) to fuel filter. – Carry out a leakage test ⇒ page 196 .
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Rep. gr.20 - Fuel supply system
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200
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– Attach supply hose -1- (white marking) to fuel filter.
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
21 –
Turbocharging/supercharging
1
Charge air system with turbocharger
Safety precautions ⇒ page 201 . Rules for cleanliness ⇒ page 201 . Installing hose connections with connector couplings ⇒ page 202 Assembly overview - turbocharger ⇒ page 203 . Removing and installing turbocharger ⇒ page 216 . Assembly overview - parts of charge air cooling ⇒ page 218 . Checking charge air system for leaks ⇒ page 221
1.1
Safety precautionsVolkswa
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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐ vated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original po‐ sitions. ♦ Ensure that there is sufficient clearance to all moving or hot components.
Note the following if testers and measuring instruments have to be used during a road test: ♦ Test and measuring instruments must always be secured to rear seat and operated by a second person from this location. If test and measuring instruments are operated from front pas‐ senger seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered. r fo ng
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When working on the turbocharger, pay careful attention to the following rules for cleanliness: agen lksw Vo by
♦ Thoroughly clean all unions and adjacent areas before dis‐ connecting. AG.
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♦ Place removed parts on a clean surface and cover. Use only lint-free cloths. ♦ Carefully cover opened components or seal if repairs cannot be carried out immediately. ♦ Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.). ♦ Existing transport and protective packaging and sealing caps must only be removed immediately prior to installation. ♦ When making repairs, remove oil from connection and hose ends. 1. Charge air system with turbocharger
201
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 ♦ When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely nec‐ essary.
1.3
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. – 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 andgeis G. Volkswagen AG d Aproperly a n oes ksw engaged by pulling hose. not l o V
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Rep. gr.21 - Turbocharging/supercharging
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Installing
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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. ♦ Renew self-locking nuts.
Observe rules for cleanliness ⇒ page 201 .
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Observe safety precautions ⇒ page 201 .
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♦ Charge air system must be free of leaks.
1. Charge air system with turbocharger
203
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Engine codes AVQ, BJB, BKC, BRU, BXE and BXF ⇒ page 204 Engine codes BLS and BXJ ⇒ page 206 Changing and adjusting vacuum unit on turbocharger - only ve‐ hicles with engine code: BLS from model year 2008 ⇒ page 208
1.4.1
Engine codes AVQ BJB, BKC, BRU, BXE and BXF
1 - 10 Nm 2 - Union nut, 22 Nm
ProCarManuals.com
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10 - Connecting pipe ❑ Air filter/turbocharger 11 - Connecting piece 12 - Seal ❑ Renew. 13 - Seal ❑ Renew. 14 - Union, 40 Nm 15 - Oil return line ❑ To cylinder block. ❑ Tighten union nut to 30 Nm. 16 - 17 Nm 17 - Vacuum hose ❑ To solenoid valve block
204
Rep. gr.21 - Turbocharging/supercharging
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8 - Support ❑ Between turbocharger and cylinder block.
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6 - Washer
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5 - Seal ❑ Renew. ❑ Note installation posi‐ tion.
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4 - Union nut, 22 Nm
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3 - Oil supply line ❑ Before installing oil sup‐ ply line, ensure that it is not blocked. ❑ Before installing, fill tur‐ bocharger with engine oil through oil supply line connection. ❑ Removing and installing ⇒ page 112
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 18 - Turbocharger ❑ Can only be renewed with exhaust manifold. ❑ To remove turbocharger, remove right drive shaft ⇒ Running gear, axles, steering; Rep. gr. 40 ; Re‐ moving and installing drive shafts . 19 - 20 Nm ❑ First hand tighten all bolts 20 - 20 Nm ❑ Renew. 21 - Heat shield 22 - Seal ❑ Renew. ❑ Note installation position. 23 - Clamp, 7 Nm 24 - Front exhaust pipe
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26 - 22 Nm ❑ Renew.
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28 - Union, 30 Nm ❑ Renew. ❑ Coat threads and bolt head seating surface with „G 052 112 A3“.
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25 - Bracket ❑ For oil supply line ⇒ Item 3 (page 204) . ❑ Before installing, secure oil supply line.
1. Charge air system with turbocharger
205
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.4.2 12-
Engine codes BLS and BXJ
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4 - Oil supply hose ❑ To oil supply line con‐ nection on turbocharger ❑ Before installing oil sup‐ ply line, ensure that it is not blocked. ❑ Before installing, fill tur‐ bocharger via oil supply hose with engine oil
6 - Vacuum hose
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9 - Clamp, 7 Nm ❑ For turbocharger/partic‐ ulate filter
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8 - To particulate filter
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7 - Seal ❑ Renew. ❑ Note installation posi‐ tion.
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5 - Turbocharger ❑ Can only be renewed with exhaust manifold. ❑ Removing and installing ⇒ page 216
10 - Exhaust manifold ❑ Can only be renewed to‐ gether with turbocharg‐ er 11 - 25 Nm ❑ Renew. 12 - 25 Nm 13 - Seal ❑ Renew. 14 - Connecting pipe ❑ For exhaust gas recirculation. ❑ Assembly overview - parts of exhaust gas recirculation ⇒ page 267 . 15 - 25 Nm ❑ Renew. 16 - 15 Nm 17 - O-ring ❑ Renew. 18 - Banjo bolt, 60 Nm ❑ Renew.
206
Rep. gr.21 - Turbocharging/supercharging
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 19 - Support ❑ For turbocharger ❑ With oil return line 20 - Exhaust gas temperature sender bank 1 -G235- , 45 Nm ❑ Lubricate thread of sender using high-temperature paste -G 052 112 A3❑ To remove and install, use wrench -T1039521 - Heat shield 22 - Connection ❑ For intake hose for air filter/turbocharger ❑ Assembly overview - air filter ⇒ page 238 . 23 - 9 Nm 24 - 10 Nm Installation position of exhaust gas temperature sender with an‐ gled cable guide
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Note
1. Charge air system with turbocharger
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.4.3
Changing and adjusting vacuum unit on turbocharger - only vehicles with engine code: BLS from model year 2008
Special tools and workshop
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Rep. gr.21 - Turbocharging/supercharging
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 equipment required ♦ Hand vacuum pump -VAS 6213♦ Turbocharger tester -V.A.G 1397A♦ Pressure regulating valve -VAS 6342♦ Ring spanner -T10423♦ Allen key, long reach -T10454-
Caution
The special tools indicated, in particular the socket inset, T10454- is designed solely for use according to the following work instructions and must not be used for other threaded con‐ nections. There is a danger of deformation if high torques are applied.
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– Remove engine cover.
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– Pull cover off air duct (release clips on sides) -arrows-.
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1. Charge air system with turbocharger
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Golf 2004 4-cylinder
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– Unclip lower air duct -2- by releasing retaining clips on left and right -arrow A-. – Unclip air duct at mountings -3-.
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– Swing air duct downwards and slightly to rear for this.
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– Detach air pipe -1- from lower air duct -arrow B-.
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– Remove bolt -4- and remove air filter housing.
– Detach hose -2- from crankcase breather. – Lay aside ventilation hose -4- and vacuum hoses -1- at air hose. – Unscrew bolt -3-. – Swing air duct hose to rear and pull off of turbocharger. – Seal opening in turbocharger with the plug from the spareparts kit. – Pull off vacuum hose on turbocharger. Golf Plus, Touran – Remove plenum chamber bulkhead ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead . All other vehicles continued
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Rep. gr.21 - Turbocharging/supercharging
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– Pull off vent hose -3- and also air duct hose -2-.
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– Disconnect electrical connector -1- from air mass meter G70- .
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Depending on version, unscrew nut -arrow- where the oil sup‐ ply line/vacuum line is connected to the cylinder head. Caution
When detaching the oil supply line, counterhold the connec‐ tion. Risk of damage as a consequence! – Prepare a 14 mm open-ended wrench for counterholding.
14 mm tool for counterholding connection piece of oil supply line ♦ A = 110 mm
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th – Seal oil supply opening in turbochargerauwith the plug ss spare-parts kit.
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– Counterhold lock nut -B- with ring spanner -T10423- and un‐ screw securing nut -A- from the control rod using socket inset -T10454- .
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♦ B = 25 mm
1. Charge air system with turbocharger
211
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove bolt -1-, then bolt -2- and remove vacuum unit -A-. Installing
– Colour mark vacuum unit and control rods -as shown-. Note AG. Volkswagen AG d agen oes
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Only use new bolts and nuts from the spare-parts kit! – If necessary, remove lower securing nut of the control rod from the new vacuum unit. – Screw locknut by hand onto the control rod as far as possible in the direction of the vacuum unit. – Push control rod through the adjusting lever on turbocharger, fit vacuum unit -A- and lock.
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– Tighten bolts -1- and -2- to 8 Nm.
– Subtract 650 mbar from atmospheric pressure displayed and note value. (Value 2)
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Rep. gr.21 - Turbocharging/supercharging
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– Subtract 600 mbar from atmospheric pressure displayed and note value. (Value 1)
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– Switch on turbocharger tester -V.A.G 1397A- and set sliding switch to position „I“.
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– Fit bolts -1- and -2- from repair kit.
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Connect test and measuring instruments together as illustrat‐ ed and connect to connection „I“ -arrow- of turbocharger tester -V.A.G 1397A- and to turbocharger vacuum unit. – Close lever -1- on pressure regulating valve -VAS 6342- .
Caution
Excessive pressure may damage the vacuum unit. The pressure must not fall below the read atmospheric pres‐ sure minus 800 mbar. ht rig py Co t.
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Note
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♦ An accuracy of +/- 20 mbar is acceptable when setting value 2. AG.
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– Move slide ring -1- on hand vacuum pump -VAS 6213- to po‐ sition -A- for „vacuum“.
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♦ 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- .
1. Charge air system with turbocharger
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Open pressure regulating valve -1- until value 1 is set exactly.
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– Hold adjusting lever -1- on »stop« of adjustment screw -2- by hand.
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♦ Screw securing nut -A- back if this occurs.
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♦ During next procedure, ensure adjusting lever -1- remains against stop screw -2- and is not already contacting the se‐ curing nut -A-.
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Note
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– Screw nut -A- up a couple of threads on control rod.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Volkswa
gen AG en AG. by hand, – Screw control rod lock nut -B- down until doesit agslowly, ksw not l o contacts the adjusting lever b-1-, gu y V do not turn further. a d se
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– Release vacuum, move slide ring -1- on hand vacuum pump to position -B- for this, then move slide ring back to position -A- again.
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– Check colour marks on control rod, the must align -as shown-.
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Note
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ri on control rod until it lies against – Screw securing nut -A-thoup u a adjusting lever. ss
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.
1. Charge air system with turbocharger
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – 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
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– Depending on version, reconnect oil supply line/vacuum line to the cylinder head and tighten nut -arrow-. Golf Plus, Touran
– Install plenum chamber bulkhead ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead . All other vehicles continued – Complete the engine.
– Start motor and delete event memory ⇒ Vehicle diagnostic, testing and information system VAS 5051.
1.5
Removing and installing turbocharger
AG.
Rep. gr.21 - Turbocharging/supercharging
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♦ Torque wrench -V.A.G 1331-
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Special tools and workshop equipment required
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– Counterhold connection piece and tighten oil supply line -arrow- on turbocharger.
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♦ B = 25 mm
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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When a mechanical fault is found on the turbocharger, e.g. a destroyed compressor impeller, it is not only sufficient to renew the turbocharger. To prevent this from causing further damage, perform the following repairs:
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Caution
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♦ Tool set -T10395-
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♦ Lambda probe open ring spanner set -3337-
♦ Check air filter housing, air filter element and intake hoses for soiling. ♦ Check complete charged air routing and charge air cooler for foreign objects. If foreign objects are found in the charge air system, the charged air routing must be cleaned and the charge air cooler must be renewed, if necessary. Removing – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Body - front; Noise insulation . Vehicles with four-wheel drive: – Remove front propshaft ⇒ Final drive 02D, 0AV; Rep. gr. 39 ; Assembly overview - repairing propshaft . – Remove right drive shaft ⇒ Running gear, axles, steering; Rep. gr. 40 . Vehicles with particulate filter – Pull electrical connector off exhaust gas pressure sensor 1 G450- in engine compartment and unscrew securing bolts. – Separate electrical connectors to particulate filter. – Remove subframe including steering and right drive shaft ⇒ Running gear, axles, steering; Rep. gr. 40 .
1. Charge air system with turbocharger
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove particulate filter. – On vehicles with four-wheel drive remove the bevel box to reach the threaded connection for turbocharger support ⇒ 6speed manual gearbox; Rep. gr. 34 ; Removing and installing bevel box . Continuation for all vehicles: – Disconnect fasteners -arrows- of coolant pipes for auxiliary heater, if part of original equipment.
– Unbolt pendulum support -arrows-.
– Remove connecting pipe to exhaust gas recirculation cooler. – Separate charge pressure line from turbocharger. – Pull vacuum hose off turbocharger. AG. Volkswagen AG d agen oes ksw not l o V gu by ara d Unscrew securing bolts for exhaust manifold.rise nte o eo h ut and remove tur‐ ra Tilt the engine forwards in lower mounting a c s s bocharger with exhaust manifold downwards.
– Separate oil supply line from turbocharger. –
Installing – Install in reverse order.
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Torque setting of pendulum support ⇒ page 22 .
1.6
Assembly overview - parts of charge air cooling Note
♦ Charge air system must be free of leaks.
♦ All hose connections of charge air system are secured by spring-type clips or by connector couplings.
Rep. gr.21 - Turbocharging/supercharging
AG.
218
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♦ Checking charge air system for leaks ⇒ page 221
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♦ When making repairs, remove oil from connection and hose ends. ht rig py Co t.
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– Remove support and oil return line or combi support ⇒ Item 19 (page 206) for turbocharger.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Engine codes AVQ BJB, BKC, BRU, BXE and BXF ⇒ page 219 Engine codes BLS and BXJ ⇒ page 220 Installing hose connections with connector couplings ⇒ page 202
1.6.1
Engine codes AVQ BJB, BKC, BRU, BXE and BXF
1 - 8 Nm ❑ Fitting location ⇒ page 220 2 - Bracket ❑ Note installation posi‐ tion. 3 - Charge air cooler
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4 - Connecting hose
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8 - To intake connecting pipe. 9 - Vacuum reservoir 10 - 15 Nm 11 - 8 Nm
12 - O-ring ❑ Renew if damaged. 13 - Charge air pressure sender -G31- with intake air temperature sender -G42-
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14 - 3 Nm
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7 - Connecting pipe
1. Charge air system with turbocharger
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.6.2
Engine codes BLS and BXJ
1 - 8 Nm
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Fitting location ⇒ page 220
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2 - Bracket ❑ Note installation posi‐ tion.
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3 - Charge air cooler ❑ To remove, bring lock carrier into service posi‐ tion ⇒ General body re‐ pairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier - service position 4 - Sealing strip ❑ Pushed onto top and bottom of charge air cooler
6 - Charge air pressure sender -G31- with intake air tempera‐ ture sender -G42-
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9 - 5 Nm
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8 - Bracket 10 - Connecting hose 11 - Charge air pipe
12 - Connecting hose ❑ To intake manifold flap motor -V157❑ Assembly overview - in‐ take manifold ⇒ page 235 . 13 - 8 Nm 14 - Connecting hose ❑ To turbocharger. Securing bolts for charge air cooler To loosen or tighten securing bolts -arrows- remove bumper cov‐ er.
220
Rep. gr.21 - Turbocharging/supercharging
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7 - O-ring ❑ Renew if damaged.
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5 - 3 Nm
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.7
Checking charge air system for leaks
Special tools and workshop equipment required ♦ Charge air system tester -V.A.G 1687-
♦ Adapter -V.A.G 1687/10– Remove intake hose -1- from air filter. – Insert adapter -V.A.G 1687/10- in intake hose -1- and secure AG. Volkswagen AG d with clip. agen oe w olks
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To turn the pressure regulating valve -2- the knob must be pulled upwards.
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– Close valves -3- and -4-.
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– Turn pressure regulating valve -2- anti-clockwise onto stop.
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yV bfollows: Prepare charge air system tester -V.A.G 1687- as ed
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1. Charge air system with turbocharger
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Connect charge air system tester -V.A.G 1687- to adapter V.A.G 1687/10- as shown.
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 ksw not l o V gu y b ara d nte ise r o The pressure must not exceed 0.5 bar! If the pressure is too eo h t u ra high this cans acause damage to the engine. c s
– Open valve -4- and wait until the test circuit is filled. If neces‐ sary readjust pressure to 0.5 bar.
Note
♦ How to use the ultrasonic tester -V.A.G 1842- ⇒ operating instructions ♦ If leaks occur, when doing any repair work observe notes for charge air system ⇒ page 218 . ♦ Depressurise test circuit by detaching coupling from adapter V.A.G 1687/10- before removing adapter.
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Rep. gr.21 - Turbocharging/supercharging
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222
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– Check the charge air system for leaks by hearing, touching, with leak detector spray or using ultrasonic tester -V.A.G 1842- .
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Caution
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– Connect compressed air hose -1- (compressed air source) to charge air system tester -V.A.G 1687- .
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.8
Vacuum hose schematic diagram
Vehicles with particulate filter ⇒ page 223 Vehicles without particulate filter ⇒ page 224
1.8.1
Vehicles with particulate filter
1 - Turbocharger 2 - Connecting pipe air filter/ turbocharger 3 - Non-return valve ❑ Note installation posi‐ tion. 4 - To brake servo 5 - Charge pressure control solenoid valve -N756 - Air filter
14 - Vacuum unit ❑ Turbocharger
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13 - Non-return valve ❑ Note installation posi‐ tion.
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12 - Exhaust gas recirculation cooler changeover valve N345-
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11 - Exhaust gas recirculation valve -N18-
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10 - Radiator ❑ For exhaust gas recircu‐ lation.
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9 - Bypass flap ❑ For exhaust gas recircu‐ lation cooler.
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8 - Intake manifold
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7 - Cylinder head/cylinder block
1. Charge air system with turbocharger
223
Vehicles without particulate filter
6 - Intake manifold 7 - Cylinder head/cylinder block 8 - Vacuum reservoir
ProCarManuals.com
10 - Radiator ❑ For exhaust gas recircu‐ lation. 11 - Exhaust gas recirculation valve -N1812 - Turbocharger 13 - Non-return valve ❑ Note installation posi‐ tion.
224
Rep. gr.21 - Turbocharging/supercharging
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9 - Bypass flap ❑ For exhaust gas recircu‐ lation cooler.
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5 - Air filter
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4 - Connecting pipe air filter/ turbocharger
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3 - To brake servo
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2 - Non-return valve ❑ Note installation posi‐ tion.
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1 - Solenoid valve block
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1.8.2
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Golf 2004 4-cylinder
AG. Volkswagen AG d agen oes ksw not l o ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ ,VTouran 2003 ➤ gu by ara d e nte diesel engine (1.9 l engine) - Edition is 08.2010 r o eo h ut ra a c s s
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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. Safety precautions ⇒ page 225 . Rules for cleanliness ⇒ page 226 . Removing and installing pre-wired wiring harness for unit injec‐ tors and glow plugs ⇒ page 226 Assembly overview - unit injector ⇒ page 229 Removing and installing unit injector ⇒ page 230 Adjusting non-contact gap of unit injectors ⇒ page 232 Removing and installing O-rings for unit injector ⇒ page 233 . Repairing intake manifold flap ⇒ page 235
1.1
Safety precautions
n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o When doing any h repair work, especially in the engine com‐ t or u ac a partment, pay attention to the following due to the cramped ss
WARNING
♦ Ensure that there is sufficient clearance to all moving or hot components.
Note the following if testers and measuring instruments have to be used during a road test: ♦ Test and measuring instruments must always be secured to rear seat and operated by a second person from this location. ♦ If test and measuring instruments are operated from front pas‐ senger seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered. To prevent injuries to persons and/or destruction of the injection and glow plug system, the following must be noted: ♦ The ignition must be switched off before connecting or dis‐ connecting injection or glow plug system wiring or tester ca‐ bles.
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♦ 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.
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♦ If the engine is to be turned at starter speed, without starting, e.g. when checking compressions, disconnect unit injector connector on cylinder head. AG.
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Assembly overview - air filter ⇒ page 238 .
♦ Before disconnecting battery, obtain radio code for radios with anti-theft coding.
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1.2
Rules for cleanliness
♦ Thoroughly clean all unions and adjacent areas before dis‐ connecting. ♦ Place removed parts on a clean surface and cover. Use only lint-free cloths. ♦ Carefully cover opened components or seal if repairs cannot be carried out immediately. ♦ Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.).
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Removing and installing pre-wired wiring harness for unit injectors and glow plugs AG.
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1.3
Special tools and workshop equipment required ♦ Puller -T10312-
♦ Special wrench -T10310-
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♦ 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.
Rep. gr.23 - Mixture preparation - injection
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♦ When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely nec‐ essary.
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When working on fuel supply and injection system, pay careful attention to the following rules for cleanliness:
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♦
t gu yV ara db e s tee ri and connecting the battery must only bendone Disconnecting o h or ut with the ignition switched off, as otherwise the control unit for ac a ss diesel direction injection system could become damaged.
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Note
Disconnecting connectors on piezo unit injectors may only be un‐ dertaken using special tool puller -T10312- . – Remove engine cover. To do this, pull engine cover upwards abruptly at front and right -arrows A- and then pull forwards out of rear fastening -arrow B-.
AG.
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– Disconnect central connector on cylinder head.
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– Remove cylinder head cover ⇒ page 64 .
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Removal and installation of the pre-wired wiring harness may only be undertaken by unscrewing the clips. Releasing the ca‐ ble channel at the clips bends the clips which may break the cables due the excessive play. This also applies when chang‐ ing the unit injectors and all work which does not require the central connector to be completely removed.
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Caution
– 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.
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–
o yV db e risthe unit injector connector from Slide the puller -T10312- onto ho ut the side and pull it off in -direction of arrow-. Use pointed pliers a ss for the older connector version.
– Pull connectors off glow plugs -1- Unscrew securing bolts -2of steel clips and remove complete pre-wired wiring harness. Installing
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– Guide central connector through opening in retaining frame, ensure securing clips -arrows- are seated correctly when do‐ ing this. AG.
– Fit adapter ring (colour marked „longer“ stud -arrow- faces 12 o'clock)
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– Route pre-wired wiring harness and tighten securing bolts to 10 Nm.
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Installation is carried out in the reverse order. When installing, note the following:
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Fit special wrench -T10310- on adapter ring and lock it by AG. Volkswagen AG d agen oes turning key through 90° (1/4 turn) in opposite ksw not l o V gu by ara -direction of arrow-. d e un le pe rm itte d
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When adapter ring is installed correctly the colour marked „short‐ er“ stud faces 12 o'clock. – Fit central connector to cylinder head and lock in position. – Install cylinder head cover ⇒ page 64 . – Fit engine cover.
1.4
Assembly overview - unit injector
♦ Observe rules for cleanliness ⇒ page 226 .
AG.
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4 - Adjuster screw ❑ Renew.
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3 - Lock nut, 30 Nm
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2 - Rocker arm shaft ❑ With rocker arms ❑ Removing and installing ⇒ page 230
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1 - 20 Nm + turn (90°) ❑ Renew.
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♦ Always renew seals and O-rings
5 - Ball stud ❑ Renew. 6 - Unit injector ❑ Removing and installing ⇒ page 230 7 - O-ring ❑ Renewing ⇒ page 233 . 8 - O-ring ❑ Renewing ⇒ page 233 . 9 - O-ring ❑ Renewing ⇒ page 233 . 10 - Heat shield seal ❑ Renew. 11 - Circlip 12 - Cylinder head 13 - Tensioning block 14 - 12 Nm + turn (270°) ❑ Renew.
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1.5
Removing and installing unit injector
Special tools and workshop equipment required ♦ Universal dial gauge brack‐ et -VW 387♦ Special wrench, long reach -3410♦ Special wrench, long reach -T10054AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
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– 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.
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Rep. gr.23 - Mixture preparation - injection
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– Remove toothed belt guard upper part.
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♦ Torque wrench V.A.G 1331-
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♦ Puller -T10055-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Insert puller -T10055- in place of the clamping block in the slot on the side of the unit injector. – Pull unit injector out of cylinder head seat by gently tapping upwards.
♦ Each time work is performed which requires adjustment of the unit injector, the adjustment screw in the rocker arm and also the unit injector ball stud must be renewed. ♦ New unit injectors are supplied with O-rings and heat shield seal. – Heat shield seal and O-rings must be renewed if old unit in‐ jector is reused. ⇒ page 233 – Check that the 3 O-rings and the heat shield seal along with securing clip are seated correctly before installing unit injector. Note
The seals must not be twisted.
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– Oil the seals and fit the unit injector into the seat in cylinder head with great care. agen lksw Vo by
– Push the unit injector evenly into the cylinder head onto its limit stop. AG.
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Installing
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1.5.2
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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.
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Check 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 2 3 4
333.0 ± 0.8 mm 245.0 ± 0.8 mm 153.6 ± 0.8 mm 65.6 ± 0.8 mm
– If necessary, adjust the unit injector and tighten the securing bolt as follows: n AG. Volkswagen A
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– First evenly tighten inner bolts -2- and then outer bolts -1hand-tight. Then using same sequence, tighten to 20 Nm and 90° (1/4 turn) further evenly.
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1.6
Adjusting non-contact gap of unit injec‐ tors
– Fit dial gauge onto adjustment screw of unit injector as shown.
– Turn 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 .
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Rep. gr.23 - Mixture preparation - injection
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– Now turn the adjuster screw into rocker arm until significant resistance can be felt (unit injector is at limit stop).
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– Remove dial gauge.
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– 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.
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– Adjust non-contact gap of unit injectors ⇒ page 232 .
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.7
Removing and installing O-rings for unit injector
Special tools and workshop equipment required
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1.7.1
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♦ Assembly sleeves -T10056-
Removing
– Lever old O-rings very carefully out of unit injector.
1.7.2 Note
Installing
♦ Always use the assembly sleeves to fit the O-rings. There is a danger of damaging the O-rings if the sleeves are not used.
♦ Prevent O-rings from rolling when sliding them on. The O-rings must not be twisted in their seats in unit injector. AG.
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– Clean seating surfaces for O-rings on unit injector very care‐ fully.
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– Pull heat shield seal off together with securing clip.
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♦ Gradual introduction of O-rings without different coloured markings. Note the correct allocation of O-rings to grooves: the thickness of the rings reduces towards injector nozzle.
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– Above all ensure that burrs are not caused on O-ring seating.
– 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.
1. Diesel direct injection system
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Place assembly sleeve -T10056/2- onto stop on unit injector. – Slide the middle, thinner O-ring carefully onto assembly sleeve and into seat on unit injector. – Remove assembly sleeve.
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– Remove assembly sleeve.
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– Push the lower O-ring carefully onto the assembly sleeve and into the seat of the unit injector.
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Rep. gr.23 - Mixture preparation - injection
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– Fit new heat shield seal together with securing clip.
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– Place assembly sleeve -T10056/3-
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.8
Assembly overview - intake manifold
Engine codes AVQ BKC, BRU, BXE and BXF ⇒ page 235 Engine code BJB ⇒ page 236 Engine codes BLS and BXJ ⇒ page 237
1.8.1
Engine codes AVQ, BKC, BRU, BXE and BXF
1 - Intake manifold ❑ Tighten securing bolts to 22 Nm. 2 - O-ring ❑ Renew. 3 - Intake connecting pipe ❑ With exhaust gas recir‐ culation valve 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 ❑ Renew.
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4 - 10 Nm
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1.8.2
Engine code BJB
1 - Intake manifold ❑ Tighten securing bolts to 22 Nm. 2 - O-ring ❑ Renew. 3 - Intake connecting pipe ❑ With exhaust gas recir‐ culation valve and in‐ take manifold flap 4 - 10 Nm 5 - Seal ❑ Renew.
9 - Vacuum actuator
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8 - Bracket
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10 - To solenoid valve block
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11 - 22 Nm
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7 - 10 Nm
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6 - Connecting pipe ❑ To exhaust gas recircu‐ lation cooler.
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.8.3
Engine codes BLS and BXJ
1 - Seal ❑ Renew. 2 - Intake manifold ❑ Tighten securing bolts to 22 Nm 3 - Seal ❑ Renew. 4 - Connection 5 - Intake manifold flap motor V157❑ The intake manifold flap is closed for approx. 3 seconds when stopping engine and then opens again. This reduces the stop jolt. 7 - 10 Nm 8 - Exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer G212❑ Assembly overview - ex‐ haust gas recirculation ⇒ page 267 AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
11 - 22 Nm 12 - Bracket 13 - 22 Nm
Note
Carbon deposits can occur in the throttle valve support through the combination of unfavourable factors. If these are found, e.g. when disassembling the exhaust gas recirculation valve -N18- or the intake manifold flap motor -V157,- , the support will have to be cleaned.
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Cleaning the intake manifold flap sup‐ port, Engine code BLS and BXJ
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1.9
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⇒ page 264
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10 - Connecting pipe ❑ For exhaust gas recircu‐ lation cooler. ❑ Assembly overview parts of exhaust gas re‐ circulation
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9 - Seal ❑ Renew.
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6 - From charge air cooler
1. Diesel direct injection system
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 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.
Assembly overview - air filter
1 - Intake hose ❑ To turbocharger. 2 - Air mass meter -G70-
4 - 8 Nm
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3 - O-ring ❑ Renew if damaged.
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5 - Air filter upper part 6 - 8 Nm
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7 - Vacuum hose ❑ To solenoid valve block 8 - Filter element
9 - Air duct ❑ To lock carrier.
10 - Air filter lower part
AG.
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11 - 10 Nm
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1.10
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
2
Engine control unit . Volkswage
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Removing and installing engine control unit (Golf Plus) ⇒ page 243 Removing and installing anti-theft engine control unit (Golf Plus) ⇒ page 244 Removing and installing engine control unit (Touran) ⇒ page 240 Removing and installing anti-theft engine control unit (Touran) ⇒ page 247 Removing and installing engine control unit (Passat)
Reading and clearing engine control unit fault memory
Special tools and workshop equipment required r fo ng
♦ Vehicle diagnostic, testing and information system -VAS 5051ht rig py Co t.
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2.1
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Removing and installing anti-theft engine control unit (Golf) ⇒ page 241
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Removing and installings engine control unit (Golf) ⇒ page 240
ran tee or ac
– Connect vehicle diagnostic, testing and information system VAS 5051- as follows: – Push diagnosis cable connector onto diagnosis connector. – Start engine and run at idling speed. Only when engine does not start: – Switch on ignition. Select operating mode – Press button on display for „Vehicle self-diagnosis“. Select vehicle system – Press button „01 - Engine electronics“ on display. The control unit identification and engine control unit coding are indicated on display. Select diagnostic function – Press button „02 - Read fault memory“ on display.
2. Engine control unit
239
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – If no fault is stored in engine control unit „0 fault detected“ is displayed. – If faults are stored in the engine control unit, these are shown one below the other on the display. – Press the ← button. – Press button „05 - Clear fault memory“ on display. – Press function „06-End output“.
2.2
Adapting functions and components
Special tools and workshop equipment required
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Select „guided fault finding“ in vehicle diagnostic, testing and in‐ formation system -VAS 5051- . When all control units have been read: – Press „GoTo“ button.
– Select „Function/component selection“. – Select „Drive train“. – Select „Engine code“.
– Select „01 Systems capable of self-diagnosis“.
– Select „Function or component“.
Removing and installing engine control unit (Golf) Prote cted by
Removing – Switch off ignition. – Remove wiper arms, plenum chamber cover and plenum chamber bulkhead: ⇒ Electrical system; Rep. gr. 92 ; Wind‐ screen wiper system; Removing and installing windscreen wiper system .
240
Rep. gr.23 - Mixture preparation - injection
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– Before removing engine control unit, read control unit identifi‐ cation and, with it, coding of current control unit as well ⇒ page 240 .
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2.3
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– Select „Functions“.
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– Select „Engine management“.
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♦ Vehicle diagnostic, testing and information system -VAS 5051-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Bend catch open slightly -1-. – Then push engine control unit out of retainer -arrow-. – Release now connector from engine control unit, disconnect connector. Installing – Fit connector to engine control unit and lock connector in po‐ sition. – Push engine control unit onto bracket.
– Press catch -1- against engine control unit.
2.4
Removing and installing anti-theft en‐ n AG. Volkswagen AG do gine control unit age(Golf) es n lksw ot g u
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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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– 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. Engine control unit
241
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note ♦ If the engine control unit is to be renewed, connect vehicle diagnostic, testing and information system -VAS 5051B- and perform „Renewing engine control unit“ in guided functions. ♦ The shear-head bolt threads are coated with locking com‐ pound. To simplify removing, the shear-head bolts can be heated using hot air blower -VAS 1978/14- . When doing this, ensure that no adjacent cables, connectors or components are damaged! Removing – Switch off ignition. – Remove wiper arms, plenum chamber cover and plenum chamber bulkhead: ⇒ Electrical system; Rep. gr. 92 ; Wind‐ screen wiper system; Removing and installing windscreen wiper system . – Cut into heads of shear-head bolts so that 2 parallel surfaces are created -arrows-.
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– Insert a screwdriver between protective housing -A- and bracket -arrow-.
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– Lever up protective housing using screwdriver -A- and pull to side off bracket -arrow-.
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– Remove bolts with grip pliers .
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Bend catch open slightly -1-. – Then push engine control unit out of retainer -arrow-. – Release now connector from engine control unit, disconnect connector. Installing –
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– Press catch -1- against engine control unit.
– Tighten new shear-head bolts -1- evenly until heads shearhead off. r fo ng
– 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 . agen lksw Vo by
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– Push protective housing onto bracket.
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Removing and installing engine control unit (Golf Plus) Note
If the engine control unit is to be renewed, connect vehicle diag‐ nostic, testing and information system -VAS 5051B- and perform „Renewing engine control unit“ in guided functions. Removing: – Switch off ignition. – Remove plenum chamber bulkhead ⇒ General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
2. Engine control unit
243
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Loosen securing nuts -arrows-. – Release connector from engine control unit, disconnect con‐ nector.
– Push bracket -1- off engine control unit in direction of arrow. Installing:
– Tighten securing nuts -arrows- to 10 Nm. – Fit connectors and lock in position.
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Removing and installing anti-theft en‐ gine control unit (Golf Plus)
Special tools and workshop equipment required ♦ Grip pliers Note
♦ If the engine control unit is to be renewed, connect vehicle diagnostic, testing and information system -VAS 5051B- and perform „Renewing engine control unit“ in guided functions.
r fo ng
♦ 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!
Rep. gr.23 - Mixture preparation - injection
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– Switch off ignition.
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Removing
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2.6
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– Install plenum chamber bulkhead ⇒ General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
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– Push bracket onto engine control unit.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Remove plenum chamber bulkhead ⇒ General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead . – Twist shear-head bolts -arrows- out using grip pliers and re‐ move cover from protective housing. – Then remove securing nuts for control unit bracket -arrows-.
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– Press catches -1- and -2- outwards. Then pull engine control unit off control unit bracket in direction of arrow. Installing
– Push engine control unit onto control unit bracket until it en‐ gages in catches.
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– Install cover of protective housing.
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– Tighten securing bolts -arrows- to 10 Nm.
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– Fit connectors to engine control unit and lock in position.
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2. Engine control unit
245
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Tighten new shear-head bolts -arrows- evenly until heads shear off.
2.7
Removing and installing engine control unit (Touran)
– Before removing engine control unit, read control unit identifi‐ cation and, with it, coding of current control unit as well ⇒ page 240 .
2.7.1
Removing
– Remove plenum chamber bulkhead. ⇒ General body repairs; Rep. gr. 50 ; Body - front, plenum chamber bulkhead . – Loosen securing nuts -arrows-.
– Push bracket -1- off engine control unit in direction of arrow.
2.7.2
Installing r fo ng
– Push bracket onto engine control unit.
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246
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– Release connector from engine control unit, disconnect con‐ nector.
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– Switch off ignition.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Tighten securing nuts -arrows- to 10 Nm. – Fit connectors and lock in position. – Check previous coding and adapt coding of the new control unit ⇒ page 240 . – Read fault memory of new engine control unit and erase fault memory if necessary. ⇒ page 239 – Carry out a road test. – Read control unit fault memory again.
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Special tools and workshop equipment required
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Removing
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♦ Hot air blower from wiring harness repair set -VAS 1978-
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♦ Grip pliers
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Removing and installing anti-theft en‐ gine control unit (Touran)
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– Switch off ignition. – Remove plenum chamber bulkhead ⇒ General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead . Note
The shear-head bolt threads are coated with locking compound. Heating the shear-head bolt with a hot air blower releases the locking effect of the locking compound. Caution
Cover lines, connections and control units in the vicinity of the engine control unit to prevent damage through heat. Perform settings on hot air blower -4- as shown:
2. Engine control unit
247
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Turn temperature settings potentiometer -2- to a maximum heat output of 600 °C. – Set two-stage switch for volume of air -3- to position 3. WARNING
When shear-head bolts are heated up, parts of the protective housing will be subjected to a large amount of heat. Wear pro‐ tective gloves to avoid possible injury. – Place nozzle of hot air blower close to shear bolt. – Switch on hot air blower and heat the bolts. – Unscrew shear-head bolts -arrows- out using pliers and re‐ move cover from protective housing.
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– Release connector from engine control unit, disconnect con‐ nector.
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– Press catches -1- and -2- outwards. Then pull engine control unit off control unit bracket -in direction of arrow-. Installing
– Push engine control unit onto control unit bracket until it en‐ gages in catches.
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– Fit connectors to engine control unit and lock in position.
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– Then remove securing nuts for control unit bracket -arrows-.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Tighten securing bolts -arrows- to 10 Nm. – Install cover of protective housing.
– Tighten new shear-head bolts -arrows- evenly until heads shear off.
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– Install plenum chamber bulkhead ⇒ General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
2. Engine control unit
249
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
3
Engine control unit (Passat)
Removing and installing engine control unit ⇒ page 250 . Removing and installing anti-theft engine control unit ⇒ page 251 .
3.1
Removing and installing engine control unit
If the engine control unit is to be renewed, connect vehicle diag‐ nosis, testing and information system -VAS 5051B- and perform guided functions „Renewing control unit“. DANGER!
Removing – Switch off ignition. – Remove wiper arms ⇒ Rep. gr. 92 . – Remove plenum chamber cover ⇒ Rep. gr. 64 . – Pull connector -1- off heated windscreen control unit -J505- . – Slide connector locking devices -2- on engine control unit out‐ wards and pull off both connectors. – Remove securing bolts -3-.
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Installing
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– Press locking device -1- outwards and slide engine control unit -2- in -direction of arrow-.
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For vehicles with heavy duty running gear; vehicle must be re‐ stricted to a maximum of 210 km/h via the engine control unit. Drive shafts can be damaged at speeds above 210 km/h. Per‐ form function „Restricting maximum speed“ in guided function using vehicle diagnostic, testing and information system -VAS 5051B- .
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– Fit retainer frame with engine control unit onto retainer -4-. Specified torque of securing nuts for retainer -4-: 6 Nm. – Tighten securing bolts -3- to 7 Nm.
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– Fit connectors to engine control unit and slide locking devices -2- inwards.
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– Slide engine control unit -1- into retaining frame in -direction of arrow-.
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– Install plenum chamber cover ⇒ Rep. gr. 64 .
3.2
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– Install wiper arms ⇒ Rep. gr. 92 .
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– Fit connector -1- to heated windscreen control unit -J505- .
Removing and installing anti-theft en‐ gine control unit
Special tools and workshop equipment required ♦ Hot air blower from wiring harness repair set -VAS 1978-
♦ Nozzle attachment from wiring harness repair set -VAS 1978If the engine control unit is to be renewed, connect vehicle diag‐ nosis, testing and information system -VAS 5051B- and perform guided functions „Renewing control unit“. DANGER!
For vehicles with heavy duty running gear; vehicle must be re‐ stricted to a maximum of 210 km/h via the engine control unit. Drive shafts can be damaged at speeds above 210 km/h. Per‐ form function „Restricting maximum speed“ in guided function using vehicle diagnostic, testing and information system -VAS 5051B- .
3. Engine control unit (Passat)
251
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Removing – Switch off ignition. – Remove wiper arms ⇒ Rep. gr. 92 . – Remove plenum chamber cover ⇒ Rep. gr. 64 . Note
The shear-head bolt threads are coated with locking compound. Heating the shear-head bolt with a hot air blower releases the locking effect of the locking compound. Caution olkswagen AG en AG. V
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Perform settings on hot air blower -4- as shown: urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p
– 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-head bolt. – Switch on hot air blower and heat bolt for about 20 to 25 sec‐ onds. – Unscrew shear-head bolt -2- using pliers on bolt head.
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– Pull connector -1- off heated windscreen control unit -J505- .
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Rep. gr.23 - Mixture preparation - injection
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252
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The procedure for the second shear-head bolt is exactly the same.
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– Turn temperature setting potentiometer -2- to maximum heat output (600 °C).
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Lift cover -1- and pull it forwards.
– Slide connector locking devices -1- on engine control unit out‐ wards and pull off both connectors.
Installing
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–
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– Slide engine control unit -1- into retaining frame in -direction of arrow-. – Fit retainer frame with engine control unit onto retainer in plenum chamber. Specified torque of securing nuts for retainer: 6 Nm.
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– Remove retainer frame with engine control unit from plenum chamber.
3. Engine control unit (Passat)
253
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Fit connectors to engine control unit and slide locking devices -1- inwards.
– Slide cover -1- over engine control unit and press it down‐ wards.
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– Tighten new shear-head bolts -2- evenly until bolt head shears off. – Fit connector -1- to heated windscreen control unit -J505- . – Install plenum chamber cover ⇒ Rep. gr. 64 . – Install wiper arms ⇒ Rep. gr. 92 .
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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 fourwheel drive) ⇒ page 262 . Assembly overview - silencers (Passat) ⇒ page 261 .
1.1
Assembly overview - front exhaust pipe with catalytic converter
1 - Front exhaust pipe with cat‐ alytic converter 3 - Support
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4 - Marking ❑ For clamp. ❑ Installation position of clamp ⇒ page 256 . es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng
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5 - To front silencer 6 - 25 Nm
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7 - Mounting ❑ Renew if damaged. 8 - 7 Nm
9 - Seal ❑ Note installation posi‐ tion.
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10 - Clip
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2 - 40 Nm
1. Exhaust system
255
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Installation position of clamp
Assembly overview - front exhaust pipe with particulate filter
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Position clamp at distance -a- = 5 mm from marking on front ex‐ haust pipe.
Special tools and workshop equipment required
256
Rep. gr.26 - Exhaust system
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If the particulate filter or the exhaust gas pressure sensor 1 G450- is changed, the exhaust gas pressure sensor 1 -G450must always be adapted using diagnosis tester : Guided func‐ tions; adapting exhaust pressure sensor 1 -G450- .
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♦ Tool set -T10395-
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♦ Lambda probe open ring spanner set -3337-
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If the particulate filter or the exhaust gas pressure sensor 1 G450- is changed, the exhaust gas pressure sensor 1 -G450must always be adapted using diagnosis tester : Guided func‐ tions; adapting exhaust pressure sensor 1 -G450- .
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 1 - 8 Nm 2 - Exhaust gas pressure sen‐ sor 1 -G4503 - Bracket ❑ For control lines 4 - 10 Nm 5 - Control line, 45 Nm AG. Volkswagen AG d oes not gu ara nte eo ra c
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7 - Exhaust gas temperature sender bank 2 -G448- , 45 Nm ❑ Lubricate thread of sender using high-tem‐ perature paste -G 052 112 A3-
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10 - Marking ❑ For clamp. ❑ Installation position of clamp ⇒ page 258 .
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9 - Front exhaust pipe
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8 - Particulate filter ❑ is removed downwards with exhaust gas pres‐ sure sensor 1 -G450❑ To remove, remove subframe and steering ⇒ Running gear, axles, steering; Rep. gr. 40 .
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6 - Lambda probe -G39- , 50 lkswagen o Nm yV db e s ri ❑ Grease only the ho threads ut a with high-temperature ss paste -G 052 112 A3- ; high-temperature paste -G 052 112 A3- must not get into the slots of probe body. ❑ To remove use Lambda probe open ring span‐ ner set -3337- .
11 - To front silencer 12 - 25 Nm 13 - Mounting ❑ Renew if damaged. 14 - Temperature sender after particulate filter -G527❑ 45 Nm ❑ Lubricate thread of sender using high-temperature paste -G 052 112 A315 - From turbocharger 16 - Clamp, 7 Nm 17 - Seal ❑ Renew. ❑ Note installation position.
1. Exhaust system
257
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 18 - 40 Nm
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Installation position of clamp
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– Position double clamp -a- = 5 mm from marking on front ex‐ haust pipe of particulate filter.
258
Rep. gr.26 - Exhaust system
AG.
3 - Separating point ❑ Marked by indentation on exhaust pipe ❑ During production, front and rear silencers are installed as a single component. For repairs, front and rear silencers are supplied separately. ❑ The connection is made with a clamp. ❑ Separating exhaust end pipe ⇒ page 259 ❑ Installation position of rear clamp (repair dou‐ ble clamp) ⇒ page 259 . ❑ Evenly tighten threaded connections of clamping sleeve (repair double clamp) ❑ Specified torques for clamp (repair double clamp): M8 = 25 Nm, M10 = 40 Nm ❑ Before tightening, align cold exhaust system free of tension ⇒ page 262
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2 - Retaining ring ❑ Renew if damaged.
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1 - 25 Nm ❑ Renew.
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Assembly overview - silencer with mountings (vehicles with front wheel drive)
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1.3
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19 - Bracket ❑ Bolted to cylinder head.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 4 - Rear silencer 5 - Mounting ❑ Renew if damaged. 6 - 25 Nm 7 - Tunnel bridge 8 - Front silencer 9 - Mounting ❑ Renew if damaged. Installation position of rear clamp (repair double clamp) – Install clamp so that ends of bolts do not protrude beyond bot‐ tom of clamp. Bolt connection faces to left.
1.3.1
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♦ Eye protection Procedure
WARNING
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•
1. Exhaust system
259
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 – Cut exhaust end pipe at right angles at separating point -arrow 2-. – When installing, position repair double clamp -4- at side mark‐ ings -arrow 1- and -arrow 3-.
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– Install repair double clamp so that end of bolt does not extend beyond lower edge of clamp. •
Bolted connection faces rear.
– Align cold exhaust system free of stress ⇒ page 262 .
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Specified torque, M10: 40 Nm
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Tightening torque M8: 25 Nm
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– Tighten bolts on repair double clamp.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
1.4
Assembly overview - silencers (Passat)
1 - From front exhaust pipe 2 - Clamp ❑ Before tightening, align cold exhaust system free of tension ⇒ page 262 ❑ Tighten bolted connec‐ tions evenly. ❑ Specified torque: M8 = 25 Nm, M10 = 40 Nm. 3 - Front silencer 4 - Mounting ❑ Renew if damaged.
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 es n wage s clamping sleeve for pur‐ k l ot g Vo y ua b poses of connection d ran ir se tee o h ❑ Cut through exhaust t or u ac a pipe at right angles at ss separating point -arrow A- using e.g. body saw -V.A.G 1523(wear eye protection) ❑ During installation, posi‐ tion repair double clamp at side markings -arrows B❑ Evenly tighten threaded connections of clamping sleeve (repair double clamp) ❑ Specified torques for clamp (repair double clamp): M8 = 25 Nm, M10 = 40 Nm. ❑ Before tightening, align cold exhaust system free of tension ⇒ page 262
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8 - Rear silencer
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7 - Retaining ring ❑ Renew if damaged.
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5 - 25 Nm ❑ Renew.
1. Exhaust system
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1.5
Assembly overview - silencer with mountings (vehicles with four-wheel drive)
1 - From particulate filter 2 - Clamp ❑ Align exhaust system free of stress before tightening clamp ⇒ page 262 . AG. Volkswagen AG d ❑ Installation position ⇒ agen oes ksw not l page 262 . o V gu y b ara d nte ❑ Tighten bolted connec‐ ise r o eo h tions evenly. aut ra
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3 - Bracket ❑ For retaining ring 4 - 25 Nm
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5 - Retaining ring ❑ Renew if damaged. 7 - Mounting ❑ Renew if damaged.
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– 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
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Installation position of clamp
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6 - Rear silencer
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Procedure – Loosen bolted connection of clamp between front exhaust pipe and silencer. – Position clamp at distance -a- = 5 mm from marking on front AG. Volkswagen AG d agen oes exhaust pipe and lightly tighten front bolted connection. w s n lk
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– 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 direction of travel. – Align rear silencer horizontally. Specified torque, M8: 25 Nm
Specified torque, M10: 40 Nm
– Once clamp has been tightened, check distance -a- and cor‐ rect if necessary.
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– With parts in this position, tighten bolted connections of clamp.
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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 Engine codes BLS and BXJ ⇒ page 267 Check mechanical exhaust gas recirculation valve AVQ, BKC, BRU, BXE, BXF ⇒ page 268 .
2.1.1
Engine codes AVQ, BKC, BRU, BXE and BXF
♦ The exhaust gas recirculation system is activated by the diesel direct injection system control unit -J248- via exhaust gas re‐ circulation valve -N18- (electric-pneumatic) to the exhaust gas recirculation valve (mechanical). ♦ The electro-pneumatic exhaust gas recirculation valve -N18is located in the solenoid valve block. ♦ The cone-shaped plunger in the mechanical exhaust gas re‐ circulation valve ensures that various cross sectional openings are possible at different plunger lifts. ♦ Pulsed control enables every conceivable valve position.
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♦ Renew self-locking nuts.
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Note
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 1 - 22 Nm 2 - Intake manifold ❑ With exhaust gas recir‐ culation valve and in‐ take manifold flap motor -V157- . ❑ Tighten securing bolts to 22 Nm. 3 - Seal ❑ Renew. 4 - Connecting pipe 5 - Radiator ❑ For exhaust gas recircu‐ lation. 6 - 10 Nm 7 - Exhaust manifold 8 - Connecting pipe
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1. Attach to bypass flap 2. Attach to manifold 3. Tighten to bypass flap 4. Tighten to manifold
9 - Bypass flap ❑ When activated, directs exhaust gas to exhaust gas recirculation cooler via the electro-pneu‐ matic exhaust gas recir‐ culation valve -N18- . 10 - Bracket ❑ For bypass flap 11 - 5 Nm
2-
Exhaust gas recirculation valve
3-
Bypass flap
4-
Air filter
5-
Vacuum reservoir
6-
Vacuum unit on turbocharger
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Vacuum connection (on non-return valve for brake servo) agen lksw Vo by
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Connector assignment on solenoid valve block, engine codes BKC, BRU, BXE and BXF
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Tightening sequence:
AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s
2. Exhaust gas recirculation system
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2.1.2
Engine code BJB
Note ♦ The exhaust gas recirculation system is activated by the diesel direct injection system control unit -J248- via exhaust gas re‐ circulation valve -N18- (electric-pneumatic) to the exhaust gas recirculation valve (mechanical). ♦ The electro-pneumatic exhaust gas recirculation valve -N18is located in the solenoid valve block. ♦ The cone-shaped plunger in the mechanical exhaust gas re‐ circulation valve ensures that various cross sectional openings are possible at different plunger lifts. ♦ Pulsed control enables every conceivable valve position.
1 - Intake manifold ❑ With exhaust gas recir‐ culation valve and in‐ take manifold flap. ❑ Tighten securing bolts to 22 Nm. 2 - From charge air cooler 3 - Seal ❑ Renew. 5 - Exhaust manifold
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6 - Connecting pipe
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4 - 22 Nm
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♦ Renew self-locking nuts.
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Pin assignment on solenoid valve block for engine code BJB 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
2.1.3
Engine codes BLS and BXJ
Note ♦ The exhaust gas recirculation system is activated by the diesel direct injection system control unit -J248- via the exhaust gas recirculation potentiometer -G212- .
1 - Coolant hose ❑ To connection 2 - Seal ❑ Renew. 3 - 22 Nm 4 - Connecting pipe n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss
5 - From exhaust manifold 6 - 25 Nm ❑ Renew. un le
8 - Exhaust gas recirculation cooler 9 - 10 Nm
10 - Coolant hose ❑ From rear coolant pipe 11 - Connecting hose 12 - Exhaust gas recirculation cooler changeover valve N345r fo ng
13 - Connecting pipe
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14 - Vacuum actuator ❑ For bypass flap. ❑ Renew only together
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7 - To connection for exhaust gas recirculation valve -N18with exhaust gas recirculation potentiometer -G212❑ Assembly overview - in‐ take manifold ⇒ page 237 .
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♦ Renew self-locking nuts.
2. Exhaust gas recirculation system
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 with exhaust gas recirculation cooler
2.2
Checking mechanical exhaust gas re‐ circulation valve
Special tools and workshop equipment required
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– Pull vacuum hose off exhaust gas recirculation valve. – Connect hand vacuum pump with accessories -V.A.G 1390to valve. – Operate hand vacuum pump a few times.
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– Pull hand vacuum pump hose off exhaust gas recirculation valve. The diaphragm rod must audibly return to its original position.
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Test procedure
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♦ Hand vacuum pump with accessories -V.A.G 1390-
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010
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
Special tools and workshop equipment required
AG. Volkswagen AG d agen oes ksw not l o V gu by ara d e nte is r o eo h ut ra a c s s
•
Battery voltage at least 11.5 V
•
Ignition switched on
Checking
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Test requirements
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♦ Jointed spanner -3220-
The glow plug system is monitored by the engine control unit's self-diagnosis system. Removing glow plugs
– Remove glow plugs using U/J extension and socket -3220- . Installing glow plugs
– Install glow plugs using jointed extension and socket -3220- . Specified torque: 15 Nm
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The necessary checks are performed with Guided fault finding.
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♦ Vehicle diagnosis tester
1. Checking glow plug system
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Characteristics of ceramic glow plugs
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WARNING
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1.2
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The ceramic glow plugs ⇒ page 270 are sensitive to jolts and bending. For this reason a glow plug which has dropped from a small height (approx. 2 cm) must not be used. Even if no damage is apparent. It is absolutely necessary to follow the installation instructions, otherwise the heater pin of the glow plug can break and cause engine damage. Visual features of ceramic glow plugs Vehicles with 2 valves per cylinder head -A- = Metal glow plug, colour-coded -arrow-. -B- = Ceramic glow plug with support tube -arrow-, not colourcoded. Vehicles with 4 valves per cylinder head
Remove and install or check ceramic glow plugs ⇒ page 271 .
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-D- = Ceramic glow plug with support tube -arrow-, not colourcoded.
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-C- = Metal glow plug, colour-coded -arrow-.
Golf 2004
Removing, installing and checking ceramic glow plugs
♦ Torque wrench (5... 50 Nm) -V.A.G 1331♦ Hand-held multimeter V.A.G 1526 A-
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♦ Auxiliary measuring set V.A.G 1594 C-
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♦ Jointed spanner -3220-
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Special tools and workshop equipment required
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1.3
AG. Volkswagen AG d agen oes ksw no l o V ua ➤ , Golf Plusd2005 ➤ , Passat 2006 ➤ , Tourant g2003 by ran ➤ e s tee ridiesel 4-cylinder engine (1.9 l engine) Edition 08.2010 o h or ut ac a ss
Test prerequisites •
Engine is cold
•
Ignition switched off
Procedure Note
Do not cant ceramic glow plugs when removing and installing. Remove any components hindering assembly. – Pull connectors off ceramic glow plugs. – Remove ceramic glow plugs using U/J extension and socket, 10 mm -3220- . Installation is carried out in the reverse order. When installing, note the following: – Before installing the drilling in cylinder head and the threads must completely cleaned of all deposits.
1. Checking glow plug system
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤ 4-cylinder diesel engine (1.9 l engine) - Edition 08.2010 Note
Do not oil or grease thread of cylinder head bore or of ceramic glow plugs. – Screw ceramic glow plugs into cylinder head by hand using U/ J extension and socket, 10 mm -3220- . – Then tighten the ceramic glow plugs. Specified torque: 15 Nm. WARNING
♦ After installing and before the engine is started, perform a resistance test on all ceramic glow plugs when engine is cold. ♦ If the defective ceramic glow plug is broken, remove all fragments from the engine, otherwise these can cause damage to the engine.
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– If the specification is exceeded, renew the defective ceramic glow plug.
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♦ Specification: max. 1 Ω