Service: Golf 2004 Golf Plus 2005 Passat 2006 Touran 2003

Service
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Workshop Manual
Golf 2004 Golf Plus 2005 Passat 2006 Touran 2003
Engine ID
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4-cylinder diesel engine (2.0 l engine, 4 valve)

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Edition 02.2011
Service Department. Technical Information
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling 20 - Fuel supply system 21 - Turbocharging/supercharging 23 - Mixture preparation - injection 26 - Exhaust system 28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
All rights reserved. No reproduction without prior agreement from publisher. Copyright 2011 Volkswagen AG, Wolfsburg K0058971620
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1.1 1.2 1 1.1 1.2 1.3 1.4 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3 1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.4 2.5 1 1.1 1.2 1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling engine . . . . . .. . . l. swa.g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. e n AG n AG Vo k w . Assembly overview - poly V-belt drive age. . . . . . . . . . . . . .does.no . . . . . . . . . . . . . . . . . . . . . .. . ks tg Vol by Removing and installing poly eV-belt . . . . . . . . . . . . . . . . . . . . . . ua.ra.n . . . . . . . . . . . . . . . . . . d t ris Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . ee.or. . . . . . . . . . . . . . . . tho a au Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c . . . . . . . . . . . . . . ss Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1 1 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3 4 11 13 14 15 15 16 18 23 24 25 33 35 37 39 39 40 40 42 44 44 44 45 47 47 49 51 66 71 72 72 74 76 79 84 86 86 86 86
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing roller rocker finger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil capacities - Golf, Golf Plus, Touran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil capacities - Passat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 2 2.1 2.2 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 4 4.1 4.2 4.3 4.4 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 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 Parts of lubrication system (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of lubrication system (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - oil pump, sump, balancer shaft module with chain drive . . . . . . . . . . Removing and installing oil pump (for balancer shaft module with chain drive) . . . . . . . . . . Removing and installing balancer shaft module with chain drive . . . . . . . . . . . . . . . . . . . . Retrofitting spur gear drive for balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - oil pump, sump, balancer shaft module with spur gear drive . . . . . . Removing and installing oil pump (for balancer shaft module with spur gear drive) . . . . . . Removing balancer shaft module with spur gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing spur gear for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter bracket, oil cooler, oil pressure and oil supply line . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - oil filter bracket and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - parts of cooling system, engine side (Golf, Golf Plus, Touran) . . . . Assembly overview - parts of cooling system, engine side (Passat) . . . . . . . . . . . . . . . . . . Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing fan support with fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing thermostat . . .e.n.A. .. Volks. . gen.A.G. . . . . . . . . . . . . . . . . . . . . . . . . . G . . . wa . . do s wag lks. . . . . . . . . . . . . . . . . . .e. not . . . . . . . . . . . . . . . . . . . . . Checking cooling system for leaks o . ..g V u by d Checking oil cooler for leaksrise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . aran. . . . . . . . . . . . . . . . . ..t 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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87 87 89 92 93 95 98 101 104 107 107 108 111 117 120 120 121 123 123 125 126 127 129 131 134 139 140 142 144 146 148 150 150 151 151 152 152 156 162 164 166 166 171 173 175 176 177 180 182 183 184
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Contents
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20 - Fuel supply system . . .
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 4.7 4.8 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 6 6.1 7 7.1 7.2 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 2 2.1 2.2 3 3.1 3.2 4 4.1 4.2 1 1.1 1.2 2 2.1 Removing and installing fuel gauge sendersw. . . . . . . . . . . . . . . . . es.n.ot.g. . . . . . . . . . . . . . . . olk yV u d.b . . . . . . . . . . . . . . . . . . . . . . . . . . . ara . . . . . . . . . . . . Checking fuel pump . . . . . . . . . .ri.se . . .nte e ho ut Parts of fuel supply system (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r ac . . . . . . . . . sa s Fuel tank, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emptying fuel tank, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emptying fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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186 186 192 192 202 206 213 215 219 221 223 223 225 225 227 230 230 230 231 232 235 237 238 240
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - turbocharger with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - intake manifold with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - pre-wired wiring harness for unit injectors and glow plugs . . . . . . . . Removing and installing pre-wired wiring harness for unit injectors and glow plugs . . . . . . Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning unit injectors (engine codes BMN, BKP, BMA, BUZ and BMR) . . . . . . . . . . . . . . Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine control unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine control unit (Golf Plus, Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine control unit (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . . . Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . Silencer (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - silencer, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . .
Contents
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

273 273 274 277 277
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242 242 243 244 246 246 249 251 255 257 259 260 260 260 264 264 265 268 268 269
iii
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 4 4.1 4.2 4.3 5 5.1 Assembly overview - silencer, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . Cutting exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation position and specified torque of the clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Silencer (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Silencer (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview - silencer, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . Assembly overview - silencer, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n AG. Vo . . . e . . . d . Assembly overview - exhaust gas recirculation lkswag. n AG . oe. . . . . . . . . . . . . . . . . . . . . . . . . wage 278 278 279 280 282 282 283 283 284 284 285 285 287 287
28 - Glow
1 1.1 1.2
ks Vol by d. . . . . . . . . . . . plug system . . . . . . .or.ise . h ut metal or ceramic glow Optical characteristics sof a s
....
plugs . . . . . . . . 290 Removing and installing metal glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 Removing and installing ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
s no t gu . . . . . . . . a.ra.nte . . . . . . . . eo . . . . . . . . . . . . . r . c. . . . . . a
. . . . . . . 290

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Contents
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00
1
Technical data
Technical data
Engine number page 1 Engine data page 1
1.1
Engine number
The engine number (code letters and serial number) can be found on the joint between engine and gearbox. In addition, there is a sticker on the toothed belt guard with engine code and serial number. The engine code can also be found on the vehicle data sticker. The engine number consists of up to nine characters (alphanu meric). The first part (maximum 3 characters) makes up the engine code, and the second part (6 characters), the serial number. If more than 999,999 engines with the same engine code are produced, the first of the six characters is replaced with a letter.
1.2
Engine data
AZV BKD
Edition 02.2011 version 24.0 Engine code Manufac tured
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BMN
BKP
BMA
BVE
BMR
BUZ
BWV
Emissions fulfil Capacity Output Torque Bore Stroke Valves per cylinder Compres sion ratio Fuel
18.5
18.5
18.5
18.5
18.5
18.5
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18.5
18.5
accord DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN ing to 590 590 590 590 590 590 590 590 590 Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 Catalytic yes yes yes yes yes yes yes yes yes converter Exhaust yes yes yes yes yes yes yes yes yes gas recircu lation
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Golf/ 10.03 Golf Plus Touran 11.02 Passat --EU4 stand ard l 2.0 kW at 100/40 rpm 00 Nm at 320/ rpm 1750..2 500 mm 81.0 mm 95.5 4
10.03 01.06 03.04 01.06 ----EU4 EU4 stand stand ard ard 2.0 2.0 103/40 125/42 00 00 320/ 350/ 1750..2 1800 500 81.0 81.0 95.5 95.5 4 4
---
---
---
---
---
---
------------03.05 03.05 05.05 09.05 09.05 01.06 EU4 EU4 EU4 EU4 EU4 EU4 stand stand stand stand stand stand ard ard ard ard ard ard 2.0 2.0 2.0 2.0 2.0 2.0 103/40 100/40 90/400 125/42 120/42 88/400 00 00 0 00 00 0 320/ 320/ 320/ 350/ 350/ 300/ 1750..2 1750 1750 1800 1800 1750 500 81.0 81.0 81.0 81.0 81.0 81.0 95.5 95.5 95.5 95.5 95.5 95.5 4 4 4 4 4 4 18.5
1. Technical data
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Engine code Turbo charging/ supercharg ing Charge air cooling Particulate filter AZV yes BKD yes
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BWV yes
yes no
yes no
yes yes
yes no
yes no
yes no
yes yes
yes yes
yes no
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Rep. gr.00 - Technical data
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1
Removing and installing engine

Removing and installing engine
Removing engine page 4 . Securing engine to assembly stand page 11 . Notes on installing page 13 . Assembly mountings page 14 . Special tools and workshop equipment required Torque wrench -V.A.G 1331
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Spring-type clip pliers -VAS 5024 Aurposes, in part or in wh ole, cial p is n mer ot com
Stepladder -VAS 5085 Engine bracket -T10012-
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V.A.G 1383 A-
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1. Removing and installing engine
1.1
Note
Removing engine
Before carrying out further work, disconnect battery earth
strap. First check whether a coded radio is fitted. Obtain antitheft coding first if necessary.
The engine is removed downwards together with the gearbox. All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine is installed.

WARNING
When doing any repair work, especially in the engine compart ment, pay attention to the following due to the cramped condi tions: Route all the various lines (e.g. for fuel, hydraulics, acti vated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original po sitions. Ensure that there is sufficient clearance to all moving or hot components.
Procedures for Golf, Golf Plus, Touran page 4 Procedures for Passat page 7
1.1.1
With ignition switched off, disconnect earth strap from battery. Electrical system; Rep. gr. 27 ; Disconnecting and recon necting batteries . 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-. Remove plenum chamber bulkhead. General body repairs, exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
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test or VAS 5052; Vehicle self-diagnosis .
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Rep. gr.10 - Removing and installing engine
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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 battery and battery tray. Remove insulation tray General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation . Bring lock carrier into service position General body repairs; Rep. gr. 50 ; Body - front; Lock carrier service position . Drain coolant page 134
n AG. Volkswagen AG do es n wage ot g olks yV ua db ran WARNING e s tee ri ho t or ac au ss fuel and the fuel lines in the fuel system can become
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!
Disconnect fuel supply and return lines as well as coolant line on cylinder head. Pull fuel filter module upwards out of bracket and lay it with hoses to side. Vehicles with air conditioner Note
The very hot (danger of scalding)!

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To facilitate removing and installing engine without opening re frigerant circuit: Remove poly V-belt page 16 .
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Separate air conditioner compressor from compact bracket. Heating, air conditioning; Rep. gr. 87 ; Removing and instal ling compressor bracket . Secure air conditioner compressor to lock carrier so that re frigerant lines are relieved. Continuation for all vehicles Remove exhaust pipe and coolant hoses from supplementary heater. Remove connecting pipes between charge air cooler and en gine. Pull retainer for wiring harness of oil level and oil temperature sender -G266- off subframe. Remove right drive shaft and unscrew left drive shaft from gearbox Running gear, axles, steering; Rep. gr. 40 ; Re moving and installing drive shaft . Remove left wheel housing liner.
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To prevent damage to condenser and also to refrigerant lines/ hoses, ensure that the lines and hoses are not stretched, kinked or bent.
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Disconnect front exhaust pipe from turbocharger, loosen dou ble clamp and slide exhaust pipe back page 273 . Pull engine wiring harness connector off control unit: Golf page 260 Golf Plus, Touran page 264 Open cable guide catches on longitudinal member -arrows-. Remove wiring harness from cable guide and lay to side on engine.
For engine code BMN: Separate connections at engine bulkhead for: -1- Exhaust gas temperature sender 2 -G448 -2- Temperature sender after particulate filter -G527 -3- Exhaust gas temperature sender 1 -G235 -4- Lambda probe -G39AG. Volkswagen AG d agen oes not lksw Vo gu by ara d valve -N75 -5- Charge pressure control solenoid nte ise or eo th u ra Continuation for all vehicles ss a c
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. For engine code BMN: Release connecting clamp for front exhaust pipe/front silenc er. Remove subframe and steering Running gear, axles, steer ing; Rep. gr. 40 . Note
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The engine is lowered downwards with particulate filter fitted.

Engine codes AZV, BKD:
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Disconnect front exhaust pipe from turbocharger, loosen dou ble clamp and slide exhaust pipe back page 273 . Disconnect selector mechanism from gearbox 6-speed manual gearbox 02Q; Rep. gr. 34 . Separate pressure line for hydraulic clutch control. Remove pendulum support.
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Continuation for all vehicles:
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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. The threaded support pin must be on the gearbox side.
Fit engine bracket -T10012- to cylinder block with M10 x 25/ 8.8 bolt and tighten to approx. 40 Nm. Lift engine and gearbox lightly using engine and gearbox jack -V.A.G 1383/A- . Unbolt engine side of assembly mounting from engine support from above -arrows-. G. Volkswage
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Unbolt gearbox side of assembly mounting from gearbox bracket from above -arrows-. Note
To remove securing bolts, use stepladder VAS 5085. Engine with gearbox must be guided carefully when lowered
to prevent damage to bodywork.
Carefully lower engine with gearbox.
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With ignition switched off, disconnect earth strap from battery Rep. gr. 27 . 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-.
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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 .
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1.1.2
Procedures for Passat
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Remove bolt -arrow A- and pull air filter housing upwards out of mounting. Remove air filter housing together with air mass meter and connecting pipe. Disconnect all necessary vacuum lines or, when fitted, con nectors on solenoid block page 240 . Remove battery and battery tray. Remove wiper arms Rep. gr. 92 . Remove plenum chamber cover Rep. gr. 64 . Vehicles without anti-theft alarm system Release connector on engine control unit and pull it off page 268 . Vehicles with anti-theft alarm system Release connector on engine control unit and pull it page 269 . Continuation for all vehicles
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Remove feed-through for engine control unit wiring harness -arrow-.
Open cable guide fasteners -arrows-.
Remove wiring harness from cable guide on longitudinal mem ber and lay to side on engine.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pull off fuel supply hose -2-, fuel return hose -1- and coolant hose -3-. 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 wire from central electrics -arrow-.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Unscrew earth cable -arrow- from longitudinal member. Move wiring clear. Pull off or disconnect all other electrical connections from en gine and gearbox as necessary and lay to side.
n AG. olkswa hoses Separate all connecting, vacuum andVintakegen AG dofrom en es n wage ot g olks gine. yV u
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Vehicles with four-wheel drive: Disconnect gear selector mechanism from gearbox 6-speed manual gearbox 02Q, four-wheel drive; Rep. gr. 34 ; Repairing gear selector mechanism . Continuation for all vehicles: Remove slave cylinder for hydraulic clutch or, disconnect line at slave cylinder Rep. gr. 30 . Remove noise insulation tray Rep. gr. 50 . Pull connector off oil level and oil temperature sender -G266- . Pull retainer for oil level and oil temperature sender -G266wiring harness off subframe. Drain coolant page 134 . Bring lock carrier into service position Rep. gr. 50 . Completely remove exhaust pipes from supplementary heater Rep. gr. 82 .
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ss Disconnect gear selector mechanism from gearbox 6-speed manual gearbox 02Q; Rep. gr. 34 ; Repairing gear selector mechanism .
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Remove right drive shaft and disconnect left drive shaft from gearbox Rep. gr. 40 . Vehicles with four-wheel drive: Remove front propshaft Final drive 02D, 0AV; Rep. gr. 39 ; Assembly overview - repairing propshaft . Vehicles with particulate filter: Release connecting clamp for front exhaust pipe/front silenc er. Remove subframe and steering Running gear, axles, steer ing; Rep. gr. 40 . Note
The engine is lowered downwards with particulate filter fitted.

Vehicles with no particulate filter: Disconnect front exhaust pipe from turbocharger, loosen dou ble clamp and remove exhaust pipe Item 1 (page 273) . Continuation for all vehicles:
10
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Separate all other coolant hoses from engine.

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Pull coolant hoses off supplementary heater.
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Remove poly V-belt page 16 . Separate air conditioner compressor from compact bracket Rep. gr. 87 . Secure air conditioner compressor to lock carrier so that re frigerant lines are free of stress. Note
wag olks yV Unbolt pendulum support -arrows-. ed b is or To facilitate removing and installingauth engine without opening ss frigerant circuit:
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To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
Fit engine bracket -T10012- onto cylinder block with securing nut and M1025/ 8.8 bolt and tighten to approx. 40 Nm. Insert engine bracket -T10012- in engine and gearbox jack V.A.G 1383/A- .
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Lift engine and gearbox lightly using engine and gearbox jack -V.A.G 1383/A- .
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Unbolt engine side of assembly mounting from engine support from above -arrows-.
Unbolt gearbox side of assembly mounting from gearbox bracket from above -arrows-. Carefully lower engine with gearbox. Note
Engine with gearbox must be guided carefully when lowering to prevent damage to bodywork.
1.2
Securing engine to assembly stand
Before carrying out repair work, secure engine on engine and gearbox support -VAS 6095/1- using universal mounting -VAS 6095- .
AG.
To remove securing bolts, use stepladder -VAS 5085- .
11
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Special tools and workshop equipment required Lifting tackle -2024 A Workshop hoist -VAS 6100 Engine and gearbox sup port -VAS 6095-
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Procedure
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Unbolt gearbox.
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Attach lifting tackle -VAS 2024A- as follows and lift from engine and gearbox jack -V.A.G 1383/A- using workshop crane. Belt pulley end: 1st hole in hook rail at position 1 Flywheel end: 4th hole in hook rail at position 8
not gu by ara ed nte ris eo ho The hooks andt locating pins must be secured with locking pins.r ac au s s
WARNING Volksw
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Note
The positions marked 14 on the bar must be towards the
pulley end.
The holes in the hook rails are counted up from the hook. Secure engine on engine and gearbox support -VAS 6095/1using universal mounting -VAS 6095- .
1.3
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. Lightly grease input shaft splines with G 000 100 grease.
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Check whether dowel sleeves for centring engine and gearbox are in cylinder block and install if necessary. Rock engine to align engine mountings stress-free.
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Note
Specified torques for engine and gearbox mountings
page 14 . gr. 97 .
Electrical connections and routing Electrical system; Rep. On vehicles with particulate filter install subframe and steering Running gear, axles, steering; Rep. gr. 40 . Install pendulum support. Install drive shaft Running gear, axles, steering; Rep. gr. 40 ; Removing and installing drive shafts . Vehicles with no particulate filter, install front exhaust pipe page 277 . Install poly V-belt page 16 . Install hydraulic line for hydraulic clutch 6-speed manual gearbox 02Q; Repair group 30; Repairing clutch mechanism; Assembly overview - hydraulic system . Install selector mechanism and, if necessary, adjust gear se lector cables 6-speed manual gearbox 02Q; Rep. Gr. 34; Repairing selector mechanism . Replenish coolant page 134 .
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Install insulation tray General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation . Carry out road test and read fault memories Vehicle diag nostic tester. Specified torques Threaded connection Bolts, nuts M6 M8 M10 M12 Specified torque 10 Nm 20 Nm 45 Nm 60 Nm
1.4
Assembly mountings
Engine assembly mounting A = 20 Nm + 90 (1/4 turn) further 1) B = 40 Nm + 90 (1/4 turn) further 1) C = 60 Nm + 90 (1/4 turn) further 1)
1)
Renew.
Gearbox assembly mounting 1 = 40 Nm + 90 (1/4 turn) further 1) 2 = 60 Nm + 90 (1/4

1)
Renew.
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Pendulum support
A = 40 Nm + 90 (1/4 turn) further 1) B = 100 Nm + 90 (1/4 turn) further 1)

1)
Renew.
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13
1
Note
Crankshaft group
Dismantling and assembling engine
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 oil cooler in order to prevent subse quent damage.
Assembly overview - poly V-belt drive page 15 . Removing and installing poly V-belt page 16 . Assembly overview - toothed belt drive page 18 . Assembly overview - crankcase page 23
1.1
Assembly overview - poly V-belt drive
1 - Belt pulley and vibration damper Can only be installed in one position, holes are offset. 2 - 25 Nm 3 - Alternator 4 - Retainer
n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tensioning ele tee ri 5 - Poly V-belt ho or ment aut ac ss
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Swivel with open-end spanner to slacken poly V-belt page 16 .
6 - 25 Nm 7 - Air conditioner compressor 8 - 45 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 16 .
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1. Dismantling and assembling engine
15
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 G. Volkswagen AG A does agen not lksw 4-cylinder diesel engine (2.0 l engine, 4 valve) - Editiono02.2011 V g
1.2
Removing and installing poly V-belt

Special tools and workshop equipment required Locking pin -T10060 A-
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Removing
Mark direction of rotation of poly V-belt.
Lock tensioning element using locking pin -T10060 A- . Remove poly V-belt. Installing Install in reverse order. Note Before installing poly V-belt, ensure that all ancillaries (alter
nator, air conditioner compressor) are secured tightly. proper seating of belt in pulleys. tor last.
When installing poly V-belt, check direction of belt rotation and For vehicles without air conditioning, fit poly V-belt on alterna For vehicles with air conditioning, fit poly V-belt over air con
ditioner compressor last.
After completing repairs always: Start engine and check belt running.
16
Rep. gr.13 - Crankshaft group
AG.
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Swing tensioning element in direction of arrow to remove ten sion from poly V-belt.
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Pull fuel filter out of bracket and lay it with hoses to side.
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Remove insulation tray. General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula tion .
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Belt drive without air conditioner compressor
Belt drive with air conditioner compressor
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1.3
Assembly overview - toothed belt drive

1 - Toothed belt guard upper part 2 - Toothed belt Mark direction of rota tion before removing. Check for wear. Do not kink. Removing, installing and tensioning page 51 . 3 - Guide roller 4 - 100 Nm 5 - 25 Nm 6 - Camshaft pulley 7 - Hub Use counterhold tool T10051- to loosen and tighten. To remove, use puller T10052- . Removing and installing page 79 . 8 - Camshaft pulley 9 - Hub With sender wheel Use counterhold tool T10051- to loosen and tighten. To remove, use puller T10052- . Removing and installing page 79 . 10 - 10 Nm 11 - Rear toothed belt guard

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12 - Tensioning roller Remove engine support in order to remove and install page 19 . 13 - 20 Nm + 1/8 turn (45) further 14 - Guide roller 15 - 20 Nm 16 - Coolant pump Removing and installing page 142 . 17 - 15 Nm 18 - Crankshaft toothed belt pulley 19 - 120 Nm + 1/4 turn (90) further Renew. Use counterhold tool -3415- to loosen and tighten.
18
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Do not additionally oil or grease thread and shoulder. Turning further can be done in several stages. 20 - Bolt M10 = 40 Nm + 90 further M12 = 90 Nm + 90 further Renew. 21 - Toothed belt guard lower part 22 - Belt pulley and vibration damper Can only be installed in one position. Holes are offset. 23 - 10 Nm + 1/4 turn (90) further Renew. 24 - Cover 25 - Toothed belt guard centre part 26 - Engine support Removing and installing page 19 . 27 - 40 Nm + 1/2 turn (180) further Renew.
1.3.1
Removing and installing engine support
Special tools and workshop equipment required Support bracket -10 - 222 A Torque wrench -V.A.G 1331 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 G. Volkswagen AG d A agen oes ksw not -arrow B-. Vol g
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19
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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.
AG. Volkswagen AG d agen oes not lksw Vo gu by ara Disconnect coolant hose from top of expansion tank.sed nte i or eo th u ra Remove expansion tank and lay it to side. a c ss
Remove charge air pipe between charge air cooler and turbo charger. Carefully cover or seal open ends. Golf, Golf Plus and Touran:
Fit engine support bracket -10-222A- with adapters -10-222A/ 22- and take up weight of engine in installation position. Passat:
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Continuation for all vehicle types:
20
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Set up support bracket -10-222A- with legs -10-222A/1- and support engine in installation position, as shown.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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! mounting has been removed.

WARNING
The engine support must only be loosened when the assembly
When raising and lowering engine using support bracket -10-222A- , ensure that no components or hoses are damaged or torn off.
Remove noise insulation tray General body repairs, exteri or; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation . Remove front right wheel housing liner. Raise engine with support bracket -10-222A- until both upper bolts of engine support can be loosened and removed. Lower engine with support bracket -10-222A- until lower bolt can be loosened and removed. Remove engine support en AG. V g upwards. swa
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Insert new bolts and tighten hand-tight.

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Caution
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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21
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Tighten bolts for engine support in the sequence shown -13- to 40 Nm + 1/2 turn (180 ) further. To do this, raise or lower engine using support bracket -10 - 222 A- . I : Engine support with less clearance to engine II: Engine support with greater clearance to engine Note
Before installing assembly mounting, tighten all engine support bolts to prescribed torque.
Install assembly mounting between engine and body (renew securing bolts) page 14 .
Bolt engine assembly mounting to engine support -arrows- by bringing contact surfaces together using support bracket -10-222A- . Specified torque: 60 Nm + 90 (1/4 turn) 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 and return lines (return line blue or with blue markings, supply line black). When installing charge air pipes, ensure that locking lugs en gage correctly. Install wheel housing liner. Install noise insulation tray. General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise n AG. Volkswagen A insula G do es n wage tion . o olks
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22
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1.4
Assembly overview - crankcase
1 - Cylinder block Removing and installing sealing flange and fly en AG. Volkswagen AG does wag not wheel page y Vol. s 24 k gu ara db nte Removingrise installing and eo ho ut crankshaft ra c s a 44 . s page Dismantling and assem bling pistons and con rods page 39 . 2 - Seal Renew. 3 - Oil filter bracket Dismantling and assem bling page 120 .
4 - 15 Nm + 1/4 turn (90) fur ther Renew. First fit upper left and lower right bolts and then tighten all four bolts diagonally. 5 - Retainer 7 - Connection For thermostat. 9 - O-ring Renew.
AG.
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6 - 20 Nm
8 - 15 Nm
10 - Thermostat Observe installation po sition, Removing and installing thermostat page 144 . Checking: heat thermostat in water. Opening begins at approx. 85 C. Ends at approx. 105 C. Opening lift at least 7 mm. 11 - 45 Nm 12 - Retainer For alternator and, if fitted, air conditioner compressor. 13 - Poly V-belt tensioning element 14 - 25 Nm 15 - Oil sump Clean sealing surface before fitting. Install with silicone sealant -D 176 404 A2- . 16 - 15 Nm
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2
Note
Removing and installing sealing flange and flywheel
Repairing clutch: 6-speed manual gearbox 02Q; Rep. gr. 30 ; Repairing clutch .
Renewing crankshaft sealing flange - flywheel end page 25 . Renewing crankshaft oil seal - belt pulley end page 33 . Removing and installing sealing flange - pulley end page 35 . Removing and installing engine speed sender -G28 page 37 1 - Seal 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 33 . 2 - Sealing flange Must be positioned on dowel sleeves. Removing and installing page 35 . Install with silicone seal ant -D 176 404 A2 page 35 . 3 - Cylinder block Removing and installing crankshaft page 44 . Dismantling and assem bling pistons and con rods page 39 . 4 - 60 Nm + 1/4 turn (90) fur ther Renew. 5 - Flywheel To loosen securing bolts, lock using coun terhold -3067- . 6 - Intermediate plate Must be positioned on dowel sleeves. Do not damage or bend when assembling.
AG. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss

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24
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 7 - 15 Nm
AG. Volkswagen AG d 8 - Sealing flange with oil seal agen oes not lksw Vo gu Removing and installing page 25 . by ara d nte ise or With sender wheel for engine speed.th eo u ra a c Renew complete only. ss Do not additionally oil or grease the oil seal sealing lip. Before installing, remove oil residue from crankshaft journal using a clean cloth. Use support sleeve supplied when installing.
9 - Engine speed sender -G28 Removing and installing page 37 .
2.1
Renewing crankshaft sealing flange flywheel end
Special tools and workshop equipment required Assembly tool -T10134-
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Torque wrench -V.A.G 1331 24 mm tool insert -V.A.G 1332/11 Vernier gauge Three hexagon bolts M6 x 35 mm Two hexagon bolts M7 x 35 mm
2.1.1
Pressing out sealing flange with sender wheel
Remove flywheel. Rep. gr. 34 ; Removing and installing gearbox Remove flywheel. Remove intermediate plate.
2. Removing and installing sealing flange and flywheel
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gen AG en AG. Rotate crankshaft as shownoto wag No. 1 cylinder. does no lks TDC
Volkswa
Remove sump.
Golf, Golf Plus, Touran page 89 ss Passat page 117 Note
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For the sake of clarity, the work is performed with the engine
removed. removed.
The procedure is identical whether the engine is installed or
Remove engine speed sender -G28- -arrow-. Unscrew sealing flange securing bolts. Note
Sealing flange and sender wheel are pressed off the crankshaft together using three M6 x 35 mm bolts.
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Screw three M6 x 35 mm bolts into threaded holes -arrows- of sealing flange. Screw bolts alternately (max. 1/2 turn (180 ) for each bolt) into sealing flange and press sealing flange together with sender wheel off crankshaft.
AG.
26
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2.1.2
Pressing in sealing flange with sender wheel
Note
gen gen with The sealing flange with a PTFE seal is equipped AG. a sealingAG does swa
Volkswa lk lip support ring. This support ring servesoas a fitting sleeve and yV db must not be removed prior to installation. ise r tho au Sealing flange and sender wheel must not be separated or ss
sembly device -T10134- by a locating pin.

Sealing flange and oil seal form one unit and must only be
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The sender wheel is held in its installation position on the as
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turned after removal from packaging.
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renewed together with the sender wheel.
The assembly device -T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the crankshaft.
Assembly tool -T10134A - Clamping surface B - Hexagon nut D - Locating pin
C - Assembly housing
E - Hexagon socket head bolt
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F - Guide pin for diesel engines (black knob)

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G - Guide pin for petrol engines (red knob)

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Screw in hexagon nut -B- to just before clamping surface -Aof threaded spindle.
AG.
2.1.3
A - Assembling seal with sender wheel on assembly tool -T10134-
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27
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Clamp assembly device -T10134- in a vice on clamping sur face -A- of threaded spindle. Press assembly housing -C- downwards so that it lies on hex agon nut -B- -arrow-. Screw hexagon nut onto threaded spindle until inner part of assembly device and assembly housing are level.
Remove securing clip -arrow- from new sealing flange. Note
The sender wheel must not be taken out of the sealing flange. or lkswag en AG AG Vo does twisted. agen ksw
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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.
ss

Push sealing lip support ring -A- downwards in direction of ar row until it lies on flat surface.
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28
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AG.
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Upper edge of sender wheel and front edge of sealing flange must align -arrows-.
Place sealing flange with front side on assembly tool -T10134so that locating pin -B- can be inserted in sender wheel hole -A-. Note
Ensure sealing flange lies flat on assembly device.

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.
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Note
When installing sealing flange, ensure that sender wheel remains fixed in assembly device.
2.1.4

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

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Align flat side of assembly housing on sump side of crankcase sealing surface.
AG.
Press threaded spindle of assembly tool -T10134- in direction of arrow, until hexagon nut -B- lies against assembly housing -A-.
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29
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Secure assembly tool -T10134- to crankshaft flange using hexagon socket head bolts -A-. Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap prox. 5 full turns).
To guide sealing flange, screw two M7 35 mm bolts -A- into cylinder block.
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2.1.5
C - Bolting assembly tool -T10134- onto crankshaft flange
Push assembly housing -C- by hand in direction of arrow until sealing lip support ring -B- contacts crankshaft flange -A-.
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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.
AG.
Note
The guide pin for petrol engines (red knob) -F- must not be inser ted 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-.
30
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Golf 2004 , Golf Plus 2005 G. VoPassatn2006 , Touran 2003 , lkswage AG gen A does n4-cylinder dieselVolkswa (2.0 l engine, 4 valve) ot Edition 02.2011 engine
2.1.6
Tighten hexagon nut of assembly tool -T10134- to 35 Nm us ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G 1332/11- . Note
D - Pressing sender wheel onto crank ss shaft flange using assembly tool T10134un le
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After hexagon nut is tightened to 35 Nm, a small air gap must be present between cylinder block and sealing flange.
2.1.7
E - Checking sender wheel installation position on crankshaft

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Screw hexagon nut -E- to end of threaded spindle. Remove the two bolts -A- from cylinder block. Remove assembly tool -T10134- . Remove sealing lip support ring. Screw the three knurled screws -B- out of sealing flange.
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 32 If dimension -a- is attained: Tighten new securing bolts for sealing flange to 15 Nm using alternate and diagonal sequence.
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31
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Install engine speed sender -G28- -arrow- and tighten secur ing bolt to 5 Nm. Installing sump: Golf, Golf Plus, Touran page 89 Passat page 117 Install intermediate plate. Install flywheel using new bolts. Tighten securing bolts to 60 Nm +1/4 turn (90).
2.1.8
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. Push assembly tool -T10134- by hand to sealing flange.
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Screw hexagon nut -E- onto threaded spindle by hand lies on assembly housing -C-.
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Tighten hexagon nut of assembly tool -T10134- to 40 Nm us ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G 1332/11- . Check installation position of sender wheel on crankshaft again. page 31 If dimension -a- is too small again: Tighten hexagon nut for assembly tool -T10134- to 45 Nm.
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Check installation position of sender wheel on crankshaft again. page 31
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32
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AG.
2.2
Renewing crankshaft oil seal - pulley end
Special tools and workshop equipment required Oil seal extractor -3203 Counterhold tool -3415wa Assembly tool -T10053- ge olks
Torque wrench (40200 Nm) -V.A.G 1332-
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Removing Remove poly V-belt page 16 . Remove toothed belt page 51 . Remove crankshaft toothed belt pulley. To do this, lock tooth ed belt pulley using counterhold -3415- . To guide oil seal extractor -3203- , screw central bolt by hand into crankshaft to stop. Unscrew inner part of oil seal extractor two turns (approx. 3 mm) out of outer part and lock with knurled screw. Oil threaded head of oil seal extractor.
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33
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine,AGvalve) agEdition 02.2011 4 . Volksw - en AG d gen Using great pressure, ble into seal.
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as far as
Installing Note
Loosen knurled screw and turn inner part against crankshaft until oil seal is pulled out.
oes not gu ara possi nte eo ra c

The oil seal sealing lip must not be additionally oiled or greased.
Remove oil residue from crankshaft journal using clean cloth. Place guide sleeve -T10053/1- onto crankshaft journal. Slide oil seal over guide sleeve onto crankshaft journal.
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Press oil seal in to stop using assembly tool -T10053- and centre bolt.
AG.
Install crankshaft toothed belt pulley. To do this, lock toothed belt pulley using counterhold -3415- . Specified torque of new centre bolt Item 19 (page 18) . Install toothed belt page 51 . Install poly V-belt page 16 .
34
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2.3
Removing and installing sealing flange - pulley end
Special tools and workshop equipment required Counterhold tool -3415 Assembly tool -T10053 Torque wrench (550 Nm) -V.A.G 1331 Torque wrench (40200 Nm) -V.A.G 1332-
Not illustrated:
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Used oil collection and extraction unit -V.A.G 1782Hand drill with plastic brush attachment
AG.
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Eye protection Removing
Remove poly V-belt page 16 . Remove toothed belt page 51 .
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Flat scraper
Silicone sealant -D 176 404 A-
35
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Remove crankshaft toothed belt pulley. To do this, lock tooth ed belt pulley using counterhold -3415- . Disconnect right drive shaft at gearbox Rep. gr. 40 . Unscrew securing bolts on engine block for water pipe from supplementary heater. Remove sump. Golf, Golf Plus, Touran page 89 Passat page 117 Pull off front sealing flange. Remove sealing flange; if necessary, loosen by blows with a rubber-headed hammer.
n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au applying light ss
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Remove sealant residue from cylinder block using a flat scra per. WARNING
Wear eye protection.
Remove residual sealant from sealing flange using a plastic rotary brush. Clean sealing surfaces. They must be free of oil and grease. Installing Note
Observe expiry date of sealing compound.
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plying the silicone sealant.
Note The sealant bead must not be thicker than 23 mm, otherwise
excess sealant could enter the sump. Excess sealant could drop onto the sealing surface of the crankshaft oil seal or block the strainer in the suction line of the oil pump. with a clean cloth.
Before applying sealant bead, cover sealing surface of oil seal
36
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Cut off tube nozzle at forward marking ( of nozzle approx. 3 mm).
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The sealing flange must be installed within 5 minutes of ap
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Apply silicone sealant bead as shown to the clean sealing sur face of sealing flange. Install sealing flange immediately and tighten all bolts lightly. Note
When fitting sealing flange with oil seal installed use guide sleeve -T10053/1- .
Tighten securing bolts for sealing flange to 15 Nm using alter nate and diagonal sequence. Install crankshaft toothed belt pulley. Specified torque of new centre bolt Item 19 (page 18) . Installing sump: Golf, Golf Plus, Touran page 89 Passat page 117 Install toothed belt page 51 . Install poly V-belt page 16 . Note
Sealing compound must dry for approx. 30 minutes after instal lation. Only then fill with engine oil.
2.4
Removing and installing engine speed sender -G28n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss
Special tools and workshop equipment required Hexagon key extension, 4 mm -T10370-
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Remove insulation tray. General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula tion . Clamp off coolant hoses at oil cooler using hose clamp and pull off hoses. Remove oil filter bracket.
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37
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note
If the securing bolt is a 5 mm Allen bolt (old version) use a com mercially available 5 mm key with ball end. If necessary reduce key to a suitable length.
Loosen securing bolt -arrow- using 4 mm socket -T10370- and pull out speed sender. Installation is performed in the reverse order. Observe the follow ing: specified torque for engine speed sender securing bolt is 5 Nm.

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38
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3
e ris
Pistons and conrods

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Assembly overview - gen AG. Volkswagen AG d page 39 . pistons and conrods

yV Piston and cylinder dimensions page 40 . db
ho Checking piston projection at TDC ut
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Piston rings, cylinder bore and piston installation position page 42
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3.1
Assembly overview - pistons and conrods

1 - Piston rings Offset gaps by 120. Use piston ring pliers to remove and install. TOP faces towards piston crown. Checking ring gap page 42 . Checking ring-to-groove clearance page 42 . 2 - Piston With combustion cham ber. Mark installation posi tion and cylinder num ber. Installation position and allocation of piston to cylinder page 43 . Arrow on piston crown points to belt pulley end. Install using piston ring clamp. Cracks on piston skirt, renew piston. Checking piston projec tion at TDC page 40 .
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3 - Piston pin If difficult to remove, heat piston to 60 C. Remove and install us ing drift -VW 222- . 4 - Circlip 5 - Conrod Mark cylinder allocation -A- with coloured pen. Installation position: Marking -B- faces towards pulley end. With industrially cracked conrod cap. 6 - Bearing shell Note installation position. Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi cation: Black line on bearing surface in area of joint. Do not interchange used bearing shells.
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3. Pistons and conrods
39
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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 42 . Piston and cylinder dimensions page 40 . 8 - Conrod bearing cap Note installation position. Caps fit only in one position and only on the corresponding conrod due to breaking procedure (cracking) for separating cap from conrod. 9 - Oil spray jet For piston cooling. 10 - 25 Nm Insert without sealant. 11 - Conrod bolt, 30 Nm + 1/4 turn (90) further Renew. Oil threads and contact surface. Use old bolt for measuring radial clearance.
3.2
Basic di mension
Piston and cylinder dimensionsen AG. Volkswagen AG does n ag ksw

mm
Vol by d Cylinder bore e Piston ris ho ut 80.96 s a 81.01 s
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3.3
Checking piston projection at TDC
Special tools and workshop equipment required Measuring bridge -VW 382/7-

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40
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 End dimension plate -VW 385/17-
Dial gauge
Note
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gasket depending upon piston projection, according to following table:
Turn engine clockwise to measure piston projection at TDC. If different values are determined during the projection meas
urement, use the largest dimension for selecting the gasket.

Identification Holes/notches 1 2 3
Piston projection
0.91 mm 1.00 mm 1.01 mm 1.10 mm 1.11 mm 1.20 mm
Cylinder head gasket identification Part No. = -arrow 1 Holes = -arrow 3ht rig py Co t.
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Production control code = -arrow 2- (disregard) Installation position: identification faces upwards. Note
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Different thicknesses of cylinder head gasket are fitted depending on the piston projection. When replacing cylinder head gasket, install a new gasket with same identification -arrow 3-.
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41
3.4
Piston rings, cylinder bore and piston in stallation position
Checking piston ring gap
Special tools and workshop equipment required Feeler gauges Push piston ring squarely from above down to approx. 15 mm from bottom end of cylinder. Piston ring dimensions in mm 1. compression ring 2. compression ring Oil scraper ring New 0.20...0.40 0.20...0.40 0.25...0.50 Wear limit 1.0 1.0 1.0
Checking ring-to-groove clearance
Clean ring groove before checking. Piston ring dimensions in mm 1. compression ring 2. compression ring Oil scraper ring New Wear limit 0.25 0.25 0.15
Feeler gauges
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0.06...0.09 0.05...0.08 0.03...0.06
Checking cylinder bores
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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.
42
AG.
Internal dial test indicator 50100 mm
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Special tools and workshop equipment required

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Cylinder bores must not be measured when the cylinder block is secured to engine and gearbox support -VAS 6095/1- with uni versal mounting -VAS 6095- , as measurements may be incorrect.
Piston installation position and allocation of piston to cylinder Arrow points towards No. 1 cylinder -arrows-.
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Golf 2004 , Golf Plus 2005 , Passat G. Volksagen AG doe 2003 n A 2006 w , Touran wage s no olks t gu 4-cylinder diesel engine (2.0 byengine, 4 valve) - Edition 02.2011 l V
Assembly overview - crankshaft page 44 . Crankshaft dimensions page 44 . Pulling needle bearing out of and driving into crankshaft page 45 .
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4.1
Assembly overview - crankshaft
1 - Bearing shells 1, 2, 4 and 5 For bearing cap without oil groove. For cylinder block with oil groove. Do not interchange used bearing shells (mark). 2 - 65 Nm + 1/4 turn (90) fur ther Renew. To measure radial clear ance, tighten to 65 Nm but not further. 3 - Bearing cap Bearing cap 1: belt pul ley end. Bearing cap 3 with re cesses for thrust wash ers. Bearing shell retaining lugs in cylinder block and bearing caps must align.
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4 - Bearing shell 3 For bearing cap without oil groove. For cylinder block with oil groove. 5 - Thrust washer For bearing cap 3. Note fixing arrange ment. 6 - Crankshaft Axial clearance new: 0.070.17 mm, wear limit: 0.37 mm Check radial clearance with Plastigage new: 0.030.08 mm, wear limit: 0.17 mm Do not rotate crankshaft when checking radial clearance. Crankshaft dimensions page 44 . 7 - Thrust washer For cylinder block, bearing 3
4.2
Crankshaft dimensions
(Dimensions in mm)
44
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Crankshaft main journal Basic dimension 54.00 -0.022 -0.042 50.90 Conrod journal -0.022 -0.042
4.3
Pulling needle bearing out of and driving into crankshaft

Vehicles with direct shift gearbox only Special tools and workshop equipment required Puller -T10055es, in part or in w l purpos hole ercia , is n mm ot p co erm or te itte va ri d p
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With adapter -T10055/3 Centring mandrel -3176-
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or drift -VW 207 C Puller, e.g. Kukko -21/2Note
Vehicles with dual clutch gearbox, the needle bearing must be installed in rear end of crankshaft.
4. Crankshaft
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45
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing Pull out using commercially available puller, e.g. Kukko 21/2 -arrow-, adapter -T10055/3- and puller -T10055- . Installing Note
The lettering on the needle bearing must be visible when installed.
Drive in with drift -VW 207 C- or centring mandrel -3176- .
Installation depth: dimension -a- = 2 mm.

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Assembly overview - cylinder head page 47 . Removing and installing cylinder head cover page 49 Removing, installing and tensioning toothed belt page 51 . Removing and installing cylinder head page 66 . Checking compression page 71 .
1.1
Note
Assembly overview - cylinder head
The plastic protectors fitted to protect the open valves must be
removed only immediately before the cylinder head is fitted.

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Cracks between the unit injector holes and the valve seats are
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not critical and do not justify exchanging the cylinder head.
1. Cylinder head
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If the cylinder head is replaced, all the coolant in the system
must also be renewed.
47
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - Toothed belt guard upper part 2 - Toothed belt Mark direction of rota tion before removing. Check for wear. Do not kink. Removing and installing page 51 . 3 - 100 Nm 4 - 25 Nm 5 - Camshaft pulley 6 - Hub Use counterhold tool T10051- to loosen and tighten. To remove, use puller T10052- . Removing and installing page 79 . 7 - 10 Nm
8 - Cylinder head Removing and installing page 66 . After renewing, renew entire coolant. 9 - Cable channel 10 - 25 Nm 11 - Lifting eye 12 - Cylinder head cover gas ket Renew if damaged.
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13 - Cylinder head cover Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth. Note sequence when tightening page 49 . 14 - Crankcase breather 15 - Seal Renew if damaged. 16 - Cap Renew seal if damaged. 17 - 10 Nm Observe tightening sequence page 49 .
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18 - Cylinder head bolt Observe sequence when loosening and tightening page 66 . Before installing, place washers in cylinder head Item 6 (page 72) . 19 - Seal Renew.
48
Rep. gr.15 - Cylinder head, valve gear
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 20 - Tandem pump For fuel and vacuum supply. Check page 225 . Removing and installing page 227 . 21 - 20 Nm 22 - Hall sender -G40 For camshaft position. To remove and install, toothed belt must be removed from camshaft pulleys and idler roller must be released. 23 - 10 Nm 24 - Rear toothed belt guard 25 - Hub With sender wheel Use counterhold tool -T10051- to loosen and tighten. n AG. Volkswagen AG do To remove, use puller -T10052- . es n wage ot g olks yV ua Removing and installing page 79 . db r
26 - Stud, 10 Nm For tensioning roller.
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Checking cylinder head for distortion
Special tools and workshop equipment required Straight edge Feeler gauges
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Note
Reworking diesel cylinder heads is not permissible.
not critical and do not justify exchanging the cylinder head.
1.2
Removing and installing cylinder head cover
1. Cylinder head
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Max. permissible distortion: 0.1 mm.
49
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Torque wrench -V.A.G 1331-
Removing
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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-. Remove upper toothed belt guard. Disconnect crankcase breather hose at union on rear of charge air pipe. Remove cylinder head cover. Installing Install in reverse order. When doing this, note the following: Note
Renew cylinder head cover gasket and bolts with seal if damaged.
Screw on cylinder head cover hand-tight in the sequence 1 to 11.
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Tighten bolts to 10 Nm in the sequence 1 to 11.

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50
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1.3
Removing, installing and tensioning toothed belt

Note
Determine which type of engine support is installed in the ve hicle. -1-: Engine support with less clearance to engine (removal nec essary) page 52 . -2-: Engine support with greater clearance to engine (removal not necessary) page 60
a From 05.06 a modified engine support (witholess g ksw clearance to en V l by gine) has been introduced. For the procedure removing, instal d se ling and tensioning toothed belt it tisrionly necessary to remove ho the engine support and support s au engine when changing the the s tensioning roller (e.g. type of service). The toothed belt can be removed and installed without removing the engine support.
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1.3.1
Removing and installing toothed belt (vehicles with engine support with less clearance to engine)
Special tools and workshop equipment required Locking pin -3359 2-hole pin wrench -T10020 Locking pin -T10115 Crankshaft stop -T10050 Torque wrench (550 Nm) -V.A.G 1331 Torque wrench (40200 Nm) -V.A.G 1332-

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Support bracket -10-222Awith adapters -10-222A/22(for Golf, Golf Plus and Touran) or adapters -10-222A/1- (for Passat) Counterhold tool -T10172with pins -T10172/4 Crankshaft stop -T10100- wagen AG. Volkswagen AG doe s no olks for vehicles with oval crank t gu yV ara shaft belt pulley ised b n
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Note
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.
Characteristics of crankshaft belt pulley
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1. Cylinder head
53
From model year 2004, a new toothed belt tensioner is installed. The tensioner has an additional hexagon hole -arrow-. To tension and release toothed belt, use Allen key instead of pin wrench T10020- . This does not alter the procedure.
Removing Note
Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature.
Remove engine cover. To do this, pull engine cover upwards abruptly at front and right -arrows A- and then pull forwards out of rear fastening -arrow B-. Remove poly V-belt page 16 . Remove poly V-belt tensioning element. Remove upper toothed belt guard. Remove front right wheel housing liner. Remove exhaust pipe from auxiliary heater. Loosen connecting bolt for coolant pipe -arrow-. Remove charge air pipe between charge air cooler and turbo charger.
w Carefully cover or seal open ends.ag olks
Remove Remove
Turn crankshaft to TDC No. 1 cylinder.
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Turn crankshaft until marking on crankshaft pulley and tooth seg ments of camshaft pulleys are on top. Marking on toothed belt guard must align with camshaft sender wheel -arrows-.
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The marks on the crankshaft toothed belt pulley and the crank shaft stop must align. When doing this, the pin of the crankshaft stop must insert in the drilling of the sealing flange.
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Separate push-on connectors of fuel lines -arrows-. Note
Do this by pressing in catch of push-on connectors. Ensure that no fuel escapes (use a cloth). Lay fuel filter with hoses to side. Disconnect coolant hose from top of expansion tank. Golf, Golf Plus and Touran:
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Remove expansion tank and lay it to side.

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Fit engine support bracket -10-222A- with adapters -10-222A/ 22- and take up weight of engine in installation position. Passat:
AG.
Set up support bracket -10-222A- with legs -10-222A/1- and support engine in installation position, as shown. Continuation for all vehicle types:
1. Cylinder head
55
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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! mounting has been removed.

WARNING
The engine support must only be loosened when the assembly
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. Note
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The engine support can be removed only when toothed belt is slack.
Mark direction of rotation of toothed belt.
Loosen camshaft pulley securing bolts -1 and 2- until camshaft pulleys can be turned in elongated holes. Lock hubs using locking pin -3359- . To do this, slide locking pins through outer free elongated holes into holes in cylinder head. 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- .
56
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Now turn pin-wrench clockwise to stop and tighten securing nut -1- hand-tight. Remove engine support downwards. Remove toothed belt first from coolant pump and then from remaining pulleys. Installing Caution
Strictly follow the procedure described here. If, for example, the final check is not performed and the locking tool is not fitted again, there is a danger that the timing is not correctly adjusted and the vehicle will exhibit engine running problems and rough idling.
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Adjustment work on toothed belts must be performed only on
cold engines, as the indicator position on the tensioning ele ment varies depending on the engine temperature.
Specified torques page 18 .
Tensioning roller must be locked with locking pin -T10115- and secured to right stop.
Camshafts are locked using diesel injection pump locking pin -3359- . Crankshaft is locked using crankshaft stop -T10050 bzw. T10100- .
Turn camshaft pulleys in their elongated holes clockwise to stop.
Fit toothed belt to crankshaft pulley, tensioning roller and cam shaft pulley and idler roller. Then fit toothed belt on coolant pump toothed belt pulley.
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Install engine support from below and insert lower securing bolt.
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Raise engine with support bracket -10-222A- until indicator of tensioning roller can be seen. Loosen tensioning roller securing nut and pull out locking pin -T10115- . Note
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Ensure that tensioning roller seats correctly in rear toothed belt guard -arrow-.
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1. Cylinder head
57
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Now carefully turn tensioning roller clockwise using pin wrench until indicator is in middle of gap in 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. Note
When securing nut is tightened, indicator will turn maximum 5 mm to right out of base plate notch. This setting must not be corrected because the toothed belt will settle after it has run a while.
Apply counterhold -T10172- as shown. Press counterhold T10172- in direction of arrow keeping camshaft pulley under wagen AG. Volkswagen AG does ks not tension. Vol gu by
ris In this position, tighten camshaft pulley securing bolts ho ut -arrows- to 25 Nm. sa
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Remove locking pins -3359- and crankshaft stop -T10050 bzw. T10100- .
Turn crankshaft at least two rotations in engine direction of rotation and set again to just before TDC No. 1 cylinder.
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Lock hub -A- by turning in engine direction of rotation until locking pin -3359- engages whilst turning. Check whether: Hub -B- can be locked using locking pin -3359- . Crankshaft can be locked in position with crankshaft stop T10050 bzw. T10100- .
Tensioning roller indicator is centred or maximum 5 mm to right of base plate notch. If the hub -B- cannot be locked: Loosen camshaft pulley -A- securing bolts -1-.
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Loosen camshaft pulley -B- securing bolts -2-.
58
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Turn crankshaft until hub of camshaft pulley -B- can be locked using locking pin -3359- .
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Hub -A- must be locked using locking pin -3359- .
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Turn crankshaft slightly against engine direction of rotation until the pin of the crankshaft stop is positioned just before the hole in the sealing flange -arrow-. Now turn crankshaft in engine direction of rotation until crank shaft stop pin engages. in lsealing AG o kswagen flange whilst turning. en AG V
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Apply counterhold -T10172- as shown. Press counterhold T10172- in direction of arrow keeping camshaft pulley under tension. In this position, tighten camshaft pulley securing bolts -arrows- to 25 Nm. Remove locking pins -3359- and crankshaft stop -T10050 bzw. T10100- . Turn crankshaft at least two rotations in engine direction of rotation and set again to just before TDC No. 1 cylinder. Repeat check.
Tighten bolts for engine support in the sequence shown -13- to 40 Nm + 1/2 turn (180 ) further. To do this, raise or lower engine using support bracket -10 - 222 A- .
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II: Engine support with greater clearance to engine

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Install centre and lower parts of toothed belt guard. Install belt pulley vibration damper: specified torque 10 Nm + 90 (1/4 turn) further. Note
Before installing assembly mounting, tighten all engine support bolts to prescribed torque.
Install assembly mounting between engine and body (renew securing bolts) page 14 .
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I : Engine support with less clearance to engine

1. Cylinder head
59
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Bolt engine assembly mounting to engine support -arrows- by bringing contact surfaces together using support bracket -10-222A- . Specified torque: 60 Nm + 90AG. Voturn) gfurther (1/4 lkswa en AG gen Install lower part of toothed belt y Vo guard. db
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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 and return lines (return line blue or with blue markings, supply line black). When installing charge air pipes, ensure that locking lugs en gage correctly. Install wheel housing liner. Install noise insulation tray. General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula tion .
1.3.2
Removing and installing toothed belt (vehicles with engine support with greater clearance to engine)
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Crankshaft stop -T10100 Counterhold tool -T10172 Special wrench, long reach -T10264-
60
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Locking pin -T10060 A-
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Diesel injection pump lock ing pin -3359-
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Locking tool -T10265Removing Note
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-. Remove poly V-belt page 16 . Remove poly V-belt tensioning element. Remove upper toothed belt guard. Remove front right wheel housing liner. Remove exhaust pipe from auxiliary heater.

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Remove charge air pipe between charge air cooler and turbo charger. Remove vibration damper/belt pulley. Turn crankshaft to TDC No. 1 cylinder.
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Carefully cover or seal open ends.
Remove lower and centre toothed belt guards
Note
Turn crankshaft until marking on crankshaft pulley and tooth seg ments of camshaft pulleys are on top. Marking on toothed belt guard must align with camshaft sender wheel -arrows-.
Lock crankshaft toothed belt pulley with crankshaft stop T10050 bzw. 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 crank shaft stop must align. When doing this, the pin of the crankshaft stop must insert in the drilling of the sealing flange.
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Loosen connecting bolt for coolant pipe -arrow-.

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1. Cylinder head
61
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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. Mark direction of rotation of toothed belt. Loosen camshaft pulley securing bolts -1 and 2- until camshaft pulleys can be turned in elongated holes. Lock hubs using locking pin -3359- . To do this, slide locking pins through outer free elongated holes into holes lin wage cylinder . Vo ks n AG d gen AG head. oes swa n lk
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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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62
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Now turn tensioning roller eccentric clockwise -arrow- onto stop and tighten securing nut -1- hand-tight. Remove toothed belt first from coolant pump and then from remaining pulleys. Installing Caution
Strictly follow the procedure described here. If, for example, the final check is not performed and the locking tool is not fitted again, there is a danger that the timing is not correctly adjusted and the vehicle will exhibit engine running problems and rough idling.
Note
Tensioning roller must be locked with locking pin -T10265- and secured to right stop. Camshafts are locked using diesel injection pump locking pin en AG. Volkswagen AG does ag -3359- . ksw not Vol
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Guide toothed belt through gap between engine support and engine. Fit toothed belt to crankshaft pulley, tensioning roller and cam shaft pulley and idler roller. Then fit toothed belt on coolant pump toothed belt pulley. Loosen tensioning roller securing nut and pull out locking pin -T10265- . Note
Turn camshaft pulleys in their elongated holes clockwise to stop.
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Ensure that tensioning roller seats correctly in rear toothed belt guard -arrow-.
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1. Cylinder head
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63
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Turn eccentric of tensioning roller clockwise -arrow- using special wrench, long reach -T10264- until indicator -2- is in middle of gap in base plate. 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. Note
When securing nut is tightened, indicator will turn maximum 5 mm to right out of base plate notch. This setting must not be corrected because the toothed belt will settle after it has run a while.
Apply counterhold -T10172- as shown. Press counterhold T10172- in direction of arrow keeping camshaft pulley under tension. In this position, tighten camshaft pulley securing bolts -arrows- to 25 Nm. Remove locking pins -3359- and crankshaft stop -T10050 bzw. T10100- . Turn crankshaft at least two rotations in engine direction of rotation and set again to just before TDC No. 1 cylinder.
Lock hub -A- by turning in engine direction of rotation until locking pin -3359- engages whilst turning. Check whether: Hub -B- can be locked using locking pin -3359- . Crankshaft can be locked in position T10050 bzw. T10100- . Tensioning roller indicator is centred right of base plate notch. If the hub -B- cannot be locked:
Loosen camshaft pulley -A- securing bolts -1-. Hub -A- must be locked using locking pin -3359- .
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Turn crankshaft until hub of camshaft pulley -B- can be locked using locking pin -3359- . Loosen camshaft pulley -B- securing bolts -2-.
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Now turn crankshaft in engine direction of rotation until crank shaft stop pin engages in sealing flange whilst turning.
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Apply counterhold -T10172- as shown. Press counterhold T10172- in direction of arrow keeping camshaft pulley under tension. In this position, tighten camshaft pulley securing bolts -arrows- to 25 Nm. Remove locking pins -3359- and crankshaft stop -T10050 bzw. T10100- . Turn crankshaft at least two rotations in engine direction of rotation and set again to just before TDC No. 1 cylinder. Install centre and lower parts of toothed belt guard.
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Install belt pulley vibration damper: specified torque 10 Nm + 90 (1/4 turn) further. Install lower part of toothed belt guard.
Install poly V-belt tensioning element: specified torque 25 Nm. Install poly V-belt page 16 . 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 and return lines (return line blue or with blue markings, supply line black). When installing charge air pipes, ensure that locking lugs en gage correctly. Install wheel housing liner. Install noise insulation tray. General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insula tion .
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Repeat check.
1. Cylinder head
65
1.4
Removing and installing cylinder head
Special tools and workshop equipment required Guide pins -3070 Drip tray -V.A.G 1306 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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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Torque wrench -V.A.G 1331Note Before carrying out further work, disconnect battery earth
strap. First check whether a coded radio is fitted. Obtain antitheft coding first if necessary. head is removed must be replaced in the same position when cylinder head is installed. not critical and do not justify exchanging the cylinder head.
WARNING
All cable ties which are opened or cut through when cylinder
When doing any repair work, especiallyAG.thelkengineAG doe n in Vo swagen compart wage s no ment, pay attention to the following due to the cramped condigu olks t V by ara tions: ed n is
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Ensure that there is sufficient clearance to all moving or hot components.
1.4.1
Removing
With ignition switched off, disconnect earth strap from battery. Electrical system; Rep. gr. 27 ; Disconnecting and recon necting batteries . 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-. Golf Plus Remove plenum chamber bulkhead. General body repairs, exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead . Continuation for all vehicles
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1. Cylinder head
67
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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 battery. Remove insulation tray General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation . Drain coolant page 134 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 -V.A.G 1390- and water drainage container -V.A.G 1390/1- page 228 . Pull fuel filter module upwards out of bracket and lay it with hoses to side. Remove poly V-belt page 16 . Remove connecting pipe between air charge cooler and tur bocharger.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Separate vibration damper and remove it from crankshaft. Lock crankshaft at TDC No. 1 cylinder using crankshaft stop T10050 bzw. T10100- page 52 . Vehicles with no particulate filter: Disconnect front exhaust pipe from turbocharger, loosen dou ble clamp and slide exhaust pipe back page 273 . Vehicles with particulate filter: Unscrew mountings for particulate filter and clamp on turbo charger and push diesel particulate filter to side page 274 . Continuation for all vehicles: 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 . n AG. Volkswagen A Remove turbocharger support and y Volreturn from turbocharg oil k b ed er. ris
au Loosen tensioning roller securing nut and release tension ss toothed belt.
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Remove tensioning roller securing nut. Remove hubs for camshaft pulleys page 79 . Separate Hall sender -G40- Item 22 (page 49) on cylinder head. Remove securing bolts between rear toothed belt guard and cylinder head. Unbolt bracket for vacuum reservoir and dipstick. Remove exhaust gas recirculation connecting pipe Item 9 (page 244) . Remove oil supply line for turbocharger page 123 . 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. Remove cylinder head cover page 49 .

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Lift cylinder head slightly and remove from engine laterally past toothed belt guard. Note
The toothed belt tensioning roller remains on the engine sup
port. age.
The cylinder head must be guided carefully to prevent dam
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Maintain sequence when loosening cylinder head bolts.
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Remove rocker arm shaft and inner securing bolts for retaining frame page 80 .
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1. Cylinder head
69
Golf 2004 4-cylinder
1.4.2
Note
Installing
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Always renew cylinder head bolts.
In cases of repair carefully remove gasket remains from cyl
inder head and cylinder block. Ensure that no long scores or scratches are created. When using abrasive paper do not use a grade less than 100.
Carefully remove emery and abrasive remains. 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.
Note
Tensioning roller must be pushed onto studs when cylinder head is fitted.
Fit cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand. Remove guide pins through bolt holes using removal tool from 3070 and install cylinder head bolts. Tighten cylinder head in four stages in sequence shown as follows: 1Tighten initially with torque wrench: Stage I = 35 Nm Stage II = 60 Nm 2Turn further with rigid spanner: Stage III = 1/4 turn (90) Stage IV = 1/4 turn (90) Secure rear toothed belt guard to cylinder head. Install hubs and camshaft pulleys. Lock camshafts using locking pin for diesel injection pump -3359- .
70
AG.
To centre, screw guide pins -3070- into outer threaded holes on intake side.
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Cylinder head gasket must lie with identification facing up wards.

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Before fitting cylinder head, remove crankshaft stop -T10050 bzw. T10100- and turn crankshaft opposite direction of rota tion until all pistons are nearly uniformly below TDC.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Now rotate crankshaft in direction of rotation to TDC and lock crankshaft using crankshaft stop -T10050 bzw. T10100- . Further installation is carried out in the reverse order. In the proc ess, note the following: Install and tension toothed belt page 51 . Install rocker arm shaft page 81 . Install cylinder head cover page 49 . Install oil supply line page 123 . Install poly V-belt page 16 . Fill with coolant page 134 . Carry out road test and read fault memories Vehicle diag nostic tester.
1.5
Checking compression
A compression test is currently only possible on engines with pie zo unit injectors Vehicle diagnostic tester.
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1. Cylinder head
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2
Note
Valve gear
Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the cracks are small and not more than 0.5 mm wide.
Assembly overview - valve gear page 72 . Removing and installing roller rocker finger page 74 . Valves page 76 Removing and installing camshafts page 79 . Removing and installing camshaft seal page 84 .
2.1
Assembly overview - valve gear
1 - Cable retainer 10 Nm 2 - 20 Nm Observe sequence when loosening and tightening page 81 . 3 - Rocker arm shaft 4 - 20 Nm + 1/4 turn (90) ther Renew. Observe sequence when loosening and tightening page 81 .
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5 - Cylinder head bolt Observe sequence when loosening and tightening page 66 . 6 - Washer For cylinder head bolts. Insert in cylinder head before installing retain ing frame. 7 - Cotters 8 - Valve spring plate 9 - Valve spring
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12 - Inlet roller rocker fingers Do not interchange used roller rocker fingers (mark). With hydraulic valve clearance compensation. Check roller bearing. Removing and installing page 75 .
72
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11 - Valve guide Check page 76 .
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10 - Valve stem seal Renewing page 77 .
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 13 - Exhaust roller rocker fingers AG. Volk Do not interchange used roller rocker fingersn(mark).swagen AG doe wage s no olks t gu With hydraulic valve clearance compensation. yV ara db e nte ris Check roller bearing. eo ho t ra au c Removing and installing spage 75 . s
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, mask off groove on camshaft taper (e.g. using Sellotape). Removing and installing page 84 . 15 - Cylinder head See note page 47 .
16 - Inlet valves Valve dimensions page 76 . 17 - Exhaust valves Valve dimensions page 76 . 18 - O-ring Renew.
22 - Shaft For roller rocker fingers. Removing and installing page 75 . 23 - Bearing shell Do not interchange used bearing shells (mark). Ensure that retaining lugs are correctly seated in bearing caps and cylinder head 24 - Exhaust camshaft 25 - Inlet camshaft 26 - Retaining frame Observe sequence when loosening and tightening page 79 . Seal using silicone adhesive sealant -D 176501 A1- .
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21 - Sealing plug Renew. 10 Nm
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20 - 10 Nm
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19 - Shaft For roller rocker fingers. Removing and installing page 75 .
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2. Valve gear
73
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Installation position of mixture tube Notch in mixture tube faces upwards -arrow-.
Checking camshaft axial clearance
Special tools and workshop equipment required Universal dial gauge bracket -VW 387 Dial gauge Wear limit: max. 0.15 mm
2.2
Removing and installing roller rocker fin ger

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Caution
When plug Item 21 (page 73) of roller rocker finger shaft is loosened, the shaft may turn relative to securing plate. If de formation of thread in shaft can be identified in a visual exami nation, the shaft must not be reinstalled because the oil supply holes for the roller rocker fingers will no longer fit. The result may be seizure.
Special tools and workshop equipment required Puller -T10055-
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2.2.1
Removing and installing exhaust roller rocker finger
Remove camshafts page 79 . Drain coolant page 134 Remove connecting pipe between exhaust gas recirculation valve and bypass flap. Remove thermostat housing from cylinder head. Unscrew securing bolt and sealing plug of shaft. Screw puller -T10055- into shaft. Pull out shaft by sliding hammer. Installation is carried out in the reverse order. When installing, note the following: Note
Do not interchange used roller rocker fingers.

Push shaft into cylinder head, n AG. Volksongroller d pushing wa en AG rocker fingers oes wage in the process. not olks V
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Removing and installing inlet roller rock er finger
Remove camshafts page 79 . Screw puller -T10055- into shaft. Pull out shaft by sliding hammer. Installation is carried out in the reverse order. When installing, note the following: Note
Do not interchange used roller rocker fingers.

Push shaft into cylinder head, pushing on roller rocker fingers in the process. Shaft must be flush with cylinder head.
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2.3 2.3.1
Note
Valves Valve dimensions
Valves must not be reworked. Only lapping-in is permitted.

Dimension a b c mm mm mm Inlet valve 29.40 5.980 88.50 45 Exhaust valve 25.50 5.965 88.20 45
2.3.2
Note
Reworking valve seats
Valve seats must not be reworked due to the very small toleran ces.
2.3.3
ksw Special tools and workshopolequipment required yV

a Dial gauge ss
Checking valve guidesswag . Volk

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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.
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Determine rock. Wear limit: max. 1.3 mm Cylinder head must be renewed if the rock is greater than the wear limit.
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2.3.4
Renewing valve stem seals
Special tools and workshop equipment required Torque wrench -V.A.G 1331/ Valve lever -VW 541/1Awith press tool -VW 541/6 Valve stem seal fitting tool -3365 Valve assembly device -2036 Valve stem seal puller -3364n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss

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Removing (With cylinder head installed) Remove camshafts page 79 . Remove unit injectors page 251 . Set piston of respective cylinder to top dead centre (TDC). Bolt valve assembly device -2036- tightly onto cylinder head.
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2. Valve gear
77
Remove valve springs using valve lever -VW 541/1A- and press tool -VW 541/6- . Note
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The valves are supported by the piston crown.

Pull off valve stem seals using valve stem seal puller -3364- . Installing
Place the plastic sleeve -A- supplied on the respective valve stem. This will prevent the new valve stem seal -B- being damaged. Place new valve stem seal in valve stem seal fitting tool -3365- .
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Oil valve stem seal sealing lip and press carefully onto valve guide to stop.
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78
AG.
2.4
Removing and installing camshafts
Special tools and workshop equipment required Counterhold tool -T10051 Puller -T10052 Rack -T10262 Torque wrench (550 Nm) -V.A.G 1331 Torque wrench (40200 Nm) -V.A.G 1332-
Diesel injection pump locking pin -3359Not illustrated: Silicone adhesive sealant -D 176501 A1ht rig py Co t.
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2.4.1
Removing
Remove plenum chamber bulkhead. General body repairs, exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead . Remove air filter housing with air mass meter and connecting pipe. Remove cooler for exhaust gas recirculation and bypass flap.
2. Valve gear
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79
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Remove bracket for exhaust gas recirculation cooler. Remove toothed belt from camshaft pulleys page 51 . Remove camshaft pulley securing bolts -1- and -2-. Remove camshaft pulleys from hubs.
Loosen hub securing bolt -1-. To do this, use counterhold -T10051- . Loosen hub securing bolt about 2 turns.
Fit puller -T10052- and align it with holes in hub. Tighten securing bolts -1-.
Note
Apply tension to hub by evenly tightening puller -2- until hub separates from taper of camshaft.
When doing this, hold puller with 30 mm spanner.

Remove hub from taper of camshaft.
Remove exhaust camshaft hub in the same way. Remove cylinder head cover page 49 . Remove tandem pump page 227 . Bolted connection for rocker arm shaft
Loosen lock nut of adjustment screw -A- and back out screw until respective rocker arm lies against plunger spring of unit injector.
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Unscrew bolts -4, 1 and 5-, then remove bolts -2 and 3- evenly and alternately. Remove rocker arm shaft. Unscrew upper securing bolts of rear toothed belt guard.
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AG.
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Remove pre-wired wiring harness for unit injectors and glow plugs page 246 . Loosen remaining 15 bolts of retaining frame equally and from the outside in. Screw 15 mm ejector bolts of rack -T10262- anticlockwise by hand to stop. Position frame -T10262- as shown on retaining frame and tighten 10 mm securing bolts to 10 Nm. Positioning frame -T10262- .
ed ris ho ut Unscrew upper securing bolt -arrow- ofabracket for bypass flap and exhaust gas recirculation cooler.ss
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Screw ejector bolts clockwise by hand until they contact the cylinder head bolts. Now screw in ejector bolts in sequence stamped on bolt heads 14 equally until retaining frame is released from cylinder head. Remove the retaining frame. Remove camshafts.
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2.4.2
Note
Installing
When camshafts are installed, cams for No. 1 cylinder must
point upwards.
Do not interchange used bearing shells (mark). When installing camshafts, ensure proper seating of retaining
lugs in retaining frame and cylinder head.
Seal parting surface between retaining frame and cylinder
head using silicone adhesive sealant -D 176501 A1 page 81
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.
Sealing parting surfaces of retaining frame Oil running surfaces of shell bearings. Install new ball studs into unit injectors. Install retaining frame and rocker arm shaft.
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2. Valve gear
81
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Evenly tighten bolts -120- as shown from inside to outside. Specified torque: 20 Nm
Now tighten rocker arm shaft bolts -15- 1/4 turn (90) further. Screw new adjustment screws into rocker arms hand-tight and fit lock nut. Install camshaft oil seals page 84 . Caution
Clean camshaft journal with a cloth and degreasing agent be fore fitting i.e. brake cleaner. An oiled camshaft journal reduces the friction between components when bolting on. This can cause items to expand and eventually lead to the hub shearing.
Set hubs on camshafts. Tighten securing bolts -1- for hubs. Torque specification: 100 Nm. To do this, use counterhold -T10051- .
Push camshaft pulleys onto hubs. Note
The toothed segment -arrow- of the camshaft toothed belt pulley must be on top.
Hand tighten securing bolts -1- and -2- on camshaft pulleys so that there is no play.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Lock hubs using locking pin for diesel injection pump -3359- . Install toothed belt and adjust valve timing page 51 .
Fit dial gauge onto adjustment screw of unit injector as shown. Turn the crankshaft in engine direction of rotation until the roll er of the rocker arm is positioned on the peak of the drive cam. Roller side -arrow A- positioned at highest point. Dial gauge -arrow B- positioned at lowest point. Remove dial gauge. Now turn adjustment screw into rocker arm until a firm resist ance is felt (unit injector positioned at stop).
Turn adjustment screw 180 back off stop. Hold adjuster screw in this position and tighten lock nut to 30 Nm.
Tighten upper securing bolt -arrow- of bracket for bypass flap and exhaust gas recirculation cooler to 10 Nm. Install tandem pump page 227 . Install cylinder head cover page 49 . Note
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When new rocker fingers have been installed, engine must not be started for about 30 minutes. Hydraulic compensation elements must settle (otherwise valves will strike pistons).
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2. Valve gear
83
2.5
Removing and installing camshaft oil seal
Special tools and workshop equipment required Fitting tool -V.A.G 10-203 Oil seal extractor -3240 Torque wrench -V.A.G 1331/ Torque wrench -V.A.G 1332/ Bolt M1265

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Remove toothed belt page 51 . Remove camshaft pulley and hub page 79 . Screw inner part of oil seal extractor -VAS 3240- two turns (approx. 3 mm) out of outer part and lock using knurled screw.
84
AG.
Removing
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Lubricate threaded head of oil seal extractor -VAS 3240- , place it in position and while exerting firm pressure, screw it into oil seal as far as possible. Loosen knurled screw and turn inner part against camshaft until the oil seal is pulled out. Installing
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Remove oil residue from camshaft journal using a clean cloth.

Mask off groove on taper of camshaft using commercial ad hesive tape (e.g. Sellotape). Fit oil seal carefully on camshaft.
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Press seal in to stop using thrust piece from fitting tool 10-203 and M1265 bolt. Install camshaft pulley and hub page 79 . Install toothed belt and adjust valve timing page 51 .
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2. Valve gear
85
17
1
Note
Lubrication
Engine oil
The oil level must not be above the max. mark - danger of damage to catalytic converter!
Engine oil specifications - Golf, Golf Plus Maintenance ; Book let 38 . Engine oil specifications - Touran Maintenance ; Booklet 18.1 . Engine oil specifications - Passat Maintenance ; Booklet 21.1 . Oil capacities - Golf, Golf Plus, Touran page 86 . Oil capacities - Passat page 86 . Checking engine oil level page 86 .
1.1
Oil capacities - Golf, Golf Plus, Touran
Engine codes AZV, BKD With change of oil filter 3.8 l Without change of oil filter 3.3 l Engine code BMN: With change of oil filter 4.3 l Without change of oil filter 3.8 l
1.2
Oil capacities - Passat

With oil filter 4.0 l Without oil filter 3.5 l
1.3
Checking engine oil level

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2 - Max. mark
a - Area of min. mark: top-up with max. 0.5 l of engine oil! b - Oil level in middle range: can be topped-up with engine oil. c - Area of max. mark: do not add engine oil!
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86
Rep. gr.17 - Lubrication
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Parts of lubrication system (Golf, Golf Plus, Touran)

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,sperform the following repairs: . Volk wage Thoroughly cleanw channels. olks oil yV
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Assembly overview - oil pump, sump page 87 Removing and installing sump page 89 .
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2.1
1 - 15 Nm
Assembly overview - oil pump, sump
3 - Chain tensioner with ten sioning rail, 15 Nm When installing, preten sion spring and fit. 4 - Oil dipstick The oil level must not be above the max. mark! Markings page 86 . 5 - Dipstick guide 6 - Guide tube 7 - Dowel sleeves 8 - O-ring Renew. 9 - 15 Nm 10 - Suction line Clean strainer if soiled.
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2 - Sealing flange With seal. Must be positioned on dowel sleeves. Removing and installing page 35 . Install with silicone seal ant -D 176 404 A2- . 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.
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2. Parts of lubrication system (Golf, Golf Plus, Touran)
87
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 11 - Baffle plate 12 - 15 Nm 13 - 15 Nm 14 - Oil sump Removing and installing page 89 . Clean sealing surface before fitting. Install with silicone sealant D 176 404 A2. 15 - Oil drain plug, 30 Nm Renew. 16 - 10 Nm 17 - Oil level and oil temperature sender -G266 Black connector, 3-pin. Check Vehicle diagnostic tester. 18 - Seal Renew. 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. 20 - Chain sprocket for oil pump 21 - Retainer For oil level and oil temperature sender -G266- wiring harness. 22 - 20 Nm + 1/4 turn (90) further 23 - Chain 24 - 25 Nm Insert
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25 - Oil spray jet For piston cooling.

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2.2
Removing and installing oil sump

Special tools and workshop equipment required Jointed wrench 10 mm VAS 3185 Special wrench, long reach -T10058 Torque wrench (550 Nm) -V.A.G 1331-

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Special tools and workshop equipment required Silicone sealant -D176404A2 Hand drill with plastic brush attachment Eye protection Flat scraper Removing Remove noise insulation tray Rep. gr. 50 . Drain engine oil Maintenance ; Booklet . Note
Observe environmental regulations for disposal.

Pull connector off oil level and oil temperature sender -G266- . Remove connecting bolts for sump to gearbox.
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89
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 . Volkswagen AG gen AG does 4-cylinder diesel engine (2.0 l engine, 4 valve) - Editiona02.2011 ksw n Remove sump.
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Loosen sump with light blows of a rubber headed hammer if ss necessary. Remove sealant residue from cylinder block using a flat scra per.
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WARNING
Remove sealant residue on sump with a rotating brush, e.g. a hand drill with a plastic brush. Clean sealing surfaces. They must be free of oil and grease. Installing Note
Observe expiry date of sealing compound.
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Apply silicone sealing compound, as shown, to clean sealing surface on sump. Sealant bead must be: 23 mm thick. Run bead along inner side of bolt holes -arrows-. Note
The sealant bead must not be thicker, otherwise excess sealing compound will enter the oil sump and may block the oil suction line strainer.
90
AG.
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.
Install sump immediately and tighten the connecting bolts for sump to gearbox and all sump bolts lightly. Ensure that sump is flush against intermediate plate and gearbox flange. Note
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When installing sump with engine out of vehicle, 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 40 Nm. Note
Let sealing compound dry for approx. 30 minutes after installing oil sump. Only then fill with engine oil.
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Further assembly is basically the reverse of the dismantling se quence.

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Parts of lubrication system (Passat)

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: Thoroughly clean oil channels. Renew oil cooler Renew oil filter element
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Assembly overview - oil pump, sump, balancer shaft module with chain drive page 93 Removing and installing oil pump (for balancer shaft module with chain drive) page 95 Removing and installing balancer shaft module with chain drive page 98 Retrofitting spur gear drive for balancer shaft module page 101 Assembly overview - oil pump, sump, balancer shaft module with spur gear drive page 104 Removing and installing oil pump (for balancer shaft module with spur gear drive) page 107 Removing and installing balancer shaft module with spur gear drive page 107 Renewing spur gear for crankshaft page 108 Removing and installing sump page 117 .
3.1
1 - 15 Nm
Assembly overview - oil pump, sump, balancer shaft module with chain drive
2 - Sealing flange With seal. Must seat on dowel sleeves. To remove, first remove sump page 117 . AG. Volkswagen AG d agen oes not lksw Removing and installing o V gu by ara d page 35 . nte ise or eo th seal Install with silicone u ra a c ss ant -D176404A2- . 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 33 . 3 - Chain When removing mark direction of rotation with a permanent felt-tip pen. 4 - 25 Nm Insert without sealant. 5 - Oil spray jet For piston cooling. 7 - Oil dipstick Lugs of oil dipstick and guide tube must align above one another. The oil level must not be above the max. mark!
AG.
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6 - 15 Nm
3. Parts of lubrication system (Passat)
93
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Markings page 86 . 8 - Guide tube For oil dipstick. Lugs of oil dipstick and guide tube must align above one another. 9 - O-ring Renew. 10 - Dowel sleeves 11 - Balancer shaft module Removing and installing page 98 . 12 - Securing bolt M8 = 20 Nm + 1/4 turn (90) further. Renew. M7 = 13 Nm + 1/4 turn (90) further. Renew. Observe tightening sequence page 98 . 13 - Guide tube 14 - Oil pump With 12 bar pressure relief valve. Before installing, check that both dowel sleeves are fitted for centring oil pump on cylinder block. Renew if running surfaces and gears are scored. Removing and installing page 95 . 15 - 13 Nm + 1/4 turn (90) further Renew.
17 - 15 Nm 18 - Seal Renew.
16 - Oil sump Removing and installing page 117 . Clean sealing surface before fitting.
19 - Oil drain plug, 30 Nm If seal is leaking, nip open and renew. 20 - Oil level and oil temperature sender -G26621 - Seal Renew. Renew.
22 - 20 Nm + 1/4 turn (90) further 23 - Suction line Clean strainer if soiled. 24 - Shaft For oil pump drive. 25 - Circlip 26 - Cover
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27 - 6 Nm Insert with locking fluid -D 000 600 A2- .
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 28 - Chain tensioner 29 - 20 Nm 30 - 10 Nm + 1/4 turn (90) further Renew. 31 - Chain sprocket
3.2
Removing and installing oil pump (for balancer shaft module with chain drive)
Special tools and workshop equipment required Torque wrench (550 Nm) -V.A.G 1331-
Locking pin -T10115-
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Used oil collection and extraction unit -V.A.G 1782Removing

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Remove toothed belt page 51 . Remove sump page 117 .

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Remove sealing flange page 35 .
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Drain engine oil.

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Position crankshaft at TDC for cylinder No. 1.
95
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Remove cover securing bolts -arrows- and remove cover.
Push guide rail of chain tensioner in -direction of arrow- with a screwdriver and secure chain tensioner with pin -T10115- . Remove chain tensioner securing bolts -1 and 3-. Loosen securing bolt -2- and remove chain tensioner.
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Remove circlip -1- using circlip pliers.
Remove oil pump securing bolts -arrows- and remove oil pump downwards. Installing Note
Before installing check whether dowel sleeves are fitted in bal ancer shaft module.
96
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Remove suction line from oil pump.
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Screw a M3 bolt in input shaft -2- and pull input shaft out of oil pump.
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Install oil pump and tighten securing bolts -arrows- to correct specified torque: M6 = 10 Nm M7 = 13 Nm + 1/4 turn (90) further (renew). Install oil pump suction line and tighten securing bolts to cor n AG. Volkswagen AG does wage rect specified torque: no olks M6 = 10 Nm Install chain tensioner.
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M8 = 20 Nm + 1/4 turn (90) further (renew).

First tighten securing bolt -2- to 20 Nm and then tighten se curing bolts -1- and -3- to 10 Nm. Carefully push guide rail of chain tensioner in -direction of arrow- with a screwdriver to relieve tension on chain tensioner. Remove locking pin -T10115- from chain tensioner. Note
Insert bolts for cover with locking fluid -D 000 600 A2- .
Install cover and tighten bolts -arrows- to 6 Nm. Install sealing flange page 35 . Install sump page 117 . Install toothed belt page 51 .
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3.3
Removing and installing balancer shaft module with chain drive
Special tools and workshop equipment required Torque wrench (550 Nm) -V.A.G 1331 Locking device -T10255 Locking pin -T10115-

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Used oil collection and extraction unit -V.A.G 1782Removing Position crankshaft at TDC for cylinder No. 1. Remove toothed belt page 51 . Drain engine oil. Remove sump page 117 . Remove sealing flange page 35 .
98
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Lock balancer shaft as shown using locking device -T10255- . Note
When doing this the locking device -T10255- must engage in groove in balancer shaft -1-.
Remove cover securing bolts -arrows- and remove cover.
Push guide rail of chain tensioner in -direction of arrow- with a screwdriver and secure chain tensioner with pin -T10115- . Note
Do not loosen bolt -2-.

Remove securing bolts -1- and -3- for chain
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Remove securing bolts -arrows- from chain sprocket and pull chain sprocket off balancer shaft. Remove suction line from oil pump.
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99
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Remove securing bolts in sequence -81-. Remove balancer shaft module. Installing Prerequisites Engine set to TDC No. 1 cylinder. Balancer shaft is locked with locking device -T10255- . Note
Before installing check whether dowel sleeves are fitted in bal ancer shaft module.
Install balancer shaft module and tighten all new securing bolts hand-tight. Then place chain sprocket onto shaft so that the bolt holes in the shaft are central in elongated holes in chain sprocket. Note
Turn chain sprocket one tooth further if the bolt holes do not lie centrally in elongated holes. The balancer shaft module must be unscrewed again for this.
Tighten the new securing bolts -arrows- hand-tight. Then loos lkswagen A Vo en securing bolts about one turn. by
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Then tighten the balancer shaft module securing bolts to the prescribed torque in the sequence -18-. M7 = 13 Nm + 1/4 turn (90) further. M8 = 20 Nm + 1/4 turn (90) further.
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100
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Tighten securing bolts -1- and -3- to 10 Nm. Carefully push guide rail of chain tensioner in -direction of arrow- with a screwdriver to relieve tension on chain tensioner. Remove locking pin -T10115- from chain tensioner. Note
Check marking arrows on uncoupled chain sprocket. Arrows must align.

Tighten the new securing bolts -arrows- for the chain sprocket. Specified torque: 10 Nm + 1/4 turn (90) further. Note
Insert bolts for cover with locking fluid -D 000 600 A2- .
Install cover and tighten bolts -arrows- to 6 Nm. Remove locking tool -T10255- . Install oil pump suction line and tighten securing bolts to cor rect specified torque: M6 = 10 Nm
AG. Volkswagen AG d agen oes not lksw o gu M8 = 20 Nm + 1/4 by V (90) further (renew). turn ara d nte ise or eo th Install sealing flange page 35 . u ra a c ss
Install toothed belt page 51 .
3.4
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Install sump page 117 .
Retrofitting spur gear drive for balancer shaft module
Note
When worn, the chain drive element of the balancer shaft module must be changed to a spur gear drive element. Chain drive bal ancer shaft modules are no longer available.
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101
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Special tools and workshop equipment required
AG. Volkswagen AG d agen oes not lksw Vo gu by ara d Torque wrench (550 Nm) nte ise or -V.A.G 1331eo th u ra a c ss Locking device -T10255pe rm itte d
Locking pin -T10115urposes, in part or in wh ole, cial p is n mer ot com
Two-arm puller -T40001with claw -T40001/5- and claw -T40001/3 Thrust plate -30 - 11 Temperature gauge -VAS 6519- or hand-held multi meter -V.A.G 1526D- in combination with tempera ture sensor -V.A.G 1526D/ 1-
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Commercially available hotplate
Procedure Remove insulation tray General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview . Remove front right wheel housing liner General body re pairs, exterior; Rep. gr. 66 ; Removing and installing wheel housing liners . Remove balancer shaft module page 98 .
102
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Caution
Position two-arm puller -T40001- with thrust plate -30 - 11- on drive sprocket of crankshaft journal as shown.
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Ensure puller is positioned correctly. Crankshaft may suffer damage if sprocket is pulled of skew. The crankshaft is then unrepairable.
Pull drive sprocket off crankshaft. Note
Check temperature when heating the new drive pulley using
maining to position the drive pulley onto crankshaft. C = approx. 6 seconds).
Ensure absolute cleanliness on crankshaft end. Caution
The maximum temperature of 240 C must not be exceeded, because this will lead to discolouring and distortion of the drive pulley.
Place new spur drive gear completely onto a commercially available hot plate and heat to at least 200 C, maximum 240 C. The inscription faces upwards. WARNING
There is a risk of burning. Wear suitable protective gloves for further procedure.
Grasp new drive gear with a pair of pliers once temperature has been achieved. Ensure you do not damage the teeth. Slide gear quickly onto crankshaft journal as far as the stop without canting the gear. Use puller -10 - 203- as an aid. Allow the drive gear to cool down a few minutes and then install new balancer shaft module page 111 .
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There is more time for positioning at a higher temperature (220
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temperature gauge -VAS 6519- , or hand-held multimeter V.A.G 1526D- in combination with temperature sensor -V.A.G 1526D/1- . To do this, push measuring tip of temperature sen sor onto drive pulley.
103
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engineA(2.0ollkengine, 4 valve) - Edition 02.2011 G. V swagen A
3.5
1 - Oil sump Removing and installing page 117 . With oil level and oil temperature sender G266- page 106 . If an oil level sender is not installed, use seal ing cap ETKA (elec tronic parts catalogue) . 2 - 15 Nm 3 - Intake connecting pipe Clean strainer if soiled. 4 - 10 Nm 5 - O-ring Renew.
Assembly overview - oil pump, sump, balancer shaft module with spur gear drive s
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7 - Drive shaft for oil pump 8 - Circlip Must lie in base of groove. Renew damaged or over-tensioned circlip. 9 - Spur gear for balancer shaft 10 - 20 Nm + 90 (1/4 turn) further Renew. 11 - Hub For intermediate gear wheel. Renew. 12 - 90 Nm + 90 (1/4 turn) further Renew. 13 - Thrust washer For intermediate gear wheel. Renew. Note installation position page 106 . 14 - Intermediate gear wheel Renew. A coating is applied to the new intermediate gear wheel which sets the correct tooth backlash through wear.
104
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6 - Oil pump Removing and installing page 107 . Before installing, check that the two dowel sleeves for centring oil pump on balancer shaft module are fitted.
When installing the inter mediate gear wheel en sure that the thrust washer is seated cor rectly page 106 .
Installation position: Part number must be visible. Installing page 111 .
n AG. Volkswagen AG o es n wage 4-cylinder dieseldengine (2.0 l engine, 4 valve) - Edition 02.2011 ot g olks yV ua d bgear wheels are coated to areas around the circumference, a white spot is ran When intermediate se tee ri ensure correctoinstallation position. h t or a au ss The intermediate gear wheel without white spot is fully coated caround the circumference.
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003
fitted to
Caution
15 - Thrust washer For intermediate gear wheel. Renew. Note installation position page 106 . When installing intermediate gear wheel, secure to housing with grease, if necessary 16 - Spur gear for crankshaft
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17 - Balancer shaft module Removing page 107 Installing new balancer shaft module page 111 . Reinstalling previously run balancer shaft module page 115 . Before installing, check that the two dowel sleeves for centring balancer shaft module on cylinder block are fitted. 18 - M7 = 13 Nm + 90 (1/4 turn) further; M8 = 20 Nm + 90 (1/4 turn) further Renew. Note tightening sequence: installing new balancer shaft module page 111 , reinstalling previously run balancer shaft module page 115 . 19 - Oil extraction pipe 20 - 10 Nm 21 - 40 Nm 22 - 45 Nm 23 - 15 Nm Tighten in stages and in diagonal sequence. 24 - Seal Permanently attached to drain plug 25 - Oil drain plug, 30 Nm With seal. Renew.
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105
12-
Bolt with pressure relief valve, 27 Nm Oil spray jet (for cooling of pistons)
Oil spray jet and pressure relief valve
n AG. Volkswagen AG do es n wage ot g olks V ua by 2005 , Passat 2006 , Touran 2003 , Golfsed Plus ran tee ri oengine (2.0 l engine, 4 valve) - Edition 02.2011 diesel th or ac au ss
Removing and installing oil level and oil temperature sender G2661234Bolt -10 Nm-, self-locking, renew Seal; renew Electrical connector
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Thrust washer installation position Caution
When installing intermediate gear wheel, ensure that thrust washer -A- does not slip out of indentations in balancer shaft housing -arrows- and becomes jammed. Secure to balancer shaft housing with grease if necessary.
106
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3.6
Removing uth a
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Removing and installing oil pump (for balanceragen AG. Vmodule G does spur gear shaft olkswagen A with w not olks V gu drive) by ara ed
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Remove sump page 117 . Remove circlip -1- using circlip pliers.
Screw in a M3 bolt -2- and pull drive shaft out of oil pump -arrow-. Remove bolts -3- and -5- and remove oil pump. Caution
Unscrew bolt -4- and pull intake connecting pipe off oil pump.
Bolt on intermediate gear wheel must not be loosened.
Installing Installation is carried out in the reverse order; note the following: Note
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Renew O-ring.
Circlip must lie in base of groove.

AG.
Ensure both dowel sleeves are in place before installing oil pump. Install sump page 117 .
3.7
Removing balancer shaft module with spur gear drive
Special tools and workshop equipment required Crankshaft stop -T10050- for engines with round crankshaft toothed belt pulley
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Renew damaged or over-tensioned circlip.
107
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Crankshaft stop -T10100- for engines with oval crankshaft toothed belt pulley
Procedure Remove sump page 117 . Turn crankshaft to TDC and lock with crankshaft stop T10050- for engines with a round crankshaft toothed belt pulley or with crankshaft stop -T10100- for engines with an oval crankshaft toothed belt pulley.
Unscrew bolts in sequence -8 1- and remove balancer shaft module with oil pump.
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3.8
Renewing spur gear for crankshaft
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Commercially available hotplate
Fitting tool -10 - 203-
Puller -T10392 Thrust piece -T10392/1 Temperature gauge -VAS 6519- or hand-held multimeter V.A.G 1526D- in combination with temperature sensor -V.A.G 1526D/1 Remove sealing flange (belt pulley end) page 35 . Removing sump page 117 . Remove balancer shaft module page 107 Pulling off spur gear Insert thrust piece -T10392/1- in crankshaft end.
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109
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Insert puller -T10392- into holes of spur gear and turn clock wise -arrow-, screw in locating pins -A-.
Counterhold crankshaft with ring spanner -A-, pull spur gear off crankshaft journal by screwing spindle in using ring span ner -B- or ratchet. Shrink-fitting spur gear Note Check temperature when heating the new drive pulley using
There is more time for positioning at a higher temperature (220
C = approx. 6 seconds).
Ensure absolute cleanliness on crankshaft end. Caution
a At a temperature of 200 C there are approx. 4 seconds re ss
temperature gauge -VAS 6519- , or hand-held multimeter n AG. Volkswagen AG do V.A.G 1526D- in combination with temperature sensor -V.A.G es n wage ot g olks 1526D/1- . To do this, push measuring tip of temperature send by V ua ran se sor onto drive pulley. te ri o
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maining to position the drive pulley onto crankshaft.
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The maximum temperature of 240 C must not be exceeded, because this will lead to discolouring and distortion of the drive pulley.
Place new spur gear onto a commercially available hot plate and heat to at least 200 C, maximum 240 C. The inscription faces upwards. WARNING
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There is a risk of burning. Wear suitable protective gloves for further procedure.
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 When the temperature is reached, take spur gear up using pliers, as shown in illustration. Note
Take care not to damage the splines on the spur gear.
Slide spur gear quickly by hand without canting onto . Volkswag crank en AG does shaft end until stop using fitting tool -10 - 203- agen AG . ksw n
db Allow the spur gear to cool down a feweminutes and then install is balancer shaft module page 111o.r h t
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3.9
Installing balancer shaft module
Installing a new balancer shaft module page 111 Installing a previously used balancer shaft module again page 115
3.9.1
Installing a new balancer shaft module

Special tools and workshop equipment required Locking device -T10255-
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111
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Procedure Note The spur gear drive of the balancer shaft module must be in
stalled with correct tooth backlash. the correct tooth backlash.
A coating is applied to the new intermediate gear wheel to set Intermediate gear wheels with white spot are coated to areas
around the circumference, the intermediate gear wheel with out white spot is fully coated around the circumference. tooth backlash.
The coating is quickly worn away which in turn sets the correct For this reason a new balancer agen AG. Volkswamust always be shaft module gen AG does sw
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For intermediate gear wheels with coating around the circum
ference the installation position is not relevant.
Renew the bolts tightened with specified tightening angle. Crankshaft locked with crankshaft stop -T10100- . Caution
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s gear wheel to ensure correct installation position.
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The threaded connection of intermediate gear wheel must be loosened to position the balancer shaft module. When doing this, do not loosen the bolt fully to prevent that the thrust wash er does not slip behind the intermediate gear wheel. Thrust washer installation position page 106
Before positioning balancer shaft module on cylinder block, loosen bolt -1- for intermediate gear wheel approx. 45 (1/8 turn).
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Ensure both dowel sleeves are in place to correctly position the balancer shaft module on the cylinder block.
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112
AG.
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Position balancer shaft module on cylinder block, observe cor rect position of partly coated intermediate gear wheel when doing this: The white spot -arrow- on the intermediate gear wheel must be positioned centrally on the crankshaft. Note Take care not to damage the coating on the intermediatesgear n A n AG. Volk wage
wheel.
Tighten bolts of balancer shaft module as follows:
Tightening sequence - balancer shaft module with 8 bolted con nection points Stage 1. 2. 3. 4. 5. 6. 7. 8. Bolts -1 8-1 8-1 4-5-6-7-8-1 8Specified torque/ additional specified angle Hand-tighten in sequence Initially tighten in sequence to 6 Nm. Tighten to 20 Nm. Tighten to 13 Nm. Tighten to 20 Nm. Tighten to 13 Nm. Tighten to 20 Nm. Turn bolts 90 further in sequence us ing a fixed wrench.
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Tighten bolts of balancer shaft module as follows: Stage 1. 2. 3. 4. 5. Bolts -1 6-1 6-1 4-5 and 6-1 6Specified torque/ additional specified angle Hand-tighten in sequence Initially tighten bolts in sequence to 6 Nm. Tighten to 20 Nm. Tighten to 13 Nm. Turn bolts 90 further in sequence us ing a fixed wrench.
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Tightening sequence - balancer shaft module with 6 bolted con nection points
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113
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Lock balancer shaft using locking tool -T10255- , turn balancer shaft if necessary. Locking tool pin must engage in groove in balancer shaft when doing this.
Note
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Carefully fit the balancer shaft gear wheel onto shaft, push intermediate gear wheel slightly to side for this.
n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au the balancer ss
Ensure the threaded holes in the balancer shaft are as central
as possible within the elongated holes of the balancer shaft gear wheel.
If the elongated holes in the balancer shaft gear wheel cannot
be aligned to the threaded holes, then the balancer shaft gear wheel must be turned by the respective number of teeth and fitted again.
Tighten bolts for balancer shaft gear wheel -arrows-. Remove locking tool -T10255- .
Remove crankshaft stop. Note
No backlash may be perceptible after installing intermediate gear wheel. This can be checked by hand using light force.
114
AG.
Tighten new bolt for intermediate gear wheel Item 12 (page 104) .
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Turn balancer shaft gear wheel lightly anti-clockwise for this.
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Press intermediate gear wheel -3- forcefully (with assistance of a wooden rod if necessary) in -direction of arrow- into teeth of drive gear wheel -2- and balancer shaft gear wheel -1(meshing together).
The following 3 procedures must be performed simultaneously (2nd mechanic required):
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Install lower toothed belt guard -arrows-. Remaining installation steps are carried out in reverse sequence; note the following: Install sump page 117 . Install belt pulley vibration damper (renew securing bolts). Specified torque: 10 Nm + 90 (1/4 turn) further.
3.9.2
Installing a previously used balancer shaft module again
Caution
If the intermediate gear wheel bolt was loosened, the drive gear wheel on crankshaft was renewed or the crankshaft was re moved, a new intermediate gear wheel with coating must be installed and the hub Item 11 (page 104) with bolt Item 12 (page 104) and thrust washers must be renewed, otherwise the tooth backlash is incorrect. Procedure when in stalling page 111 .
Note
If the previously used balancer shaft module is to be reinstalled
and the drive gear wheel on crankshaft was renewed or the crankshaft was removed, proceed as follows. The intermedi ate gear wheel must also not have been loosened.
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Renew the bolts tightened with specified tightening angle.

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115
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Lock balancer shaft using locking tool -T10255- , turn balancer shaft if necessary. Locking tool pin must engage in groove in balancer shaft when doing this.
Ensure both dowel sleeves are in place to correctly position the balancer shaft module on the cylinder block. Position balancer shaft on cylinder block. The intermediate gear wheel must mesh in the crankshaft drive gear wheel when the balancer shaft is locked. The intermediate gear wheel must have a slight toothVback gen A n AG. olkswa G do es n wage lash. o olks
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Tightening sequence - balancer shaft module with 8 bolted con nection points Tighten bolts of balancer shaft module as follows: Stage 1. 2. 3. 4. 5. 6. 7. 8. Bolts -1 8-1 8-1 4-5-6-7-8-1 8Specified torque/ additional specified angle Hand-tighten in sequence Initially tighten in sequence to 6 Nm. Tighten to 20 Nm. Tighten to 13 Nm. Tighten to 20 Nm. Tighten to 13 Nm. Tighten to 20 Nm. Turn bolts 90 further in sequence us ing a fixed wrench.
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Tighten bolts of balancer shaft module as follows: Stage 1. 2. 3. 4. 5. Bolts -1 6-1 6-1 4-5 and 6-1 6Specified torque/ additional specified angle Hand-tighten in sequence Initially tighten bolts in sequence to 6 Nm. Tighten to 20 Nm. Tighten to 13 Nm. Turn bolts 90 further in sequence us ing a fixed wrench.
Remove crankshaft stop.
116
AG.
Tightening sequence - balancer shaft module with 6 bolted con nection points
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Install lower toothed belt guard -arrows-. Remaining installation steps are carried out in reverse sequence; note the following: Install sump page 117 . Install belt pulley vibration damper (renew securing bolts). Specified torque: 10 Nm + 90 (1/4 turn) further.
3.10
Hexagon key extension, 5 mm -VAS 3249 Torque wrench (550 Nm) -V.A.G 1331 Used oil collection and ex traction unit -V.A.G 1782-
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VAS 3185-
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Removing and installing oil sump
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117
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Silicone sealant -D176404A2 Hand drill with plastic brush attachment Eye protection Flat scraper Removing Remove noise insulation tray Rep. gr. 50 . Place used oil collection and extraction unit -V.A.G 1782- un der engine and drain engine oil. Note

Pull connector off oil level and oil temperature sender -G266- . Remove connecting bolts for sump to gearbox. Remove sump. Loosen sump with light blows of a rubber headed hammer if necessary. Remove sealant residue from cylinder block using a flat scra per. WARNING

Remove sealant residue on sump hand drill with a plastic brush. Installing Note
Clean sealing surfaces. They must be free of oil and grease.
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Observe expiry date of sealing compound. The sump must be installed within 5 minutes of applying sili
cone sealing compound.
Cut off tube nozzle at forward marking ( of nozzle approx. 3 mm). Apply silicone sealing compound, as shown, to clean sealing surface on sump. Sealant bead must be: 23 mm thick. Run bead along inner side of bolt holes -arrows-.
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Note
118
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The sealant bead must not be thicker, otherwise excess sealing compound will enter the oil sump and may block the oil suction line strainer.
Install sump immediately and tighten the connecting bolts for sump to gearbox and all sump bolts lightly. Ensure that sump is flush against intermediate plate and gearbox flange. Note
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When installing sump with engine out of vehicle, 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 40 Nm. Note
Let sealing compound dry for approx. 30 minutes after installing oil sump. Only then fill with engine oil.
Further assembly is basically the reverse of the dismantling se quence.
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119
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011w olks
Checking oil pressure and oil pressure switch page 121 . Assembly overview -oil supply line to turbocharger page 123 Removing and installing oil supply line to turbocharger page 123
Assembly overview - oil filter bracket and oil cooler page 120 .
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4.1
Assembly overview - oil filter bracket and oil cooler
1 - Seal Renew. 2 - 15 Nm + 1/4 turn (90) fur ther Renew. First fit upper left and lower right bolts and then tighten all four bolts diagonally. 3 - Oil filter bracket Ensure clearance to ad jacent components. 4 - Seal Renew. 5 - Connection, 30 Nm 6 - Oil supply line, 22 Nm Removing and installing page 123 . To turbocharger. 7 - 0.7 bar oil pressure switch F1- , 22 Nm Identification: brown. If seal is leaking, nip open and renew. Check page 121 . 8 - Sealing cap, 25 Nm 9 - O-ring Renew. 10 - Oil filter element See note. Observe change intervals.
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11 - Seal Renew. Lubricate before installing. Fit into lugs on oil cooler. 12 - Oil cooler Ensure clearance to adjacent components.
120
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 See note. Coolant hose schematic diagram page 131 . Checking oil cooler for leaks page 148 . 13 - Seal Renew. 14 15 16
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For wiring harness.
Checking oil pressure and oil pressure switch

Special tools and workshop equipment required Oil pressure tester -V.A.G 1342/ Voltage tester -V.A.G 1527/ B Auxiliary measuring set V.A.G 1594/C-
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Test prerequisites Engine oil level OK, checking page 86 . Engine oil temperature at least 80 C (radiator fan must have run once)
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4. Oil filter bracket, oil cooler, oil pressure and oil supply line
121
Functional check and repair of the optical and acoustic oil pres sure warning: Current flow diagrams, Electrical fault finding and Fitting locations
4.2.1
Checking oil pressure switch

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Start engine and increase speed slowly. At 0.550.85 bar the LED must light up; otherwise renew oil pressure switch.
Connect diode test lamp -V.A.G 1527 B- using auxiliary cables from -V.A.G 1594 A- to battery positive (+) and oil pressure switch. LED must not light up.
4.2.2
Checking oil pressure
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 speed, oil pressure must not exceed 7.0 bar. If necessary renew oil filter bracket.
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4.3
Assembly overview - oil supply line to turbocharger
1 - Retaining clamp 2 - 25 Nm Renew. 3 - Oil supply line To turbocharger. 4 - 10 Nm 5 - Retainer 6 - Union nut, 22 Nm 7 - 10 Nm 8 - Union nut, 22 Nm
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Removing
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Removing and installing oil supply line to turbocharger

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Remove air filter housing. Loosen securing bolts for retaining clips. Remove oil supply line.
Loosen union nuts on oil filter bracket and turbocharger.
4. Oil filter bracket, oil cooler, oil pressure and oil supply line
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Remove noise insulation tray General body repairs, exteri or; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation .
123
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Installing Note
The procedure must be followed to ensure that oil supply line is installed tension-free.
Loosen securing nut -2- from retainer -5-. Start union nuts for oil supply line on connections. Tighten union nut -8- on oil filter bracket hand tight. Now 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. Install air filter housing and noise insulation
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1
Cooling
Parts of cooling systemswagen AG n AG. Volk
Route all the various lines (e.g. for fuel, hydraulics, acti vated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original po sitions. Ensure that there is sufficient clearance to all moving or hot components.
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ment, pay attention to the following due to the cramped condi tions:
Note
When the engine is warm, the cooling system is under pres
sure. If necessary, release pressure before beginning repair work. only use spring-type clips.
Hoses are secured with spring-type clips. In case of repair, Spring-type clip pliers -VAS 5024/- or hose clip pliers -V.A.G When installing coolant hoses, route stress-free so that they
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Test for leaks in cooling system using cooling system tester V.A.G 1274/- and adapter for expansion tank -V.A.G 1274/8- and adapter for sealing cap -V.A.G 1274/9- .
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do not come into contact with other components (observe markings on coolant connection and hose).
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1921/- are recommended for installation of spring-type clips.

1. Parts of cooling system
125
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Parts of cooling system - body side page 126 , Parts of cooling system - engine side (Golf, Golf Plus, Touran) page 127 Parts of cooling system - engine side (Passat) page 129 Coolant hose schematic diagram page 131 . Draining and filling with coolant page 134 . Removing and installing radiator page 140 . Removing and installing coolant pump. page 142 Removing and installing thermostat. page 144 Checking cooling system for leaks page 146 .
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1.1
1 - Radiator Removing and installing page 140 . After renewing, renew entire coolant. 2 - O-ring Renew if damaged. 3 - Upper coolant hose Coolant hose schematic diagram page 131 .
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Parts of cooling system, body side
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4 - Cap Check using cooling system tester -V.A.G 1274/- and adapter for sealing cap -V.A.G 1274/9- . Test pressure: 1.41.6 bar. 6 - 5 Nm
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8 - Lower coolant hose Coolant hose schematic diagram page 131 . 9 - 5 Nm 10 - 5 Nm 11 - Additional radiator fan 12 - Main radiator fan 13 - Connector 14 - Cowling
126
Rep. gr.19 - Cooling
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7 - Expansion tank Carry out leak test of cooling system using cooling system tester V.A.G 1274- and adapt er -V.A.G 1274/8- .
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5 - Connector
1.2
Assembly overview - parts of cooling system, engine side (Golf, Golf Plus, n AG. Volkswagen AG do es n Touran) wage ot olks
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2 - Upper coolant pipe Bolted to cylinder head cover. 3 - To bypass flap. Coolant hose schematic diagram page 131 . 4 - O-ring Renew.
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1 - To top of Coolant hose schematic diagram page 131 .
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5 - Retaining clip Check for secure seat ing.

8 - Connection 9 - 10 Nm 10 - To heat exchanger Coolant hose schematic diagram page 131 . 11 - 40 Nm 12 - T-piece 13 - To bypass flap. Coolant hose schematic diagram page 131 . 14 - T-piece 15 - To top of radiator Coolant hose schematic diagram page 131 . 16 - 15 Nm 17 - To bottom of expansion tank Coolant hose schematic diagram page 131 . 18 - Coolant pipe 19 - To bottom of radiator Coolant hose schematic diagram page 131 . 20 - Connection For thermostat. 21 - Thermostat Removing and installing page 144 .
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7 - To exhaust gas recircula tion cooler Coolant hose schematic diagram page 131 .
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6 - Coolant temperature send er -G62 With coolant tempera ture display sender G2- .
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127
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note installation position page 144 . 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 131 . 23 - Rear coolant pipe 24 - 10 Nm
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25 - To auxiliary heater Coolant hose schematic diagram page 131 . 26 - Coolant pipe 27 - To exhaust gas recirculation cooler Coolant hose schematic diagram page 131 . 28 - Oil cooler 29 - Coolant pump Check for ease of movement. Note installation position. Removing and installing page 142 .
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1.3
Assembly overview - parts of cooling system, engine side (Passat)
1 - To top of expansion tank. Coolant hose schematic diagram page 131 . 2 - Upper coolant pipe Bolted to cylinder head cover. Coolant hose schematic diagram page 131 . 3 - O-ring Renew. 4 - Retaining clip Check for secure seat ing.
6 - To exhaust gas recircula tion cooler. Coolant hose schematic diagram page 131 . 7 - Connection 8 - 10 Nm
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9 - To top of radiator Coolant hose schematic diagram page 131 . 10 - From heat exchanger Coolant hose schematic diagram page 131 . 11 - 40 Nm 12 - T-piece
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16 - Front coolant pipe Coolant hose schematic diagram page 131 . 17 - Seal Renew. 18 - Radiator outlet coolant temperature sender -G83 If necessary, release pressure in cooling system before removing. 19 - 15 Nm 20 - To bottom of radiator Coolant hose schematic diagram page 131 .
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15 - From bottom of expansion tank Coolant hose schematic diagram page 131 .
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14 - 15 Nm
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13 - From upper coolant hose T-piece Coolant hose schematic diagram page 131 .
129
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 21 - Connection For thermostat. Coolant hose schematic diagram page 131 . 22 - Thermostat Removing and installing page 144 . Note installation position page 144 . Checking: heat thermostat in water. AG. Volkswagen AG d agen oes not lksw Opening begins at approx. 85 C. Vo gu by ara d nte Ends at approx. 105 C. ise or eo th u ra Opening lift at least 7 mm. c sa
23 - Rear coolant pipe Coolant hose schematic diagram page 131 . 24 - From exhaust gas recirculation cooler To recirculating pump -V55- . Coolant hose schematic diagram page 131 . 25 - To heat exchanger Coolant hose schematic diagram page 131 . 26 - Coolant pump Check for ease of movement. Note installation position. Removing and installing page 142 . 27 - Oil cooler For engine oil. Removing and installing page 120 .
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1.4
e Vehicles with manual gearboxd page 131 ris
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Vehicles with dual clutch gearbox page 133
1.4.1
Vehicles with automatics au gearbox page 132 s
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Vehicles with manual gearbox
1 - Expansion tank 2 - Bypass flap
3 - Radiator For exhaust gas recircu lation. 4 - Heat exchanger for heater unit 5 - Cylinder head/cylinder block 6 - Upper coolant hose 7 - Radiator 8 - Lower coolant hose 9 - Engine oil cooler
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11 - Auxiliary heater
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10 - Coolant pump and ther mostat
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131
1.4.2
Vehicles with automatic gearbox
1 - Expansion tank 2 - Bypass flap 3 - Radiator For exhaust gas recircu lation. 4 - Heat exchanger for heater unit 5 - Gearbox oil cooler 6 - Cylinder block
8 - Upper coolant hose 9 - Engine oil cooler 10 - Radiator
7 - Additional cooler Not on all vehicles.
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11 - Lower coolant hose
12 - Coolant pump and ther mostat 13 - Auxiliary heater
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132
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1.4.3
Vehicles with dual clutch gearbox
1 - Expansion tank 2 - Bypass flap 3 - Radiator For exhaust gas recircu lation. 4 - Heat exchanger for heater unit 5 - Gearbox oil cooler 6 - Cylinder head/cylinder block 7 - Upper coolant hose 8 - Engine oil cooler 9 - Radiator 10 - Lower coolant hose 11 - Coolant pump and ther mostat 12 - Auxiliary heater
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133
1.5
Draining and filling coolant
Special tools and workshop equipment required Refractometer -T10007 Drip tray for V.A.G 1202 V.A.G 1306/ Spring-type clip pliers -VAS 5024/ Cooling system charge unit -VAS 6096 Adapter for cooling system tester -V.A.G 1274/8-
1.5.1
Draining
WARNING
Hot steam may escape when expansion tank is opened. Place cloth over cap and open with caution.
Remove cap from coolant expansion tank.
Remove insulation tray General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation .
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134
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pull off lower coolant hose retaining clip -arrow- and remove coolant hose from quick-release connection of radiator.
To drain coolant from engine, also remove coolant hose from oil cooler -arrow-. Note

1.5.2
Note
Filling
An influencing factor of the effectiveness of the coolant is the amount of water used. Due to the various qualities in the various countries Volkswagen has decided to define the quality of the water to be used in the coolant system. Distilled water fulfils all requirements. It is therefore recommended that distilled water be mixed with the coolant whenever an older model's coolant is re plenished or replaced. The use of distilled water is obligatory for new types of vehicle (year of manufacture 2010 ).
Caution
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It is only permissible to use distilled water for mixing with G12 plus-plus. The use of distilled water ensures optimum protec tion against corrosion.
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Use only coolant additive G 12 plus-plus in accordance with
TL VW 774 G.
G 12, G12 plus and G 12 plus-plus must not be mixed! It is only permissible to use distilled water for mixing. G 12 plus-plus prevents frost and corrosion damage, scaling
and also raises the boiling point of coolant. Therefore, the cooling system must be filled all year round with frost and cor rosion protection additives. gine reliability under heavy loads, particularly in countries with tropical climates. with arctic climates: down to about -35 C).
Because of its higher boiling point, the coolant improves en
Frost protection is required down to about -25 C (in countries 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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gasket is renewed, do not reuse old coolant. the current anti-freeze density.
The refractometer -T10007- is recommended for determining Recommended mixing ratios (use only distilled water for mixing): Frost protection Anti-freeze to proportion -25 C -35 C
1)
G 12 plusplus 1) 3.2 l 4.0 l
Water 1) 4.8 l 4.0 l
40 % 50 %
The quantity of coolant can vary depending upon the vehicle equipment. Install lower coolant hose and secure with retaining clip -arrow-. Connect coolant hoses to oil cooler. Install insulation tray General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation . With cooling system charge unit -VAS 6096- : Screw adapter for cooling system tester -V.A.G 1274/8- onto expansion tank. Fill coolant circuit using cooling system charge unit VAS 6096- Operating instructions for cooling system charge unit VAS 6096 Without cooling system charge unit -VAS 6096- (must not be used for engine codes BMR and BUZ)
136
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If radiator, heat exchanger, cylinder head or cylinder head
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If for climatic reasons greater frost protection is required, the
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amount of G 12 plus-plus can be increased, but only up to 60 % (frost protection to about -40 C). Otherwise frost protection and cooling effectiveness are reduced again.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Slowly fill coolant to upper marking of shaded field on expan sion tank. Fit expansion tank cap. Switch air conditioner to Econ or Off. Start engine and maintain an engine speed of about 2000 rpm for about 3 minutes. Run engine until radiator fan cuts in. Check coolant level and top-up if necessary. When the engine is at normal operating temperature, the coolant level must be at the upper mark; when the engine is cold, in the middle of the shaded field.
1.5.3
Note
Filling
An influencing factor of the effectiveness of the coolant is the amount of water used. Due to the various qualities in the various countries Volkswagen has decided to define the quality of the water to be used in the coolant system. Distilled water fulfils all requirements. It is therefore recommended that distilled water be AG. Volkswa an older model's coolant is re mixed with the coolantnwhenever gen AG does wage not olks plenished orby V replaced. The use of distilled water is obligatory for gu d ran new typeseof vehicle (year of manufacture 2010 a).t ris
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It is only permissible to use distilled water for mixing with G12 plus-plus. The use of distilled water ensures optimum protec tion against corrosion. For engines with engine code BMN the cooling system must always be filled with cooling system charge unit -VAS 6096- . Otherwise air pockets can form in the area of the exhaust gas recirculation cooler, which will cause pulsations.
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137
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note Use only coolant additive G 12 plus-plus in accordance with
TL VW 774 G.
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and also raises the boiling point of coolant. Therefore, the cooling system must be filled all year round with frost and cor rosion protection additives. gine reliability under heavy loads, particularly in countries with tropical climates. with arctic climates: down to about -35 C).
Because of its higher boiling point, the coolant improves en
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Frost protection is required down to about -25 C (in countries The coolant concentration must not be reduced by adding wa
ter even in warmer seasons and in warmer countries. The coolant additive concentration must be at least 40 %.
If for climatic reasons greater frost protection is required, the
amount of G 12 plus-plus can be increased, but only up to 60 % (frost protection to about -40 C). Otherwise frost protection and cooling effectiveness are reduced again. gasket is renewed, do not reuse old coolant.
If radiator, heat exchanger, cylinder head or cylinder head The refractometer -T10007- is recommended for determining Recommended mixing ratios (use only distilled water for mixing):
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the current anti-freeze density.
Frost protection Anti-freeze to proportion -25 C -35 C

1)
G 12 plusplus 1) 3.2 l 4.0 l
Water 1) 4.8 l 4.0 l
40 % 50 %
The quantity of coolant can vary depending upon the vehicle equipment. Install lower coolant hose and secure with retaining clip -arrow-. Connect coolant hoses to oil cooler. Install insulation tray General body repairs, exterior; Rep. gr. 50 ; Body - front; Assembly overview - noise insulation . With cooling system charge unit -VAS 6096- : Screw adapter for cooling system tester -V.A.G 1274/8- onto expansion tank. Fill coolant circuit using cooling system charge unit VAS 6096- Operating instructions for cooling system charge unit VAS 6096 Without cooling system charge unit -VAS 6096- (must not be used for engine code BMN)
138
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Slowly fill coolant to upper marking of shaded field on expan sion tank. Fit expansion tank cap. Switch air conditioner to Econ or Off. Start engine and maintain an engine speed of about 2000 rpm for about 3 minutes. Run engine until radiator fan cuts in. Check coolant level and top-up if necessary. When the engine is at normal operating temperature, the coolant level must be at the upper mark; when the engine is cold, in the middle of the shaded field.
1.6
Removing and installing fan support with fans

Removing
Remove noise insulation tray Rep. gr. 50 . Remove intake air duct from air filter page 259 . Bring lock carrier into service position Rep. gr. 50 . Separate connector -1- and remove fan support securing bolts -arrows-. Remove fan support with fans upwards.
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139
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Separate connection -2- and free wiring. Unclip connector -1- from fan support and move wiring clear. Remove securing nuts -arrows- and remove fans. Installing Installation is carried out in the reverse order. When installing, note the following: Specified torques:
Component Radiator fans to fan support Fan support to radiator
Nm 10 5
1.7
Removing and installing radiator
Special tools and workshop equipment required Refractometer -T10007 Drip tray -V.A.G 1306- or drip tray -VAS 6208 Spring-type clip pliers VAS 5024 A Cooling system charge unit -VAS 6096 Adapter for cooling system tester -V.A.G 1274/8 Torque wrench 1331/n AG. Volkswagen AG do es n wage ot g olks -V.A.G V ua by ran ed is tee or th or ac au ss

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Removing Golf, Golf Plus, Touran:
Bring lock carrier into service position General body repairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po sition . Passat: Remove front bumper cover General body repairs, exterior; Rep. gr. 63 ; Bumper . Continuation for all vehicle types: Remove fan support with fans page 139 . Pull coolant hoses off radiator. Remove radiator securing bolts Item 10 (page 126) and re move radiator with fan downwards. Installing Installation is carried out in the reverse order. When installing, note the following: Replenish coolant page 134 .
Drain coolant page 134 .
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141
1.8
Removing and installing coolant pump

Drip tray -V.A.G 1306- or drip tray -VAS 6208 Spring-type clip pliers VAS 5024 A-
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Refractometer -T10007-
Cooling system charge unit -VAS 6096 Adapter for cooling system tester -V.A.G 1274/8-
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Removing Note
Always renew seals and gaskets.

Drain coolant page 134 Remove poly V-belt page 16 . Remove toothed belt. page 51
142
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Remove securing bolts -1- for coolant pump -2- and carefully remove coolant pump. Installing Installation is carried out in the reverse order. When installing, note the following:
Moisten new O-ring -3- with coolant. Insert coolant pump -2- in cylinder block and tighten securing bolts -1- to 15 Nm. Note
The coolant pump plug faces downwards.

Install toothed belt. page 51 Install poly V-belt page 16 . Replenish coolant. page 134
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143
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 olkswage 4 valve) - Edition 02.2011 l engine, .V
1.9
Removing and installing thermostat
Jointed wrench 10 mm -3185 Hexagon key extension, 5 mm -3249 Refractometer -T10007 Torque wrench (550 Nm) -V.A.G 1331 Spring-type clip pliers -VAS 5024/A Drip tray for V.A.G 1202 V.A.G 1306/- or drip tray for workshop crane -VAS 6208-
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Removing Note
Always renew seals and gaskets.

Drain coolant page 134 . Remove alternator Rep. gr. 27 Pull connector off radiator outlet coolant temperature sender -G83- . Pull coolant hose off connection.
144
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Loosen securing bolts -4- of union -3- using T-bar and socket, 10 mm -3185- and remove using hexagon key extension, 5 mm -3249- and remove union -3- with thermostat -1-. Turn thermostat -1- 1/4 turn (90 ) to left and remove from connection -3-. Installing Installation is carried out in the reverse order. When installing, note the following: Moisten new O-ring -2- with coolant. Insert thermostat -1- in union -3- and turn 1/4 turn (90 ) to right. Note
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The brace on the thermostat
Tighten securing bolts -4- using T-bar and socket, 10 mm -3185- . Specified torque: 15 Nm. Replenish coolant page 134 .
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Fit union -3- with thermostat -1- into cylinder block.
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145
1.10
Checking cooling system for leaks
Special tools and workshop equipment required Cooling system tester V.A.G 1274 Adapter for cooling system tester -V.A.G 1274/8 Adapter for cooling system tester -V.A.G 1274/9-
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Test prerequisite Test sequence: WARNING
Engine at operating temperature.
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Open cap on coolant expansion tank.
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Hot steam may escape when expansion tank is opened. Place rag over cap and open with caution.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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. Note
If the pressure test is carried out in a period of e.g. 10 minutes, the pressure will drop due to cooling of. VolkswageFor this reason coolant. n AG do the first 30 seconds of test areswagen AG important. es n lk
If
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seconds of test:
Checking pressure relief valve in 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. If the pressure relief valve opens prematurely: Renew sealing cap. Increase pressure to over 1.6 bar. The pressure relief valve must open. If the pressure relief valve does not open: Renew sealing cap.

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147
1.11
Checking oil cooler for leaks
Special tools and workshop equipment required Refractometer -T10007 Hose clips up to 25 mm -3094 Cooling system tester V.A.G 1274 Adapter for cooling system tester -V.A.G 1274/8 Spring-type clip pliers -VAS 5024 A Drip tray -V.A.G 1306- or drip tray -VAS 6208-
Special tools and workshop equipment required Torque wrench -V.A.G 1331-
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Expansion tank -1K0 121 407 A- or expansion tank -1J0 121 407 B Plug -191 211 343AG.
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Not illustrated
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Cap -1J0 121 324 Coolant hose -251 265 056Prerequisites: Engine cold Test procedure Remove insulation tray.
G age Clamp off supply and return lines to oilocooler using hose clips does no lksw t gu yV to 25 mm -VAS 3094- . ar db
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Note
Collect escaping coolant with drip tray -V.A.G 1306- or drip tray VAS 6208- .
Pull coolant hoses off oil cooler. Slide sealing cap -5- onto rear connection of 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.
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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.
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Watch pressure drop on pressure gauge. A pressure drop within 10 minutes is not permitted. Renew oil cooler page 120 .
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If pressure drops:
Installation is carried out in the reverse order. When installing, note the following: Check coolant level, replenish coolant if necessary page 134 .
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20
1
1.1
Fuel supply system

Safety precautions
Safety precautions when working on fuel supply system

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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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 performing any type of repair work on the fuel system!
When removing and installing fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel tank, observe the following: Before beginning work, place an extraction hose close to sender opening in fuel tank to extract escaping fuel fumes and switch on exhaust extraction system. 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!
150
Rep. gr.20 - Fuel supply system
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2.1
Rules for cleanliness

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: Thoroughly clean all unions and surrounding 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. Volkswa
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When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely nec essary. Also ensure that no diesel fuel runs on to the coolant hoses. Should this occur, the hoses must be cleaned immediately. Damaged hoses must be renewed.
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2. Rules for cleanliness
151
Parts of fuel supply system (Golf, Golf Plus)
Safety precautions page 150 . Rules for cleanliness page 151 . Fuel tank, vehicles with front-wheel drive page 152 . Fuel tank, vehicles with four-wheel drive page 156 . Emptying fuel tank page 162 . Removing and installing fuel delivery unit page 164 . Removing and installing fuel gauge sender page 166 . Checking fuel pump page 166 . Assembly overview - fuel filter page 171 . Removing and installing fuel cooler page 173 .
3.1
Fuel tank, vehicles with front-wheel drive

Note
Hose connections are secured with either spring-type or
clamp-type clips.
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Volkswa not olk gu yV ara Spring-type clip pliersb-VAS 5024/- or hose clip pliers -V.A.G ed n ris o 1921/- are recommended for installation of spring-type clips. tee o th ra au c ss

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3.1.1
1 - Cap 2 - 1.5 Nm
Assembly overview - fuel tank
3 - Earth connection Check for secure seat ing. 4 - 10 Nm 5 - Cable guide 6 - Fuel tank When removing, sup port using engine and gearbox jack -V.A.G 1383/A- . Removing and installing page 154 . 7 - 25 Nm Renew. 8 - Clamping washer
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11 - Seal Renew if damaged. Moisten with fuel when installing 12 - Fuel delivery unit With fuel gauge sender (G). Note installation posi tion of flange on fuel tank page 177 . Removing and installing page 164 . Checking fuel pump page 166 . Removing and installing fuel gauge sender page 186 . 13 - Locking ring Remove and install using wrench -T10202- . Specified torque: 110 Nm.

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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. Clipped onto fuel tank.
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3. Parts of fuel supply system (Golf, Golf Plus)
153
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Check for secure seating. To pull off flange, press release button on connecting piece. 16 - Tank flap unit Removing and installing General body repairs, exterior; Rep. gr. 55 ; Tank flap unit .
3.1.2
Removing and installing fuel tank
Special tools and workshop equipment required Torque wrench -V.A.G 1331/-
Engine and gearbox jack -V.A.G 1383/A-
Removing
Note safety precautions before starting work page 150 . Observe rules for cleanliness page 151 . Note
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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. 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.
154
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Remove fuel flap unit. General body repairs, exterior; Rep. gr. 55 ; Fuel flap unit Emptying fuel tank page 162 . Remove rear right wheel housing liner: General body re pairs, exterior; Rep. gr. 66 ; Removing and installing wheel housing liner . Remove bolts from filler neck -arrows-.
Disconnect fuel lines at front right of fuel tank. Note

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Press buttons on hose
If vehicle has supplementary heating, separate connector to metering pump and unclip wire. Supplementary heating; Rep. gr. 82 ; Removing and installing metering pump -V54 Remove bolts -A- and remove heat shield for fuel tank. Support fuel tank using engine and gearbox jack -V.A.G 1383/ A- . Remove securing bolts -arrows- for the fuel tank. Slowly lower fuel tank and pull it forwards. Tilt fuel tank to get it past rear axle. Installing 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 and return lines (return line blue or with blue markings, supply line black).
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Clip supply and return lines onto fuel tank.

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155
3.2 3.2.1
Fuel tank, vehicles with four-wheel drive Assembly overview - fuel tank
1 - Supply line Black Check for secure seat ing. 2 - Return line Blue Check for secure seat ing. 3 - Seal Renew. When installing, fit dry in fuel tank opening. Moisten with fuel only when installing flange. 4 - Fuel delivery unit Removing and installing page 164 . Checking fuel pump Note installation posi tion on fuel tank page 157 . With fuel gauge sender -G- . Removing and installing fuel gauge sender page 186 . 5 - Locking ring, 110 Nm Check for secure seat ing. Remove and install us ing wrench -T10202- .
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6 - Tank flap unit With rubber cup. Removing and installing General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and installing fuel tank flap unit . 7 - Cap Renew if damaged. 8 - Securing bolt Tighten to 1.5 Nm.
9 - Earth connection Check for secure seating. 10 - 10 Nm
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11 - Suction-jet pump Clipped onto fuel gauge sender 2 -G169 Removing and installing page 161 .
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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 157 . 14 - Securing strap Note installation position. 15 - 25 Nm Renew. 16 - Heat shield Riveted to exhaust pipe mounting Installation position of flange for fuel delivery unit and fuel gauge sender 2 -G169The marking on the flange must align with the marking on the fuel tank -arrow-. Note
The marking on the fuel tank is not clearly visible.
3.2.2
h ut sa s
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i Torquese or wrench (550 Nm) -V.A.G 1331-
Removing andwinstalling fuel tank olks a

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Engine and gearbox jack -V.A.G 1383 A-
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Note safety precautions before beginning work page 150 .
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157
Before disconnecting battery, open fuel tank flap and if necessary remove wheel lock adapter from luggage compartment.
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 . If necessary, drain fuel tank using fuel extractor -VAS page 162 Remove rear right wheel.
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Remove rear right wheel housing liner. General body re pairs, exterior; Rep. gr. 66 ; Removing and installing wheel housing liner; Rear wheel housing liner . Unscrew securing bolts and remove tank flap unit. General body repairs, exterior; Rep. gr. 55 ; Fuel flap unit Unscrew filler neck from body -arrows- and unclip electrical wire from filler neck. Remove bench seat General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing seat bench .

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Remove 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. Before loosening hose connections, wrap a cloth around the connec tion. Then release pressure by carefully pulling hose off con nection.
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Remove covers and separate electrical connectors -arrows-.
Pull off adapter cable
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder dieselkengine (2.0 l engine, 4 valve) - Edition 02.2011 . Vol swage unit
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Support fuel tank using engine and gearbox jack -V.A.G 1383 A- and unscrew tensioning straps and securing bolts. Slowly lower fuel tank. Note
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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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Clip in cable for four-wheel drive control unit -J492- on fuel tank.
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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.
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159
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Fit adapter cable on four-wheel drive control unit -J492- . The remaining installation steps are carried out in the reverse se quence. In the process, note the following: Install breather and fuel lines free of kinks. Do not interchange supply and return lines (return line blue or with blue markings, supply line black). Ensure that line connections are tight. Check earth connection between tank and body of filler neck.
3.2.3
Removing and installing fuel gauge sender 2 -G169-
The fuel tank should be no more than half full

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Note

Observe rules for cleanliness page 151 . Removing:
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page 162
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 . Remove bench seat General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing seat bench . Remove left cover (as seen facing direction of normal travel) from fuel gauge sender 2 -G169- . Open locking ring using wrench -T10202- .
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Disconnect electrical connectors.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pull fuel gauge sender 2 -G169- upwards slightly and unclip it from the suction-jet pump. Installing: Caution
When installing do not bend fuel gauge sender 2 -G169- float arm.
Place fuel gauge sender 2 -G169- in fuel tank. Fit suction-jet pump on sender on inside of lugs must engage.
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Note installation position of fuel gauge sender 2 -G169 page 157 Check for correct position of seal.
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Place a new flange seal dry into opening in fuel tank and mois ten inside (contact to flange) only with fuel.
Tighten locking ring using wrench -T10202- . Specified torque: 110 Nm Fit connectors. Install cover.
Install bench seat. General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing seat bench .
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3.2.4
Removing and installing suction-jet pump
Note On vehicles with four-wheel drive, fuel has to be pumped from
the area of fuel gauge sender 2 -G169- to the fuel delivery unit by means of a suction-jet pump due to the shape of the fuel tank. of fuel, even though the fuel gauge shows that the tank is still 1/4 full.
Checking is only necessary when the engine stops due to lack
Procedure Remove fuel delivery unit page 164
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161
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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 -G169- page 160 . Now the suction-jet pump can be pulled out from side of fuel gauge sender 2 -G169- (left side of vehicle). Check that the fuel lines on suction-jet pump are fitted securely and are not damaged. Additionally check suction-jet pump for possible soiling.
3.3
Emptying fuel tank
Special tools and workshop equipment required Fuel extractor -VAS 5190-
Fuel tank sender unit tool -T10202n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss
Torque wrench (40200 Nm) -V.A.G 1332 Note safety precautions before beginning work page 150 . Emptying fuel tank if it is more than 3/4 full page 162 . Emptying fuel tank if it is less than 3/4 full page 163
3.3.1
Emptying fuel tank if it is more than 3/4 full

Caution
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162
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Secure earth wire of fuel extractor -VAS 5190- to a bare metal part of the body.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Remove cotter -2- from shaft -1- of fuel extractor -VAS 5190- .
Gd At distance -a- = 1180 mm fromage mark extraction oes no with hose ksw end, t gu Vol insulating tape -arrow-. by ar d
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Remove filler cap from fuel tank filler neck. Screw shaft end -1- of fuel extractor unit -VAS 5190- onto fuel filler neck. Push extraction hose into fuel tank until marking on hose -arrow- coincides with shaft end.
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A ball valve -2- is located at the bottom of the filler neck in the fuel tank -1-; it must not be damaged by the extraction hose -3-. Therefore push hose into filler neck only as far as marking -arrow-.
Empty fuel tank as far as possible. Carefully pull out extraction hose. Note When no more fuel is extracted, the tank is emptied just
AG.
enough for the sender flange to be opened without danger. page 163
If the fuel tank has to be drained fully, proceed as follows:
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
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Note
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163
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pull connector and fuel lines off flange. Note
Press buttons on hose couplings to do this.

Open locking ring using fuel tank sender wrench -T10202- . Lift sender flange. Insert extraction hose of fuel extractor -VAS 5190- as deeply as possible into fuel tank and extract fuel. If fuel tank needed only to be emptied, reinstall sender flange.
3.4
Removing and installing fuel delivery unit
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Special tools and workshop equipment required Special wrench -T10202-
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Removing Observe safety precautions page 150 . Observe rules for cleanliness page 151 . 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 .
164
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Torque wrench -V.A.G 1332agen lksw Vo by

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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

WARNING
Remove union nut with wrench -T10202- . Pull fuel delivery unit and seal out of opening in fuel tank. Note
If delivery unit is to posal.

Installing
Installation of fuel delivery unit is carried out in reverse order.
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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
livery unit.
Ensure that fuel hose connections are tight. After installing fuel delivery unit, check that supply, return and
breather lines are still clipped onto fuel tank.
Note installation position of fuel delivery unit flange: mark on
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flange must align with mark -arrows- on fuel tank.

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165
3.5
Removing
Removing and installing fuel gauge sender
Remove fuel delivery unit page 164 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 gauge sender into guides on fuel delivery unit and press upwards until it engages.
3.6
Note
Checking fuel pump
Check fuel filter connections for correct arrangement, before starting to check the fuel pump page 171
3.6.1
Checking delivery pressure of fuel pump

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th Vehicle diagnosis tester au
Fuses must be OK. Battery voltage at least 12 V All electrical consumers, e.g. lights and rear window heating, must be switched off.
Test prerequisite:
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166
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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. 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 210 .
Separate quick release coupling -A- (black or black marking) of fuel supply line.
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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 window heating, must be switched off. Note
The delivered fuel may be cloudy. This is normal and can be ig nored.
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If the tandem pump values are OK, check fuel pump delivery rate page 167 .
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If the specifications are attained, check tandem pump to en sure the fuel filter is not blocked page 225 .
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167
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Separate quick release coupling -A- (black or black marking) of fuel supply line. Connect -VAS 6550/1- pressure tester line to fuel supply -A-. Guide open end of line into measuring container. Connect diagnosis tester and perform the 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 necessary, renew defective line and repeat test. If it is not kinked, crushed or damaged, remove rear seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats . Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor Remove cover from fuel delivery unit. Note
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Press in securing ring to
Connect -VAS 6550/1- pressure tester line to fuel supply -A-. Guide open end of line into measuring container. Connect diagnosis tester and perform the guided function Checking electric fuel pump(s). Note
Pull fuel supply line (black, or black marking) -A- off fuel de livery unit.

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 168 and current draw page 170 of fuel pump.
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Pickup clamp -V.A.G 1526B/2-
168
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Hand-held multimeter -V.A.G 1526D-
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3.6.3
Checking voltage supply of fuel pump
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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 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.agen AG. Volkswagen AG do
yV Switch on ignition. The fuel pump must be heard to run for db ise about 2 seconds. or
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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.
Switch off ignition.
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169
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Connect hand-held multimeter -V.A.G 1526D- to contacts -1and -5- of adapter. Connect diagnosis tester and perform the guided function Checking electric fuel pump(s). Note
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If no voltage is present: Check activation of fuel pump relay and wiring for an open or short circuit Vehicle diagnostic tester. Voltage supply OK: Remove fuel delivery unit page 210 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.
Read voltage value on hand-held multimeter -V.A.G 1526D- : Specification = battery voltage.
3.6.4
Checking current draw of fuel pump

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Vehicle diagnosis tester 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.
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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- .
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Switch on ignition. Connect diagnosis tester and perform the guided function Checking electric fuel pump(s). Note

Read current draw on hand-held multimeter -V.A.G 1526D- . Specification: max. 7.5 amps. If the measured value is not within specifications: Renew fuel delivery unit page 210 .
3.7
Note
Assembly overview - fuel filter
Note that there are different versions of fuel filter upper part page 173
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171
1 - Supply line From fuel tank. White or with white marking. Check for secure seat ing. 2 - 5 Nm
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3 - Return line To fuel cooler Check for secure seat ing. Blue or with blue mark ing. 4 - Plug for water extraction Remove and extract about 100 cm3 liquid us ing hand-operated vac uum pump with acces sories -V.A.G 1390- and water drainage contain er -V.A.G 1390/1- . 5 - Seal Renew. 6 - Supply line To tandem pump. 7 - Return line From tandem pump. Blue or with blue mark ing. Check for secure seat ing. 8 - Upper part of fuel filter
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9 - Fuel temperature sender -G8110 - Seal Renew. 11 - Filter insert 12 - Seal Renew. 13 - Lower part of fuel filter 14 - 8 Nm 15 - Retainer 16 - Seal Renew. 17 - Retaining clip 18 - Connection 19 - From tandem pump.
172
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3.7.1
Fuel filter upper part
Type A page 173 Type B page 173 Fuel filter upper part, 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 tank supply line, white or white marking. Check for secure seating. 4 - Fuel tank return line, blue or blue marking. Check for secure seating. n AG. Volkswagen AG
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2 - Fuel tank return line, blue or blue marking. Check for secure seating. 3 - Fuel tank supply line, 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.
3.8
Removing and installing fuel cooler

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Removing Note safety precautions before beginning work page 150 . Observe rules for cleanliness page 151 .
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173
The fuel cooler is located in the return line to tank. It is located on the vehicle underbody.
Remove underbody panel. Separate fuel lines at fuel cooler. Remove securing nuts -arrows-. Installing Install in reverse order. In the process, note the following: Tighten fuel cooler securing nuts to 15 Nm.

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174
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4
Note
Parts of fuel supply system (Touran)
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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4. Parts of fuel supply system (Touran)
175
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Safety precautions page 150 . Rules for cleanliness page 151 . Assembly overview - fuel tank with attachments page 176 . Emptying fuel tank page 177 .
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Removing and installing fuel th au cooler page 183 . Removing and installing fuel gauge sender page 186 . Checking fuel pump page 186 .
Removing and installing fuel delivery unit page 184 .
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4.1
1 - Cap 2 - 1.5 Nm
Assembly overview - fuel tank with attachments
3 - Tank flap unit Removing and instal ling. General body re pairs, exterior; Rep. gr. 55 ; Fuel flap unit 4 - Earth connection Check for secure seat ing. 6 - Pressure retention valve with connecting hose 7 - Gravity/overflow valve
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5 - 10 Nm
8 - Fuel tank When removing, sup port using engine and gearbox jack -V.A.G 1383/A- . Removing and installing page 180 . 9 - Heat shield For fuel tank. 10 - Securing strap
11 - 20 Nm + 1/4 turn (90) fur ther 12 - Fuel delivery unit With fuel gauge sender (G). Note installation posi tion of flange on fuel tank page 177 . Removing and installing page 184 . Checking fuel pump page 166 . Removing and installing fuel sender page 186 . Clean strainer if soiled.
176
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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 n AG. Volkswagen AG do es n wage Clipped onto fuel tank. ot g olks V ua by ran ed Check for secure seating. is tee or th or Black ac au ss To pull off flange, press release button on connecting piece. 16 - Return line From fuel cooler. Blue or with blue marking. Clipped onto fuel tank. Check for secure seating. To pull off flange, press release button on connecting piece.
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Installation position of fuel delivery unit flange Mark on flange must align with mark on fuel tank -arrows-. Black supply line -1- to connection marked -V-. Return line -2- (blue or with blue marking) to connection marked -R-.
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Note
4.2
Emptying fuel tank
Special tools and workshop equipment required Fuel extractor -VAS 5190-
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After installing fuel delivery unit flange, check that supply, return and breather lines are still clipped onto fuel tank.
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177
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Union nut tool -3217-
Note safety precautions before starting work page 150 . Emptying fuel tank if it is more than 3/4 full page 178 . Emptying fuel tank if it is less than 3/4 full page 179
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4.2.1
Caution
Secure earth wire of fuel extractor -VAS 5190- to a bare metal part of the body.
Remove cotter -2- from shaft -1- of fuel extractor -VAS 5190- . At distance -a- = 1,200 mm from end, mark extraction hose with insulating tape -arrow-.
178
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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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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. proceed as follows:
If work must be performed on fuel pump or fuel tank sender,
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4.2.2
Fold rear seats forwards. Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor Remove cover from fuel delivery unit. WARNING
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Pull connector and fuel lines off flange. Note
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179
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Open locking ring using union nut tool -3217- . Lift 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, reinstall fuel delivery unit page 184 .
4.3
Special tools and workshop equipment required Torque wrench -V.A.G 1331/AG. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or eo th u ra a c ss
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Note safety precautions before starting work page 150 . Observe rules for cleanliness page 151 . Note Before carrying out further work, disconnect battery earth
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.
180
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Removing
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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 Emptying fuel tank page 177 . Remove rear right wheel housing liner: General body re pairs, exterior; Rep. gr. 66 ; Removing and installing wheel housing liner . Remove bolts from filler neck -arrows-.
Disconnect fuel lines at front right of fuel tank. Note
If vehicle has supplementary heating, separate connector to metering pump and unclip wire. Supplementary heating; Rep. gr. 82 ; Removing and installing metering pump -V54 Remove bolts -A- and remove heat shield for fuel tank. Support fuel tank using engine and gearbox jack -V.A.G 1383/ A- . Remove securing bolts -B- and remove retaining strap. Slowly lower fuel tank and pull it forwards. Tilt fuel tank to get it past rear axle. Installing
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Ensure that fuel hose connections are tight. Do not interchange supply and return lines (return line blue or with blue markings, supply line black). Clip supply and return lines onto fuel tank.
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Install breather and fuel hoses free of kinks.
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Install in reverse order. In the process, note the following:
181
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4.4
1 - Fuel filter upper part Observe various types page 183 2 - Fuel temperature sender G81 Installed in engine re turn line 3 - Seal Renew. 4 - Filter insert Observe change inter vals. 5 - Seal Renew. 6 - Fuel filter lower part 7 - 8 Nm
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10 - Retaining clip Check for secure seat ing. 11 - Connection for fuel tem perature sender -G8112 - From tandem pump.
182
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9 - Seal Renew.
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8 - Retainer
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4.4.1
Type A page 183 Type B page 183 Fuel filter upper part, 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 tank supply line, white or white marking. Check for secure seating. 4 - Fuel tank return line, blue or blue marking. Check wagesecure for olks yV seating. db
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6 - Fuel return line from engine, blue or blue marking. Check for secure seating. Fuel filter upper part, type B 1 - 5 Nm
2 - Fuel tank return line, blue or blue marking. Check for secure seating. 3 - Fuel tank supply line, 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

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Torque wrench -V.A.G 1331/-
Removing Note safety precautions before starting work page 150 . Observe rules for cleanliness page 151 .
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183
The fuel cooler is located in the return line to tank. It is located on the vehicle underbody.
Remove underbody panel. Remove securing nuts Installing
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Separate fuel lines at fuel cooler.
Install in reverse order. In the process, note the following: Tighten fuel cooler securing nuts to 15 Nm.
4.6
Special tools and workshop equipment required Union nut tool -3217-
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Torque wrench -V.A.G 1332-
Removing Observe safety precautions page 150 . Observe rules for cleanliness page 151 . First check whether a coded radio is fitted. If so, obtain antitheft coding.
184
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Disconnect earth strap from battery with ignition switchedks Vol off by Electrical system; Rep. gr. 27 ; Disconnecting iand recon ed rs necting battery . ho ut
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WARNING
Unscrew union nut with union nut tool -3217- wrench . Pull fuel delivery unit and seal out of opening in fuel tank. Note
If delivery unit is to be renewed, drain old delivery unit before dis posal.
Installing Installation of fuel delivery unit is carried out in reverse order.
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
livery unit.
Ensure that fuel hose connections are tight. After installing fuel delivery unit, check that supply, return and
breather lines are still clipped onto fuel tank.
Note installation position of fuel delivery unit flange: mark on
flange must align with mark -arrows- on fuel tank.
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185
4.7
Removing
Remove fuel delivery unit page 184 Release connector lugs on lines -3-nand Volkswagepull off. -4- and n AG e AG.
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Insert fuel gauge sender into guides on fuel delivery unit and press upwards until it engages.
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4.8
Checking fuel pump
Note
4.8.1

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Special tools and workshop equipment required Pressure gauge -VAS 6550 Vehicle diagnosis tester Test prerequisite: Fuses must be OK.
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Battery voltage at least 12 V All electrical consumers, e.g. lights and rear window heating, must be switched off.
186
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Separate quick release coupling -A- (black or black marking) of fuel supply line. Connect pressure tester -VAS 6550- with cables -VAS 6550/1and -VAS 6550/2- to open ends of fuel supply line. Switch on pressure tester -VAS 6550- by pressing On/Off button. Open shut-off taps A and B of pressure tester and close shut-off tap C. Start engine and run at idling speed. Read pressure on pressure tester -VAS 6550- . Specification: min. 0.5 bar.
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If the delivery pressure temporarily drops, renew fuel delivery unit page 210 . If the specifications are attained, check tandem pump to en sure the fuel filter is not blocked page 225 . If the tandem pump values are OK, check fuel pump delivery rate page 187 .
or Increase idling speed toth2500 rpm and read the pressure on au pressure tester -VASss6550- , specification min 0.25 bar.
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4.8.2
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.
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Battery voltage at least 12 V All electrical consumers, e.g. lights and rear window heating, must be switched off.
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Note
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187
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Separate quick release coupling -A- (black or black marking) of fuel supply line. Connect -VAS 6550/1- pressure tester line to fuel supply -A-. Guide open end of line into measuring container. Connect diagnosis tester and perform the Checking electric fuel pump(s). Note
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After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s. If the specification is not attained: Check fuel supply line between fuel pump and engine com partment for kinks, crushes or damage. If necessary, renew defective line and repeat test. If it is not kinked, crushed or damaged, remove rear seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats . Detach carpet under seats and fold it back. General body repairs, interior; Rep. gr. 70 ; Load and luggage compartment trim; Removing and installing luggage compartment floor Remove cover from fuel delivery unit. Note

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Pull fuel supply line (black, or black marking) -A- off fuel de livery unit. Connect -VAS 6550/1- pressure tester line to fuel supply -A-. Guide open end of line into measuring container. Connect diagnosis tester and perform the guided function Checking electric fuel pump(s). Note

4.8.3
Special tools and workshop equipment required Hand-held multimeter -V.A.G 1526D Pickup clamp -V.A.G 1526B/2-
188
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Press in securing ring to release fuel line.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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 battery charger. All electrical consumers, e.g. lights and rear window heating, must be switched off. AG. Volkswagen A
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k Remove seat bench General body repairs, interior; Rep. gr. Vol by ed 72 ; Rear seats . ris
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:
u Detach carpet under seats and fold it back. General body sa repairs, interior; Rep. gr. 70 ; Load and sluggage compartment trim; Removing and installing luggage compartment floor
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Pull connector off fuel delivery unit flange. Connect test instrument adapter/DSO (5-pin) -VAS 5565- be tween connector and flange.
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189
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Connect hand-held multimeter -V.A.G 1526D- to contacts -1and -5- of adapter. Connect diagnosis tester and perform the guided function Checking electric fuel pump(s). Note

gen Read voltage value on hand-held multimeterlk-V.A.G 1526D- : swa Vo y Specification = battery voltage. db
If no voltage is present:
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Voltage supply OK:
Remove fuel delivery unit page 210 Check that electrical wiring between flange and fuel pump is connected and has continuity. If no open circuit can be found: Renew fuel delivery unit.
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4.8.4
Special tools and workshop equipment required Hand-held multimeter -V.A.G 1526D- or pickup clamp -V.A.G 1526B/2 Vehicle diagnosis tester Note
Test instrument adapter/DSO (5-pin) -VAS 5565-
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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.
190
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pull connector -C- off flange.
Connect test instrument adapter/DSO (5-pin) -VAS 5565- to connector and fuel delivery unit. Connect pick-up clamp -A- to red terminal with lettering pickup clamp for test instrument adapter/DSO (5-pin) -VAS 5565- . Note
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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 210 .
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191
Parts of fuel supply system (Passat)
Safety precautions page 150 . Rules for cleanliness page 151 . Fuel tank, vehicles with four-wheel drive page 192 . Emptying fuel tank, vehicles with four-wheel drive page 202 Fuel tank, vehicles with front-wheel drive page 206 . Emptying fuel tank, vehicles with front-wheel drive page 213 Checking fuel pump page 215 . Assembly overview - fuel filter page 219 . Removing and installing fuel cooler page 221 .
5.1 5.1.1
Fuel tank, vehicles with four-wheel drive Assembly overview - fuel gtank. Volkswagen AG does en AG swa
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2 - Locking ring, 110 Nm Check for secure seat ing. Remove and install us ing wrench -T10202- . 3 - Cap Renew if damaged. 4 - Securing bolt, 1.5 Nm
1 - Supply line Clipped onto fuel tank.ss Check for secure seat ing.

6 - 10 Nm
8 - Pressure retention valve with connecting hose To remove, grasp se curing ring (grey) and pull off upwards. Check for secure seat ing. From activated charcoal filter, assembly overview - activated charcoal filter system
192
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7 - Earth connection Check for secure seat ing.
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5 - Tank flap unit With rubber cup. Removing and installing General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Remov ing and installing fuel tank flap unit .
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th 10 - Suction-jet pump au ss Clipped onto fuel gauge sender 2 -G169 Removing and installing page 201 .
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11 - 25 Nm Renew. 12 - Seal Renew. When installing, fit dry in fuel tank opening. Moisten with fuel only when installing flange.
13 - Fuel gauge sender 2 -G169 Note installation position on fuel tank page 194 . Removing and installing page 198 . 14 - Fuel tank Emptying fuel tank page 202 . Removing and installing page 194 . 15 - Heat shield Bolted with clamping washers.
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16 - 25 Nm Renew. Bolt to secure securing strap, heat shield and supports for centre silencer. Secure support for centre silencer to body. 17 - Securing strap 18 - Breather line Clipped onto fuel tank. Check for secure seating. 19 - Fuel delivery unit Removing and installing. With fuel gauge sender -G- . Removing and installing fuel gauge sender -G Clean strainer if soiled. 20 - Flange with fuel filter With 6-bar pressure limiting valve. Note installation position on fuel tank page 194 . Removing and installing.
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5. Parts of fuel supply system (Passat)
193
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Installation position of flange for fuel delivery unit and fuel gauge sender 2 -G169The marking on the flange must align with the marking on the fuel tank -arrow-. Note

A - Fuel delivery unit flange B - Fuel gauge sender 2 -G169- flange
5.1.2

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Removing Note The rear axle must be lowered to remove the fuel tank. Note safety precautions before beginning work page 150 . Observe rules for cleanliness page 151 . Assembly overview - fuel tank page 192 . If necessary, empty fuel tank using fuel extractor -VAS 5190 page 202 . Remove seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats . Remove cover from fuel delivery unit.
194
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pull 5-pin connector -arrow- off flange. Note
For vehicles with auxiliary heater the metering pump -V54- con nector must be separated additionally.
Disconnect connector to four-wheel drive control unit -J492-arrow-. Unclip sealing grommet -1- downwards out of cover and guiden AG. Volkswagen AG e does wiring harness of four-wheel drive control unit -J492- out wag ks not Vol gu by downwards. ara d e
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Remove cover -1- and pull 3-pin connector -arrow- off flange. Remove rear right wheel. Remove rear right wheel housing liner General body re pairs, exterior; Rep. gr. 66 ; Wheel housing liner .
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Unclip electrical wire on filler neck.
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Unscrew tank flap unit securing bolt and remove tank flap unit General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and installing tank flap unit .
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195
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Unbolt filler neck from body -arrows-. Remove front left and right underbody panels from underbody.
Separate return line -1- and supply line -2- at connections. Pull connector -arrow- off metering pump -V54- .
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Remove tunnel bridge from underbody -arrows-.

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Remove heat shields below propshaft.

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Remove rear propshaft tube Final drive 02D, 0AV; Rep. gr. 39 ; Overview - repairing propshaft .
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Remove heat shield below fuel tank. WARNING

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Separate breather line (white) -1- and fuel line (black) -2- at connections. Note Press in securing ring to release fuel line. For vehicles with auxiliary heater the fuel line of the metering
pump -V54- must be separated additionally.
196
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Unclip brake lines -arrow- on left from body. Support rear axle using engine and gearbox jack -V.A.G 1383 A- .
Remove securing bolts -arrows- and lower rear axle.
Unscrew securing bolts for securing straps and fuel tank -arrows-. First support fuel tank with engine and gearbox jack -V.A.G 1383 A- . Slowly lower fuel tank and unclip wiring on fuel tank from fourwheel drive control unit -J492- . Note
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.
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- .
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Clip in wiring on fuel tank for four-wheel drive control unit J492- -arrows-.
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197
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Raise fuel tank slowly up to installation position and secure it in place. Secure rear axle to body again Running gear, axles, steer ing; Rep. gr. 42 . The remaining installation steps are carried out in the reverse se quence. In the process, note the following:
Observe installation position of covers -arrows-: The -arrows- on the covers point forwards. A - Fuel delivery unit cover B - Cover for fuel gauge sender 2 -G169 Install breather and fuel lines free of kinks. Ensure that line connections are tight. Check earth connection on fuel tank and body to filler neck. Specified torques: Component Fuel tank to body Tunnel bridge to underbody Filler neck to body
1)
Nm 251) 23 10
Renew.
5.1.3
Special tools and workshop equipment required Special wrench -T10202-
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Removing and installing fuel gauge sender 2 -G169-
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198
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n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se i , GolforPlus 2005 , Passat 2006 , Touran 2003 tee h t or diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 ac au ss
Removing Prerequisites:
Fuel tank must not be more than 1/2 full. Note
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Assembly overview - fuel tank page 192 .
Ensure float arm of fuel gauge sender 2 -G169- is not bent. If necessary, empty fuel tank using fuel extractor -VAS 5190 page 202 . Remove seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats . Disconnect connector to four-wheel drive control unit -J492-arrow-. Unclip sealing grommet -1- downwards out of cover and guide wiring harness of four-wheel drive control unit -J492- out downwards.
Remove cover -1- and pull 3-pin connector -arrow- off flange.
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Observe rules for cleanliness page 151 .
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199
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Open locking ring using wrench -T10202- .
Pull fuel gauge sender 2 -G169- upwards slightly and unclip locking lugs -arrows- of suction-jet pump. Installing
n AG. Volkswagen AG do es n wage ot g olks yV ua db ran Caution se tee ri ho t or ac au ss installing do not bend fuel gauge sender 2 -G169- float
When arm.
Place fuel gauge sender 2 -G169- in fuel tank.
Fit suction-jet pump on sender on inside of fuel tank. Suctionjet locking lugs -arrows- must engage. The remaining installation steps are carried out in the reverse se quence. In the process, note the following: Moisten seal with fuel only when installing flange.
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Observe installation position of flange -B-:

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The marking on the flange must align with the marking on the fuel tank -arrow-.
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Note

B - Fuel gauge sender 2 -G169- flange Tighten locking ring using wrench -T10202- . Specified torque: 110 Nm.
200
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Observe installation position of cover -B-: The -arrow- on the cover points forwards. B - Cover for fuel gauge sender 2 -G169-
5.1.4
Removing and installing suction-jet pump
Note On vehicles with four-wheel drive, fuel has to be pumped from
the area of fuel gauge sender 2 -G169- to the fuel delivery unit by means of a suction-jet pump due to the shape of the fuel tank. of fuel, even though the fuel gauge shows that the tank is still 1/4 full.
Checking is only necessary when the engine stops due to lack
Special tools and workshop equipment required Special wrench -T10202un le
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201
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Removing suction-jet pump Note
Disconnect fuel lines -1 and 2- to suction-jet pump, removing and installing fuel delivery unit. Remove fuel gauge sender 2 -G169- page 198 . Now the suction-jet pump can be pulled out from side of 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. Installing suction-jet pump Installation is performed in the reverse sequence. In the process, note the following: Fuel lines are to be installed free of kinks. Ensure that line connections are tight.
Assembly overview - fuel tank page 192 .
n AG. Volkswagen AG do es n wage ot g olks V ua b Note safety precautions before beginning work dypage 150 . ran se tee ri ho or Observe rules for cleanliness page 151 u.t ac a ss

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Special wrench -T10202-
202
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Fuel extractor -VAS 5190-
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5.2
Emptying fuel tank, vehicles with fourwheel drive
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Note safety precautions before beginning work page 150 . Emptying fuel tank if it is more than 3/4 full page 203 . Emptying fuel tank if it is less than 3/4 full page 203
5.2.1
Use insulating tape to mark the extraction hose -arrow- at a distance of -a- = 990 mm from the end of the hose. Remove filler cap from fuel tank filler neck. Push extraction hose into fuel tank until marking on hose co incides with filler neck.
n AG. Volkswagen AG do es n wage ot g olks V ua by The shaft piece -1- is not used. ran ed is tee or th or u There is a flap on theabottom end of the fuel filler neck in the ac ss fuel tank, this must not be damaged by the extraction hose.
Note
Therefore, only push the hose in as far as the marking.
Drain fuel tank as much as possible through fuel filler neck. Carefully pull out extraction hose. Note
When no more fuel can be extracted, tank is emptied suffi Emptying the fuel tank completely page 203 .
ciently for flange to be opened without danger. The tank may be removed while containing remaining fuel.
5.2.2
Remove seat bench General body repairs, interior; Rep. gr. 72 ; Rear seats .
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Note
Draining fuel tank at fuel delivery unit flange page 203 Draining fuel tank at fuel gauge sender 2 -G169- flange page 204 Draining fuel tank at fuel delivery unit flange Remove cover from fuel delivery unit.
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To drain fuel tank completely: fuel must be extracted from fuel delivery unit flange and also from fuel pump sender 2 -G169flange.
AG.
203
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 WARNING
n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au Wear eye protection and pro ss
Fuel supply line is pressurised. tective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connec tion. Then release pressure by carefully pulling hose off con nection.
Pull 5-pin connector -A- and fuel line -B- off flange. Note
Press in securing ring to release fuel line. On vehicles with auxiliary heater the connector and the fuel
line of the metering pump -V54- must also be separated.
Open locking ring using wrench -T10202- . Insert extraction hose of fuel extractor -VAS 5190- as deeply as possible into fuel tank and extract fuel.
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Drain fuel tank at fuel gauge sender 2 -G169- flange page 204 . Draining fuel tank at fuel gauge sender 2 -G169- flange
Disconnect connector to four-wheel drive control unit -J492-arrow-. Unclip sealing grommet -1- downwards out of cover and guide wiring harness of four-wheel drive control unit -J492- out downwards.
Remove cover -1- and pull 3-pin connector -arrow- off flange.
204
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Lift flange.
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Open locking ring using wrench -T10202- . Lift flange. Insert extraction hose of fuel extractor -VAS 5190- as deeply as possible into fuel tank and extract fuel. If fuel tank needed only to be emptied, install flanges with covers again page 205 . Installing flanges with covers Installation is performed in the reverse sequence. In the process, note the following: Moisten seal with fuel only when installing flange. Ensure that line connections are tight. Observe installation position of flanges -arrows-: The marking on the flange must align with the marking on the fuel tank -arrows-. Note

A - Fuel delivery unit flange B - Fuel gauge sender 2 -G169- flange Tighten locking ring using wrench -T10202- . Specified torque: 110 Nm.
. olkswagen Observe installation position ofacoversV-arrows-: AG do gen AG
b point forwards. The -arrows- on the covers y V ed

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B - Cover for fuel gauge sender 2 -G169-
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205
5.3
Fuel tank, vehicles with front-wheel drive Assembly overview - fuel tank
n AG. Volkswagen AG do es n wage ot g olks V ua by d2005 , Passat 2006 , Touran 2003 ran , Golf Plus se te ri ho t diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 e or a au c ss
5.3.1
1 - Cap 2 - 1.5 Nm
3 - Tank flap unit With rubber cup. Removing and installing General body repairs, exterior; Rep. gr. 55 ; Tank flap unit 4 - Earth connection Check for secure seat ing. 5 - Elbow 6 - 10 Nm
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8 - Securing strap Note installation posi tion. 9 - Heat shield For fuel tank. 10 - Lock washer, 2.5 Nm 11 - 25 Nm Renew. 12 - Metering pump -V54For auxiliary 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 210 . Checking fuel pump page 215 . Removing and installing fuel gauge sender page 212 .
206
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7 - Fuel tank When removing, sup port using engine and gearbox jack -V.A.G 1383/A- . Removing and installing page 207 . Emptying fuel tank page 213 .
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 15 - Suction-jet pump Clean strainer if soiled. Not necessarily installed 16 - Flange For fuel delivery unit. Note installation position of flange on fuel tank page 207 . 17 - Locking ring, 110 Nm Check for secure seating. Remove and install using wrench -3087- . 18 - Supply line 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. 19 - Return line From fuel cooler. Blue or with blue marking. Clipped onto fuel tank. Check for secure seating. To pull off flange, press release button on connecting piece. 20 - Supply line AG. Volkswagen AG d To fuel filter. agen oes not lksw Vo gu by ara Clipped onto fuel tank. d nte ise or eo Check for secure seating. th u ra a c ss Black To pull off flange, press release button on connecting piece. Installation position of fuel delivery unit flange Marking -4- on flange points opposite direction of travel. Note
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Flange of fuel delivery unit can be installed only in this position.

Connect black supply line -1- with -arrow- to union on flange. Return line -2- (blue or with blue marking) to connection marked -R-.
Black supply line -3- to metering pump -V54- for auxiliary heater. Note
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5.3.2
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After installing fuel delivery unit flange, check that fuel lines are still clipped onto fuel tank.
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207
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Torque wrench (550 Nm) -V.A.G 1331-
Removing Note The rear axle

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Before disconnecting battery, open fuel tank flap and if nec

essary remove wheel bolt lock adapter from luggage compart ment.
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n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au be lowered to remove the fuel tank. must ss
Note safety precautions before beginning work page 150 . Observe rules for cleanliness page 151 . Note
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 seat .
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Unscrew securing bolt and remove tank flap unit with rubber cup General body repairs, exterior; Rep. gr. 55 ; Tank flap unit . Empty fuel tank page 213 . 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-.
n AG. Volkswagen AG do engine (2.0 l engine, 4-cylinder diesel s n e wage ot g olks V ua by ran ed is Pull 5-pin connector -5- off fuel delivery unit flange. tee or th or ac au Open fuel tank filler flap. ss
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4 valve) - Edition 02.2011

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Unclip ABS sensor wiring on fuel tank filler neck -arrows-. Remove underbody panel. WARNING
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Separate return line -1- and supply line -2- at connections. Separate fuel line -3- for metering pump -V54- at connections. 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- .
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209
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Remove securing bolts -arrows- and lower rear axle. Then support fuel tank using engine and gearbox jack -V.A.G 1383 A- .
Remove securing strap bolts. Slowly lower fuel tank. When doing this, pull fuel tank forwards, turn and guide filler neck between rear axle and body. Installing Install in reverse order. When doing this, 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 and return lines (return line blue or with blue markings, 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.
5.3.3

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Fuel tank sender unit tool -3087-
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210
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Torque wrench (40200 Nm) -V.A.G 1332n AG. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au ss
Removing
Note safety precautions before beginning work page 150 . Observe rules for cleanliness page 151 . 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 fuel delivery unit. Empty fuel tank if necessary page 213 .
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Remove rear bench seat General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing bench seat . Pull supply line -1-, return line -2-, supply line -3- to metering pump -V54- and 5-pin connector -5- off fuel delivery unit flange. Note
AG.
Open locking ring using fuel tank sender wrench -3087- . Lift sender flange.
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211
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pull fuel line -1- off suction-jet pump (if fitted). Note

Press tab -2- of suction-jet pump in -direction of arrow- and unclip from fuel delivery unit Pull fuel delivery unit along with suction-jet pump out of open ing in fuel tank. Note
If delivery unit is to be renewed, drain old delivery unit beforewage dis olks yV posal. db
Installing
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Installation of fuel delivery unit is carried out in reverse order.

Note
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For fuel delivery units of the new generation the suction jet
pump is no longer available. If the fuel delivery unit is to be renewed, remove suction jet pump. er is not bent. fuel tank.
When inserting fuel delivery unit, ensure that fuel gauge send Insert seal for flange or fuel delivery unit dry into opening of Moisten seal with fuel only when installing flange or fuel de
livery unit.
Fuel lines are to be installed free of kinks.
with blue markings, supply line black).
Do not interchange supply and return lines (return line blue or Ensure that fuel hose connections are tight. Connections for fuel lines must engage audibly when joined.
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clipped onto fuel tank. page 207 .
Observe fitting position of fuel delivery unit flange
5.3.4
Removing
Remove fuel delivery unit page 210 .
212
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After installing fuel delivery unit, check that fuel lines are still
AG.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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 210 .
5.4
Special tools and workshop equipment required Fuel tank sender unit tool -3087-
Emptying fuel tank, vehicles with frontwheel drive
Fuel extractor -VAS 5190-
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Torque wrench (40200 Nm) -V.A.G 1332Emptying fuel tank if more than 3/4 full page 213 Emptying fuel tank if less than 3/4 full page 214
5.4.1
Procedure
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213
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Use insulating tape to mark the extraction hose -arrow- at a distance of -a- = 990 mm from the end of the hose. Open fuel tank filler flap. Push suction hose of fuel extractor -VAS 5190- into fuel filler neck until the previously made marking aligns with fuel filler neck. Note The shaft piece -1- is not used. A flap is located on the lower end of the fuel filler neck, this
must not be damaged by the extraction hose. Therefore, push the extraction hose into the fuel filler neck only up to previously made marking.
Empty fuel tank as far as possible. Then carefully remove extraction hose. Note
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.
5.4.2
Procedure
Note safety precautions before beginning work page 150 . Remove rear bench seat General body repairs, interior; Rep. gr. 72 ; Rear seat; Removing and installing bench seat . Remove cover from fuel delivery unit. WARNING
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Pull supply line -1-, return line -2-, supply line -3- to metering pump -V54- and 5-pin connector -5- off fuel delivery unit flange. Note
214
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Open locking ring using fuel tank sender wrench -3087- . Lift sender flange. Insert extraction hose of fuel extractor -VAS 5190- as deeply as possible into fuel tank and extract fuel. If fuel tank needed only to be emptied, reinstall sender flange page 210 .
n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or Golf 2004 , Golf Plus 2005 , Passat 2006 ac au ss
, Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011
5.5
Note
Checking fuel pump
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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- (black or 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. 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 210 . If the specifications are attained, check tandem pump to en sure the fuel filter is not blocked page 225 . If the tandem pump values are OK, check fuel pump delivery rate page 216 .
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5.5.1
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215
5.5.2
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
Separate quick release coupling -A- (black or black marking) of fuel supply line. Connect -VAS 6550/1- pressure tester line to fuel supply -A-. Guide open end of line into measuring container. Connect diagnosis tester and perform the guided function Checking electric fuel pump(s). Note
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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 Remove cover from fuel delivery unit. Note
216
AG.
After fuel flow, read quantity of fuel delivered on measuring container, specification: min. 1000 ml/30 s.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pull fuel supply line (black, or black marking) -A- off fuel de livery unit. Connect -VAS 6550/1- pressure tester line to fuel supply -A-. Guide open end of line into measuring container. Connect diagnosis tester and perform the guided function Checking electric fuel pump(s). Note

5.5.3
Special tools and workshop equipment required Hand-held multimeter -V.A.G 1526D Pickup clamp -V.A.G 1526B/2 Test instrument adapter/DSO (5-pin) -VAS 5565-
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Test prerequisites Fuses must be OK.
The battery voltage must be at least 12 V, if necessary connect battery charger. All electrical consumers, e.g. lights and rear window heating, must be switched off.
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.
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Switch on ignition. The fuel pump must be heard to run for about 2 seconds. If the fuel pump does not start:
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Pull connector off fuel delivery unit flange.
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AG.
217
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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 diagnosis tester and perform the guided function Checking electric fuel pump(s). Note

Read voltage value on hand-held multimeter -V.A.G 1526D- : Specification = battery voltage. If no voltage is present: Check activation of fuel pump relay and wiring for an open or short circuit Vehicle diagnostic tester. Voltage supply OK: Remove fuel delivery unit page 210
n AG. Vol swag fuel do Check that electrical wiring between flangekand en AGpump is es n wage ot g olks connected and has continuity. yV u
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If no open circuit can be oris found: th
5.5.4
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
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Test prerequisites
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Diesel fuel temperature above 10 C
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.
218
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Battery voltage at least 12 V
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pull connector -C- off flange.
Connect test instrument adapter/DSO (5-pin) -VAS 5565- to connector and fuel delivery unit. Connect pick-up clamp -A- to red terminal with lettering pickup clamp for test instrument adapter/DSO (5-pin) -VAS 5565- . Note
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If the measured value is not within specifications: Renew fuel delivery unit page 210 .
Read current draw on hand-held multimeter -V.A.G 1526D- . Specification: max. 7.5 amps.
5.6
Note
Note that there are different versions of fuel filter upper part page 221
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219
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - Return line To fuel cooler Check for secure seat ing. Blue or with blue mark ing. 2 - 6 Nm 3 - Washer 4 - Supply line From fuel tank. White or with white marking. Check for secure seat ing. 5 - Return line From tandem pump. Blue marking Check for secure seat ing. 6 - Supply line To tandem pump. White marking Check for secure seat ing. 7 - Upper part of fuel filter
8 - Fuel temperature sender G819 - Seal Renew.
10 - Filter insert Observe change intervals. 11 - Lower part of fuel filter 12 - 10 Nm
13 - Connection for fuel temperature sender -G8114 - Retaining clip Check for secure seating.
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15 - O-ring Renew.
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5.6.1
Type A page 221 Type B page 221 Fuel filter upper part, type A
n AG. Volkswagen AG do es n wage ot g olks 1 - 8 Nm yV ua db ran e is tee or 2 - Plug for water extraction (remove and extract aboutth100 cm3 or ac au liquid using hand-operated vacuum pump with accessories ss
V.A.G 1390- and water drainage container -V.A.G 1390/1- , renew seal)
3 - Fuel tank supply line, white or white marking. Check for secure seating. 4 - Fuel tank return line, blue or blue marking. Check for secure seating. 5 - Fuel supply line to engine, white or white marking. Check for secure seating. 6 - Fuel return line from engine, blue or blue marking. Check for secure seating. Fuel filter upper part, type B 1 - 5 Nm
2 - Fuel tank return line, blue or blue marking. Check for secure seating. 3 - Fuel tank supply line, 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.
5.7
Removing Note safety precautions before beginning work page 150 . Observe rules for cleanliness page 151 .
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5 - Fuel supply line to engine, white or white marking. Check for secure seating.
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221
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-. lkswagen A n AG. Vo Installing
G do es n wage ot g olks yV ua db ran e tee ris Install in reverse order. When doing this, note the following: o ho t ra au c s Tighten sfuel cooler securing nuts to 15 Nm.
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6
6.1
Accelerator mechanism
Assembly overview - accelerator mech anism
Removing and installing accelerator mechanism page 223 . 1 - Connector Black, 6-pin. 2 - Accelerator position sender -G79 Not adjustable. The accelerator position sender passes the posi tion of the accelerator on to the engine control unit. -A- openings for release tool Remove footwell cover to remove sender. 3 - 10 Nm 4 - Cap
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Removing and installing accelerator module

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6. Accelerator mechanism
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Release tool -T 10269- (for right-hand drive vehicles T10297- ).
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223
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Torque wrench (550 Nm) -V.A.G 1331-
Removing Lever off cap Item 4 (page 223) using a screwdriver. Remove securing bolt beneath it.
AG do Golf, Golf Plus and Passat: lkswagen A es n ot g Vo ua by d ra To remove accelerator module, push release tool -T 10238-nt ise or vehicles -T10240- ) into opening providedee (for right-hand drive th or ac au to stop. ss
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Touran:
To remove accelerator module, push release tool -T 10269(for right-hand drive vehicles -T10297- ) into opening provided to stop. Continuation for all vehicle types: Pull connector off accelerator module. Pull wiring guide off accelerator pedal module. Pull out accelerator module vertically. Installation is carried out in the reverse order. When installing, note the following: Attach connector and wiring guide to accelerator module. Press accelerator module onto securing pins. Insert centring pin into hole in vehicle floor. Secure accelerator module with securing bolt -3-. Specified torque: 9 Nm Attach cap. Install steering column cover.
AG.
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Installing
Tandem pump
Checking tandem pump page 225 . Removing and installing tandem pump page 227 .
7.1
Checking tandem pump
Checking delivery pressure page 225 Checking for internal leaks page 226
7.1.1
Checking delivery pressure
Special tools and workshop equipment required 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.
Procedure Remove air filter housing. Remove plug -arrow-.

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Connect tandem pump tester -VAS 5187- if necessary, with adapter -VAS 5187/7- or banjo bolt with seal -VAS 5187/1Aas shown. Remove air filter housing again. Start engine and raise engine speed to 4000 rpm. Observe pressure indicated on pressure gauge. Specification: min. 10.5 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. Repeat check. If specification is now obtained: Tandem pump is OK. Renew unit injector O-rings page 257 . If the specification is not attained: olkswag
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After removing pressure tester, tighten plug to 25 Nm. Always renew seal.
Note
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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, for example 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 Tester -V.A.G 1687r fo ng
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Procedure Pull fuel supply hose (white marking) and fuel return hose (blue marking) off tandem pump. Seal fuel return union on tandem pump with a plug. Secure sealing plug with a spring-type clip. Prepare test unit -V.A.G 1687- as follows: Unscrew pressure regulating valve -2- and close valves -3and -4-. Connect test connection -5- to fuel supply union of tandem pump using a commercially available compressed air connec tion and a section of fuel hose. Use a spring-type clip to secure. Note
To turn the pressure regulating valve -2- the knob must be pulled upwards.
Connect compressed air hose -1- (compressed air source) to charge air system tester -V.A.G 1687- . Note
If
Adjust pressure to 1.0 bar with pressure regulating valve -2-. Caution
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The maximum test pressure is 1.3 bar and this must not be exceeded.
Open valve -4- and wait until the test circuit is filled. If neces sary readjust pressure to 1.0 bar. Close valve -3- to retain pressure and observe the pressure drop over a period of 1 minute. If the pressure does not drop the tandem pump can be reused, if the pressure drops the tandem pump must be renewed.
7.2
Removing and installing tandem pump

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DANGER!
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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.
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7. Tandem pump
227
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Special tools and workshop equipment required Torque wrench -V.A.G 1331agen Hand vacuum pump with lksw accessories -V.A.G 1390- d by Vo
ho Water drainage container ut V.A.G 1390/1sa s
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Spring-type clip pliers -VAS 5024 A-

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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 -2-. Operate hand vacuum pump until no more fuel comes out of return hose. Be careful that no fuel is sucked into hand vacuum pump. Remove air filter housing page 5 .
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pull vacuum line -1- off tandem pump -4-. Pull supply hose -2- (white marking) and return hose -3- (blue marking) off tandem pump -4-.
Remove securing bolts -arrows-. Remove tandem pump -4- from cylinder head.
7.2.2
Installing
Installation is carried out in the reverse order. When installing, note the following: Note
.V Ensure that tandem pump coupling seats properlyeinAcam g n G swa
shaft.
Always renew tandem pump
Install tandem pump and tighten securing bolts to 20 Nm.

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Attach return hose (blue marking) to return connection -3- of tandem pump. Attach supply hose (white marking) to supply connection -2and vacuum hose -1- from brake servo to tandem pump. Attach supply hose -1- (white marking) to fuel filter. Connect hand vacuum pump with accessories -V.A.G 1390and water drainage container -V.A.G 1390/1- to return hose -2- (blue marking) of fuel filter. Operate hand vacuum pump until fuel comes out of return hose. Be careful that no fuel is sucked into hand vacuum pump. Attach return hose (blue marking) to fuel filter. Perform leak test page 226 .
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7. Tandem pump
229
21
1
Turbocharging/supercharging
Charge air system with turbocharger
Safety precautions page 230 . Rules for cleanliness page 230 . Hose connections with push-on connectors page 231 Assembly overview - turbocharger with attachments page 232 Assembly overview - parts of charge air cooling page 237 . Checking charge air system for leaks page 238
1.1
Safety precautions
WARNING
Route all the various lines (e.g. for fuel, hydraulics, acti vated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original po sitions. Ensure that there is sufficient clearance to all moving or hot components.
Observe following if test and measuring instruments are required 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.
When doing any repair work, especially in the engine compart ment, pay attention to the following due to the cramped condi tions:

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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.
230
Rep. gr.21 - Turbocharging/supercharging
AG.
Thoroughly clean all unions and surrounding areas before dis connecting.
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When working on the turbocharger, pay careful attention to the following rules for cleanliness:
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1.3 1.3.1
Hose connections
Installing hose connections with con nector couplings

Caution
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The seal in the plug-in connector can be damaged if the se curing clip is in the locked position when fitting the connector. This can cause leakage. Observe installation instructions.
Removing
Release plug-in connector by pulling out retaining clip -arrow-. Separate hose/pipe without tools. Installing If renewed, place 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.
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Bring securing clip to locking position -2- and then push charge air hose again. Check if connector coupling seats correctly and is properly engaged by pulling hose.
1. Charge air system with turbocharger
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1.3.2
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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. angled grinder) and must be renewed by a replacement part according to ETKA (electronic parts catalogue) .
1.4
Assembly overview - turbocharger with attachments

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Caution
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 charg ed air routing must be cleaned and the charge air cooler must be renewed, if necessary.
Engine codes AZV, BKD, BKP, BMA, BVE and BWV page 232 Engine codes BMN, BMR and BUZ page 234
1.4.1
Note
Engine codes AZV, BKD, BKP, BMA, BVE and BWV
All hose connections are secured. Charge air system must be free of leaks. Renew self-locking nuts. Before screwing on oil supply line, fill turbocharger at connection with engine oil. After installing turbocharger, run engine for about 1 minute at idling speed to ensure that oil is supplied to
turbocharger.
232
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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:
AG.
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Observe rules for cleanliness page 230 . Observe safety precautions page 230 . 1 - Seal Renew. 2 - To bypass flap 3 - 25 Nm Renew. 4 - Connecting pipe To exhaust gas recircu lation cooler. 5 - Retainer For oil supply line. 6 - 10 Nm 7 - Oil supply line Removing and installing page 123 . 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. 8 - Union nut, 22 Nm 9 - Union nut, 22 Nm 10 - Connection, 30 Nm 11 - Seal Renew. 12 - Seal Renew. Note installation posi tion. 13 - Turbocharger Can only be renewed together with exhaust manifold and vacuum unit. To remove turbocharger, first remove right drive shaft at gearbox Running gear, axles, steering - front and four-wheel drive; Rep. gr. 40 ; Repairing drive shafts; Removing and installing drive shafts . 14 - Support Between turbocharger and cylinder block. 15 - 40 Nm First hand tighten all bolts 16 - Oil return line To cylinder block. 17 - Connection, 40 Nm 18 - 20 Nm 19 - 20 Nm First hand tighten all bolts

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 20 - Heat shield 21 - 20 Nm
1.4.2
Note
Engine codes BMN, BMR and BUZ
All hose connections are secured. Charge air system must be free of leaks. Renew self-locking nuts. Before screwing on oil supply line, fill turbocharger at connec
tion with engine oil. idling
gen After installing turbocharger, run engineswagen AG. 1 minute AG does for about at
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Observe
1 - 10 Nm 2 - Retainer 3 - Heat shield
Observe safety precautions page 230 .
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to turbocharger.

4 - Oil supply hose To oil supply line con nection on turbocharg er. Before installing oil sup ply line, ensure that it is not blocked. Before installing, fill tur bocharger via oil supply hose with engine oil 5 - Turbocharger With position sender for charge pressure posi tioner -G581- . Can only be renewed with exhaust manifold. Removing and installing page 235 . 6 - Vacuum hose 7 - Seal Renew. Note installation posi tion. 8 - To particulate filter 9 - Clamp, 7 Nm For turbocharger/partic ulate filter 10 - Exhaust manifold Can only be renewed together with turbocharger
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 11 - 25 Nm Renew. 12 - Connecting pipe To exhaust gas recirculation cooler 13 - Seal Renew. 14 - 25 Nm Renew. 15 - 25 Nm 16 - 15 Nm 17 - O-ring Renew. 18 - Banjo bolt, 60 Nm On vehicles with four-wheel drive covered by bevel box. 19 - Support For turbocharger. With oil return line 20 - Exhaust gas temperature sender 1 -G235-lk,swa Nm 45 gen AG AG. Vo agen Lubricate thread of senderousing high-temperature does no -G 052 112 A3- . paste ksw l t gu yV ar d b for temperature sender with angledacable guide page 235 Note installation position nte se ri eo ho with Tool set -T10395- . Remove and install ut ra a 22 - 25 Nm Renew.
21 - Heat shield
ss
23 - Connection For intake hose for air filter/turbocharger Assembly overview - air filter page 259 . 24 - 9 Nm
Installation position of exhaust gas temperature sender with an gled cable guide Note
When installing the exhaust gas temperature sender with an Remove and install with tool set -T10395- .
gled cable guide, it is absolutely necessary to keep to dimen sion -a- of 35 mm when tightening the turbocharger support.
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1.5
Removing and installing turbocharger
Special tools and workshop equipment required Torque wrench -V.A.G 1331-
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235
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Caution
When a mechanical fault is found on the turbocharger, e.g. a destroyed compressor impeller, it is not only sufficient to renew the turbocharger. To prevent this from causing further damage, perform the following repairs: Check air filter housing, air filter element and intake hoses for soiling. Check complete charged air routing and charge air cooler for foreign objects. olkswagen AG en AG. V
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Remove noise insulation tray General body repairs, exteri or; 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 . Continuation for all vehicles: 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.
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Removing
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Remove subframe including steering and right drive shaft Running gear, axles, steering; Rep. gr. 40 . 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. Remove support and oil return line or combi support Item 19 (page 235) for turbocharger. Remove connecting pipe to exhaust gas recirculation cooler. Separate charge pressure line from turbocharger. Pull vacuum hose off turbocharger. Separate oil supply line from turbocharger. Unscrew securing bolts for exhaust manifold. Tilt the engine forwards in lower mounting and remove turbo charger with exhaust manifold downwards. Installing Install in reverse order.
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Remove particulate filter.

1.6
Note
Assembly overview - charge air cooling

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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 . Volkswagen 4-cylinder diesel AG does (2.0 l engine, 4 valve) - Edition 02.2011 engine gen AG swa
When making repairs, remove oil from connection and hose
ends.
All hose connections of charge air system are secured by Charge air system must be free of leaks. Checking charge air system for leaks page 238 Engine codes AZV, BKD, BKP, BMA BVE and BWV page 237 Engine codes BMN, BMR and BUZ page 238
spring-type clips or by connector couplings. Observe installa tion instructions page 231
1.6.1

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Assembly of hose connections page 231 1 - 5 Nm

3 - Charge air cooler To remove, bring lock carrier into service posi tion General body re pairs; Rep. gr. 50 ; Body - front; lock carrier serv ice position . 4 - Connecting hose 5 - 8 Nm 6 - Connecting hose 7 - To turbocharger 8 - Charge air pipe 9 - To intake connecting pipe 10 - Connecting hose 11 - 25 Nm 12 - Charge air pipe 13 - 8 Nm 14 - Charge air pressure send er -G31- with intake air tem perature sender -G4215 - Connecting hose
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2 - Mounting For charge air cooler.
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237
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve)V-olEdition 02.2011 kswagen AG.
1.6.2

Assembly of hose connections 1 - 5 Nm
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AG do es n ot g ua ran tee or ac
2 - Mounting For charge air cooler.
3 - Charge air cooler To remove, move lock carrier to service posi tion Rep. gr. 50 . 5 - Connecting hose 6 - Spring-type clip 8 - 8 Nm 7 - Connecting pipe
4 - To intake connecting pipe
9 - Charge air pressure sender -G31- with intake air tempera ture sender -G4210 - 8 Nm 11 - To turbocharger. 12 - Connecting hose 13 - Connecting hose 14 - 25 Nm 15 - Connecting pipe 16 - Connecting hose
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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-
238
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Remove intake hose -1- from air filter. Connect adapter -1687/10- in intake hose -1- and secure with clip. Prepare charge air system tester -V.A.G 1687- as follows:
Unscrew pressure regulating valve -2- and close valves -3and -4-. Note
To turn the pressure regulating valve -2- the knob must be pulled upwards.
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Connect charge air system tester -V.A.G 1687- to adapter -1687/10- as shown.
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239
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Connect compressed air hose -1- (compressed air source) to charge air system tester -V.A.G 1687- . Note
If there is water in the sight glass, drain at water drain screw -6-.
Open valve -3-. Adjust pressure to 0.5 bar with pressure regulating valve -2-. Caution
The pressure must not exceed 0.5 bar! If the pressure is too high this can cause damage to the engine. . Volkswage
AG agen ksw Vol y db is Open valve -4- and wait untile the test circuit is or sary readjust pressure toth0.5 bar. au ss
filled.
Check the charge air system for leaks by hearing, touching, with commercially available leak detector spray or using ultra sonic tester -V.A.G 1842- . Note
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How to use the ultrasonic tester -V.A.G 1842- operating
instructions
If leaks occur, when doing any repair work observe notes for
charge air system page 237 .
Before removing the adapter, depressurise the test circuit by
pulling coupling off adapter -1687/10- .
1.8
Vacuum hose schematic diagram
Engine codes AZV, BKD, BKP, BMA BVE and BWV page 240 Engine codes BMN, BMR and BUZ page 241
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1.8.1
123456-
Vacuum connection (on non-return valve for brake servo) To exhaust gas recirculation valve (mechanical) To bypass flap. To air filter. To vacuum reservoir To vacuum unit on turbocharger
240
AG.
Connector assignment on solenoid valve block
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1.8.2
1 - Air filter
2 - Charge pressure control solenoid valve -N753 - Cylinder head cover 4 - Non-return valve Note installation posi tion. 5 - Vacuum line to brake servo 6 - Exhaust gas recirculation cooler changeover valve N345urposes, in part or in wh ole, cial p is n mer m ot p r co erm o te itte iva du pr r nl fo e g n
7 - Intake manifold flap air control valve -N316-
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8 - Vacuum unit For changeover for ex haust gas recirculation cooler. 9 - Vacuum unit For changeover for in take manifold. 10 - Vacuum unit On turbocharger. With position sender for charge pressure posi tioner -G581- .

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241
23
1
Note
Mixture preparation - injection

The diesel direct injection system control unit -J248- is equipped with a fault memory. Read fault memory before and after per forming repairs or adjustments Vehicle diagnostic tester.
Safety precautions page 242 . Rules for cleanliness page 243 . Assembly overview - intake manifold with attachments page 244 . Removing and installing pre-wired wiring harness for unit injectors and glow plugs page 246 Assembly overview - unit injector page 251 Removing and installing unit injector page 251
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Diesel direct injection system
Removing and installing O-rings for unit injector page 257 .
WARNING
Observe following if test and measuring instruments are required 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 damage to 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.
242
Rep. gr.23 - Mixture preparation - injection
AG.
1.1
Safety precautions
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Assembly overview - air filter page 259 .
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Cleaning unit injectors (engine codes BMN, BKP and BMR) page 255
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 If the engine is to be turned at starter speed, without starting, e.g. when checking compressions, disconnect unit injector n AG. Volkswagen AG do connector on cylinder head. es wage
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When working on fuel supply and injection system, pay careful attention to the following rules for cleanliness: Thoroughly clean all unions and surrounding 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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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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Also ensure that no diesel fuel runs on to the coolant hoses. Should this occur, the hoses must be cleaned immediately. Damaged hoses must be renewed.
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1. Diesel direct injection system
243
1.3
Assembly overview - intake manifold with attachments
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Engine codes AZV, BKD, BKP, BMA, BVE and BWV page 244 Engine codes BMN, BMR and BUZ page 245
1.3.1
1 - Intake manifold 2 - 20 Nm 3 - Retainer 4 - Seal Renew. 5 - 20 Nm 6 - Cable retainer 7 - From exhaust gas recircu lation cooler 8 - 10 Nm 9 - Connecting pipe 10 - Seal Renew. 11 - 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. 12 - O-ring Renew. 13 - Exhaust gas recirculation valve 14 - 3 Nm 15 - Vacuum reservoir
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1.3.2
1 - 10 Nm 2 - Retainer 3 - 20 Nm
4 - Seal Renew. 5 - Intake manifold With optimised intake air swirl. 6 - Cable retainer 7 - 20 Nm 8 - 10 Nm 9 - Connecting pipe To exhaust gas recircu lation cooler 10 - 20 Nm
11 - Seal Renew. 12 - 10 Nm 13 - 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. 14 - O-ring Renew.
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16 - Vacuum unit For optimised swirl for intake air.
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1.4
Assembly overview - pre-wired wiring harness for unit injectors and glow plugs
1 - Glow plug connector 2 - Stainless steel clips Do not bend open. 3 - Securing bolt Tighten to 10 Nm. 4 - Adapter ring When installing, ensure positioned correctly page 246 . 5 - Central connector When installing, ensure positioned correctly page 246 . 6 - Connector 2-pin For unit injector 7 - Cable channel Remove and install to gether with Item 2 (page 246) .

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Special tools and workshop equipment required Puller -T10312-
246
AG.
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1.5
Removing and installing pre-wired wir ing harness for unit injectors and glow plugs
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Special wrench -T10310-
Removing Caution
. Volks may Removal and installation of the pre-wired wiringnharnesswagen AG do ge AG es n only be undertaken by unscrewing the clips.wa ot g olks Releasing the ca yV ua ble channel at the clips bends the sclips which may break the db ran e tee ri cables due the excessive play. This also applies when chang ho t or ac au ing the unit injectors and all work which does not require the ss central connector to be completely removed.
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-. Remove cylinder head cover page 49 . Disconnect central connector on cylinder head.
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Fit special wrench -T10310- on adapter ring and release it by turning key through 90 (1/4 turn) in -direction of arrow-.
AG.
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247
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pull the securing clip -1- upwards lightly with a screwdriver and press the central connector -2- through inwards.
Slide the puller -T10312- onto the unit injector connector from the side and pull it off in -direction of arrow-. Use pointed pliers 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 Installation is carried out in the reverse order. When installing, note the following: Route pre-wired wiring harness and tighten securing bolts to 10 Nm.
Guide central connector through opening in retaining frame, ensure securing clips -arrows- are seated correctly when do ing this.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Fit adapter ring (colour marked longer stud -arrow- faces 12 o'clock)
Fit special wrench -T10310- on adapter ring and lock it by turning key through 90 (1/4 turn) in opposite -direction of arrow-.
n AG. Volkswagen AG do es n wage ot g olks yV ua short When adapter ringeisbinstalled correctly the colour markedran d s tee rio'clock) er stud faces 12 tho or ac au ss
Note
Fit central connector to cylinder head and lock in position. Install cylinder head cover page 49 .
Fit engine cover.
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1.6
Assembly overview - unit injector
Observe rules for cleanliness page 243 . Always renew O-rings and securing bolts.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - 3 Nm + 90 (1/4 turn) further + 180 (1/2 turn) further Remove using special wrench, long reach T10054- . Renew. 2 - Rocker arm shaft With rocker arms Removing and installing page 251 . 3 - 20 Nm + 1/4 turn (90) fur ther Renew. 4 - Adjuster screw Renew. 5 - Lock nut 6 - Unit injector Removing and installing page 251 . 7 - O-ring Renewing page 257 . 8 - O-ring Renewing page 257 . 9 - Cylinder head

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1.7
Removing and installing unit injector
Special tools and workshop equipment required Universal dial gauge brack et -VW 387 Special wrench, long reach -3410 Special wrench, long reach -T10054 Torque wrench -V.A.G 1331/ Slide hammer -T10133/3 Puller -T10163-
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Assembly tool -2036-
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251
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Valve lever -VW 541/1 A- with press tool -VW 541/5-
Torque wrench -V.A.G 1783-
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Removing
Remove upper toothed belt guard and cylinder head cover. Remove pre-wiring for unit injectors page 246 and place it to side. The central connector of the pre-wiring may remain in the cylinder head. Loosen lock nut of adjustment screw -A- and back out screw until respective rocker arm lies against plunger spring of unit injector. Remove rocker arm securing bolts -51- (from outwards to inwards) using socket -3410- and remove rocker arm shaft. Loosen securing bolts -B- for unit injectors using special wrench -T10054- and remove bolts.
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Pull ball stud out of injector unit.
252
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Insert puller -T10163- in bolt holes on unit injector. Turn spindle -A- down lightly onto the unit injector. Hand-tight en lock nut -B-. Pull unit injector upwards out of cylinder head seat with cau tious taps of slide hammer -T10133/3- . Do not interchange unit injectors which have been used. Installing Caution
Each time work is performed which requires adjustment of the unit injector via adjustment screw, the adjustment screw in the rocker arm and also the unit injector ball stud must be renewed, otherwise excessive wear of the components is the result. . It is absolutely necessary to renew the securing bolts of the unit injector. olksw
Before installing erly seated.
Note
New unit injectors are supplied with O-rings. If old unit injector is reused, O-rings must be renewed
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page 257 .
The seals must not be twisted. Oil the seals and stem of unit injector. Check seat of unit injector in cylinder head for soiling or foreign objects (metal shavings/carbon deposits etc.) and clean with compressed air, if necessary. Insert unit injector into cylinder head with great care. Note
Fit valve assembly device -2036- with securing plates -2036/1on retaining frame of cylinder head as shown. Caution
AG.
If the unit injector is pulled down by the securing bolts, there is a risk of the unit injector not being pulled correctly into its seat. This can result in engine running problems and starting prob lems. For this reason the unit injector may only be secured after it has been pushed in its seat.
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If the securing plates -2036/1- cannot be fitted as described be low, due to the exhaust gas recirculation cooler, use other tools to raise the item, e.g. large washers.
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ag n Golf 2004 , Golf Plus 2005 , Passat 2006 , Touranol2003e ksw yV 4-cylinder diesel engine (2.0 l engine, 4 valve) - Editionb02.2011 ed
Fit the new securing bolts and carefully screw in by stop -arrow- without force.
ris ho ut a hand onto ss

Now fit valve lever -VW 541/1 A- with thrust piece -VW 541/5- . Carefully press unit injector in its seat using valve lever -VW 541/1 A- and maintain this force. Carefully screw in securing bolts of unit injector by hand and without force onto stop using special wrench, long reach T10054- . Tighten new securing bolts as follows: Stage I = 3 Nm Stage II = 1/4 turn (90) further Stage III = 1/2 turn (180) further Note
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Renew adjustment bolts -A- and ball pins of unit injector.

Put rocker arm shaft in place and evenly tighten new securing bolts in the sequence 15 hand tight. Then evenly tighten to 20 Nm and 90 (1/4 turn) further in the same sequence.
Fit dial gauge onto adjustment screw of unit injector as shown. Turn the crankshaft in engine direction of rotation until the roll er of the rocker arm is positioned on the peak of the drive cam. Roller side -arrow A- positioned at highest point. Dial gauge -arrow B- positioned at lowest point. Remove dial gauge. Now turn adjustment screw into rocker arm until a firm resist ance is felt (unit injector positioned at stop).
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Turn adjustment screw 180 back off stop. Hold adjuster screw in this position and tighten lock nut to 30 Nm. Push on unit injector connector and install cylinder head cover and toothed belt guard.
1.8
Cleaning unit injectors (engine codes BMN, BKP, BMA, BUZ and BMR)
Special tools and workshop equipment required Ultrasonic cleaner -VAS 6418 Mounting plate forgunitG. Volkswagen AG d 6418/3en A injectors -VAS
yV Cleaner Tickopur -D 600 300 A2db
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Note
oes not gu ara nte eo ra c

Cleaning the unit injectors may only be carried out using the
support plate for unit injectors -VAS 6418/3- . Under no cir cumstances should the unit injector be immersed in cleaning fluid. have been cleaned.
The unit injectors must be operated within 2 hours after they To reduce the warm-up period of the cleaning fluid, it is rec
ommended that warm tap water is filled into the system and the cover of the unit is fitted. unit injectors per bath.
Change cleaning fluid weekly and only clean max. five sets of Replenish evaporated cleaning fluid with tap water. Do not clean any other components in the cleaning fluid. Do not clean the outside of the unit injectors mechanically
(wire brush, abrasives, etc.).

Renew O-rings, ball studs, adjusting and securing bolts. Procedure

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Attach drain tap -arrow- from ultrasonic cleaner -VAS 6418- to right-hand side of housing. Fill cleaning unit with 1870 ml tap water and 330 ml cleaner Tickopur -D 600 300 A2- .
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Set mounting plate for unit injectors -VAS 6418/3- onto clean ing unit. WARNING
Before starting ultrasonic cleaner -VAS 6418- it is essential that the safety information is observed in the operating instructions. The ideal fluid level is reached when the olkswage agent is ap cleaning .V n AG d g prox. 1-10 mm above the baseen AG oes swa of the support plate.o The olk could become damagednift g ultrasonic cleaner -VAS by V 6418the ua d ran fluid level is too low. rise te
Insert the unit injectors in the guides of the support plate. Switch on cleaner by pressing on/off button -C-. Turn rotary temperature switch -B- until lamp indicator is at 70 C warm-up temperature Set rotary switch for operating period -A- to -arrow- (con tinuous operation).
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Press button -D- for longer than 2 seconds to switch the unit on. Note
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Temperature-controlled cleaning is now activated. During the warm-up period, ultrasonic waves are activated to mix the clean ing fluid. Once the preselected temperature is reached, the ultra sonic waves are switched to continuous operation. Cleaning time must be at least 120 minutes and cleaning only starts at a tem perature of at least 70 C.
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After 120 min. of cleaning, switch the unit off by pressing but ton -D-. Take unit injectors out of mounting plate and dry at ambient air for max. 1 hour. Reinstall unit injectors page 251 . Caution
The unit injectors must be operated within 2 hours after they have been cleaned, to prevent possible corrosion being caused by the cleaning fluid.
256
1.9
Removing and installing O-rings for unit injector

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For unit injectors with solenoid valve:

n AG. equipment required Special tools and workshopVolkswagen AG does wage
y Assemblybsleeve -T10164/1ed
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Assembly sleeve -T10164/2-
For unit injectors with piezo elements (identifying feature: octag onal feature on end of injector): Special tools and workshop equipment required Assembly sleeves -T10308-
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Removing Remove unit injector page 251 . Lever old O-rings very carefully off unit injector using a soft tool. Above all ensure that burrs are not caused on the seating for the O-ring. Installing Note 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. The procedure for both types of assembly sleeves is the same.
Take care to ensure correct allocation of O-rings to grooves. Prevent O-rings from rolling when sliding them on. The O-rings
must not be twisted in their seats in unit injector.
Clean seating surfaces for O-rings on unit injector very care fully.
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Slide assembly sleeve -T10164/1- or assembly sleeve T10308/1- onto stop on unit injector. Push the upper, thicker O-ring carefully onto assembly sleeve and into seat on unit injector. Ensure that it is correctly posi tioned page 258 . Remove assembly sleeve.
Slide assembly sleeve -T10164/2- or assembly sleeve T10308/2- onto stop on unit injector. Slide lower O-ring, marked white, carefully on to assembly sleeve and into seat on unit injector. Ensure that it is correctly positioned. Unit injector with solenoid valve page 258 Unit injectors with piezo elements (identifying feature: octagonal feature on end of injector) page 258
AG. Volkswagen AG d agen oes not lksw Vo gu by ara d nte ise or injectors with solenoid valve eo for unit th u ra a c ss
Position of O-rings -arrowses, in part or in w l purpos hole ercia , is n mm ot p co erm or te itte va ri d p
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Position of O-rings -arrows- for unit injectors with piezo elements (identifying feature: octagonal feature on end of injector -A-) Remove assembly sleeve.
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1.10
Assembly overview - air filter
1 - Intake hose To turbocharger. 2 - Air mass meter -G703 - O-ring Renew if damaged. 4 - 8 Nm 5 - Upper part of air filter 6 - 8 Nm 7 - Vacuum hose To solenoid valve block 8 - Filter element 9 - Air duct To lock carrier. 10 - Lower part of air filter 11 - 10 Nm
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259
Engine control unit (Golf)

Removing and installing engine control
Removing and installing anti-theft engine control unit page 260 .
n AG. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho unit tpage 260 . or ac au ss
2.1
Removing and installing engine control unit

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 wiper arms, plenum chamber cover and plenum bulk head Electrical system; Rep. gr. 92 ; Windscreen wiper system; Removing and installing windscreen wiper system . Bend catch open slightly -1-.
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Fit connector to engine control unit and lock connector in po sition. Push engine control unit onto bracket.
Press catch -1- against engine control unit. Install plenum chamber bulkhead, plenum chamber cover and wiper arms Electrical system; Rep. gr. 92 ; Windscreen wiper system; Removing and installing windscreen wiper sys tem .
2.2
Removing and installing anti-theft en gine control unit
Special tools and workshop equipment required Grip pliers
260
AG.
Installing:
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Now release connector on engine control unit and pull off con nector.
Then push engine control unit out of retainer -arrow-.
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Hot air blower from wiring harness repair set -VAS 1978-
Note
If the engine control unit is to be renewed, connect vehicle The shear-head bolt threads are coated with locking com
diagnostic, testing and information system -VAS 5051B- and perform Renewing engine control unit in guided functions. pound. Heating the shear-head bolt with a hot air blower releases the locking effect of the locking compound.
Removing:
Remove wiper arms, plenum chamber cover and plenum bulk head Electrical system; Rep. gr. 92 ; Windscreen wiper system; Removing and installing windscreen wiper system . Caution
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Perform settings on hot air blower -4- as shown:
Turn temperature settings potentiometer -2- to a maximum heat output of 600 C. Set two-stage switch for volume of air -3- to position 3. WARNING
When shear-head bolts are heated up, parts of the protective housing will be subjected to a large amount of heat. Wear pro tective gloves to avoid possible injury.
Place nozzle of hot air blower close to shear-head bolt. Switch on hot air blower and heat the bolts. Remove bolts with grip pliers .
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Cover lines, connections and control units in the vicinity of the engine control unit to prevent damage through heat (scorching/ melting of plastics etc.).
AG.
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2. Engine control unit (Golf)
261
If the bolts will not move, saw into heads of shear-head bolts so that two parallel slots are created -arrows- and then remove the bolts.
Insert a screwdriver between protective housing -A- and bracket -arrow-.
Lever up protective housing using screwdriver -A- and pull to side off bracket -arrow-.
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Now release connector on engine control unit and pull off con nector. Installing: Fit connector to engine control unit and lock connector in po sition. Push engine control unit onto bracket.
AG.
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Then push engine control unit out of retainer -arrow-.
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Bend catch open slightly -1-.
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Press catch -1- against engine control unit. Push protective housing onto bracket.
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Tighten new shear-head bolts -1- evenly until heads shearhead off. Install plenum chamber bulkhead, plenum chamber cover and wiper arms Electrical system; Rep. gr. 92 ; Windscreen wiper system; Removing and installing windscreen wiper sys tem .
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2. Engine control unit (Golf)
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263
Engine control unit (Golf Plus, Tour an)
Removing and installing engine control unit page 264 Removing and installing anti-theft engine control unit page 265 .
3.1

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 engine control unit Switch off ignition. Remove plenum chamber bulkhead General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead . Loosen securing nuts -arrows-. Release connectors on engine control unit and pull them off.
Push bracket -1- off engine control unit in direction of arrow. Installing engine control unit Push bracket onto engine control unit.
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264
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Tighten securing nuts -arrows- to 10 Nm. Fit connector and lock in position. Install plenum chamber bulkhead General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
3.2
Special tools and workshop equipment required Grip pliers Hot air blower from wiring harness repair set -VAS 1978n AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss
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Note
If the engine control unit is to be renewed, connect vehicle The shear-head bolt threads are coated with locking com
diagnostic, testing and information system -VAS 5051B- and perform Renewing engine control unit in guided functions. pound. Heating the shear-head bolt with a hot air blower releases the locking effect of the locking compound.
Removing:
AG.
Caution
3. Engine control unit (Golf Plus, Touran)
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Remove plenum chamber bulkhead General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
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265
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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. Place nozzle of hot air blower close to shear-head bolt. Switch on hot air blower and heat the bolts. WARNING
Twist shear-head bolts -arrows- out using grip pliers and re move cover from protective housing.
AG. Volkswagen AG d agen oes not lksw Then remove securing nuts for control unit bracket -arrows-. Vo gu by ara d nte ise Release connectors on engine control unit and pull them off. or eo th u ra a c ss
Press catches -1- and -2- outwards. Then pull engine control unit off control unit bracket in direction of arrow. Installing: Push engine control unit onto control unit bracket until it en gages in catches. Fit connector to engine control unit and lock in position.
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266
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Tighten securing bolts -arrows- to 10 Nm. Install cover of protective housing.
Tighten new shear-head bolts -arrows- evenly until heads shear off. Install plenum chamber bulkhead General body repairs; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
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3. Engine control unit (Golf Plus, Touran)
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Engine control unit (Passat)
Removing and installing engine control unit page 268 . Removing and installing anti-theft engine control unit page 269 .
4.1
If the engine control unit is to be renewed, connect vehicle diag nosis, testing and information system -VAS 5051B- and perform Renewing control unit in Guided functions. DANGER!
Vehicles with heavy duty running gear; vehicle must be re stricted to a maximum of 210 km/h via the engine control unit. Drive shafts can be damaged at speeds above 210 km/h. Per form function Restricting maximum speed in guided function using vehicle diagnostic, testing and information system -VAS 5051B- .
Removing Switch off ignition. Remove wiper arms Rep. gr. 92 .
n AG. Volkswagen AG do es n wage ot g olks Remove plenum chamber coverV Rep. gr. 64 . ua by ran ed is tee Pull connector -1- off heated windscreen control unit -J505- . or th or ac au ss Slide connector locking devices -2- on engine control unit out
wards and pull off both connectors.
Remove securing bolts -3-. Remove retainer frame with engine control unit from plenum chamber.
Press locking device -1- outwards and slide engine control unit -2- in -direction of arrow-. Installing
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268
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Slide engine control unit -1- into retaining frame in -direction of arrow-.
Fit retainer frame with

Specified torque of securing nuts for retainer -4-: 6 Nm. Tighten securing bolts -3- to 7 Nm. Fit connector to engine control unit and slide locking devices -2- inwards. 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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n AG. Volkswagen AG do es n wage ot g olks yV ua db ran e tee ris ho t or ac au engine control unit onto retainer -4-. ss
4.2
Special tools and workshop equipment required Hot air blower from wiring harness repair set -VAS 1978r fo ng
Nozzle 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 Renewing control unit in Guided functions. DANGER!
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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4. Engine control unit (Passat)
269
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - EditionA02.2011agen AG olksw en G. V Removing Switch off ignition.
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Remove plenum chamber cover Rep. gr. 64 .

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Remove wiper arms Rep. gr. 92 .
ss

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
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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
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. The procedure for the second shear-head bolt is exactly the same. Pull connector -1- off heated windscreen control unit -J505- .
270
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Lift cover -1- and pull it forwards.
Remove retainer frame with engine control unit from plenum chamber.
n AG. Volkswagen AG do es n wage ot g olks yV ua db ran e te ris ho Slide connector locking devices -1- on engine control unit out e or t ac au both connectors. wards and pull off ss
Press locking device -1- outwards and slide engine control unit -2- in -direction of arrow-. Installing
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Slide engine control unit -1- into retaining frame in -direction of arrow-.
Fit retainer frame with engine control unit onto retainer in ple num chamber. Specified torque of securing nuts for retainer: 6 Nm.
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4. Engine control unit (Passat)
271
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Fit connector to engine control unit and slide locking devices -1- inwards.
Slide cover -1- over engine control unit and press it down wards.
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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26
1
Note
Exhaust system
Front exhaust pipe
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After working on the exhaust system ensure that the system
Removing and installing exhaust manifold page 232
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is not under stress, and that there is sufficient clearance to the bodywork. If necessary, loosen clamp and align silencer and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
Renew self-locking nuts.
Assembly overview - front exhaust pipe with catalytic converter page 273 Assembly overview - front exhaust pipe with particulate filter page 274 .
1.1
Assembly overview - front exhaust pipe with catalytic converter
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2 - 40 Nm 3 - Support 4 - Marking For clamp. Specified torque and in stallation position of clamp page 279 5 - To front silencer 6 - 25 Nm 7 - Mounting Renew if damaged. 8 - 7 Nm 9 - Seal Note installation posi tion. 10 - Clip
1. Front exhaust pipe
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1 - Front exhaust pipe with cat alytic converter
273
1.2
Assembly overview - front exhaust pipe with particulate filter

Note
Removing and installing exhaust manifold page 232 After working on the exhaust system ensure that the system
is not under stress, and that there is sufficient clearance to the bodywork. If necessary, loosen clamp and align silencer and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support rings are evenly loaded.
Renew self-locking nuts. Special tools and workshop equipment required Tool set, 17 mm -T10395-
Note
If the particulate filter or the exhaust gas pressure sensor 1 -G450- is changed, the exhaust gas pressure sensor 1 -G450- must always be adapted using diagnosis tester : Guided functions; adapting exhaust pressure sensor 1 -G450- .
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274
Rep. gr.26 - Exhaust system
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - 8 Nm 2 - Exhaust gas pressure sen sor 1 -G450es, in part or in w l purpos hole ercia , is n mm ot p co erm or te itte va ri d p
3 - Retainer For control lines 4 - 10 Nm 5 - Control line, 45 Nm 6 - Lambda probe -G39- , 50 Nm Grease threads only with high-temperature 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- . 7 - Exhaust gas temperature sender 2 for cylinder bank 1 G448- , 45 Nm Lubricate thread of sender using high-tem perature paste -G 052 112 A3- . Remove and install with tool set -T10395- .
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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 ; Removing and installing subframe and steering box . 9 - Front exhaust pipe 10 - Marking For clamp. Specified torque and installation position of clamp page 279 11 - To front silencer 12 - 25 Nm 13 - Mounting Renew if damaged. 14 - Temperature sender after particulate filter -G527 Lubricate thread of sender using high-temperature paste -G 052 112 A3- . Remove and install with tool set -T10395- . 15 - From turbocharger 16 - Clamp, 7 Nm 17 - Seal Renew. Note installation position.
1. Front exhaust pipe
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275
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 18 - 40 Nm 19 - Retainer Bolted to cylinder head.
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276
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2
2.1
Silencer (Golf, Golf Plus)

Assembly overview - silencer, vehicles with front-wheel drive
Note
Removing and installing exhaust manifold page 232 After working on the exhaust system ensure that the system
is not under stress, and that there is sufficient clearance to the bodywork. If necessary, loosen clamp and align silencer and exhaust pipe so that sufficient clearance is maintained toothe ag lksw en AG ge does bodywork and the support rings are evenly loaded. n AG. V swa
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Renew self-locking nuts. Note

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Rear silencer -A- only fitted on special model Golf Speed.

1 - Mounting Renew if damaged. 2 - 25 Nm 3 - 25 Nm 4-
5 - Mounting With retaining ring. Renew if damaged.
6 - Rear silencer For repairs, renew indi vidually. 7 - Mounting With retaining ring. Renew if damaged.
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8 - Separating point For repair cases Marked by three inden tations on circumfer ence of exhaust pipe Front and rear silencers are installed as a single component during pro duction. In repair cases, the front and rear silenc ers are supplied individ ually with a repair clamp for connecting them. Cutting exhaust pipe page 278 .
2. Silencer (Golf, Golf Plus)
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277
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 9 - Front silencer For repairs, renew indi vidually. 10 - Clamp Specified torque and installation position page 279 11 - Threaded union Tighten bolted connections evenly. Specified torque and installation position page 279 12 - From front exhaust pipe
2.2
Assembly overview - silencer, vehicles with four-wheel drive

1 - Front exhaust pipe with cat alytic converter 2 - Mounting Renew if damaged. 3 - 25 Nm 4 - Clamp Specified torque and installa tion position page 279 5 - Threaded union Tighten bolted connec tions evenly. Specified torque and installation position page 279 6 - Mounting Renew if damaged. 7 - Rear silencer 8 - Retaining ring Renew if damaged. 9 - Mounting 10 - 40 Nm 11 - 40 Nm 12 - Support 13 - Seal Renew. 14 - Clip 15 - 7 Nm

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2.3
Cutting exhaust pipe
278
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Pneumatic sabre saw -V.A.G 1523/A-
Cut exhaust pipe at right angles at separating point -A-. When installing, position repair clamp at side markings -B-. Specified torque page 279
2.4
Installation position and specified torque of the clamp

Note
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Gradual introduction of clamp with continuous clip.

Specified torque and installation dimensions of clamp Clamp -A- with 2 individual clips. Specified torque: 25 Nm.
Installation dimensions -a- 5 mm (only for front clamp) Clamp -B- with continuous clip. Specified torque: 35 Nm.
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Installation dimensions -a- 8.5 mm (only for front clamp)

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279
Installation dimension -a- for vehicles with marking on front ex haust pipe 1 - Clamp 2 - Front exhaust pipe a - Installation dimension A - Marking
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Installation position of front clamp

Install clamp so that end of bolt -arrow- does not extend be yond lower edge of clamp. Threaded connection faces right
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Installation position of rear clamp Install clamp so that end of bolt -arrow- does not extend be yond lower edge of clamp. Threaded connection faces to rear.
2.5
Aligning exhaust system free of stress
Engine must be cold.
Loosen threaded connection of clamp between catalytic con verter and front silencer. Loosen bolts -3 and 4- on front clamp -1-. Align front clamp -1- to marking -A- on front exhaust pipe -2(-arrow- points forwards). Dimension -a- = page 279 The bolts must be on the right and the ends of the bolts must not protrude beyond the lower edge of the clamp.
Tighten front clamp bolts -3- hand-tight.
280
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Push rear silencer forwards into clamp until dimension -a- = 1517 mm is attained between mounting attachment points for body and rear silencer. -Arrow- points in direction of travel. Align rear silencer horizontally. Tighten clamp bolts in this position. Specified torque page 279 . Once clamp has been tightened, check distance -a- and cor gen AG. Volkswagen AG does a rect if necessary. ksw not Vol
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281
3
3.1
Note
Silencer (Touran)
Assembly overview - silencers
After working on the exhaust system ensure that the system
is not under stress, and that there is sufficient clearance to the bodywork. If necessary, loosen clamp and align silencer gen AG. Volkswagen AG d and a oes exhaust pipe so that sufficient clearance is maintainedwto the ks not Vol gu by ara bodywork and the support rings are evenly loaded. d e
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Renew self-locking nuts. 1 - Mounting Renew if damaged. 2 - Retaining ring for rear si lencer Renew if damaged. 3 - Rear silencer For repairs, renew indi vidually. 4 - 25 Nm 5 - Mounting With retaining ring. Renew if damaged. 6 - Separating point For repair cases Marked by three inden tations on circumfer ence of exhaust pipe Front and rear silencers are installed as a single component during pro duction. In repair cases, the front and rear silenc ers are supplied individ ually with a repair clamp for connecting them. Cutting exhaust pipe page 283 . 7 - Front silencer For repairs, renew indi vidually. 8 - Clamp Specified torque and in stallation position page 279
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9 - Threaded union Tighten bolted connections evenly. Specified torque and installation position page 279 10 - From front exhaust pipe
282
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3.2
Cutting exhaust pipe
Special tools and workshop equipment required Pneumatic sabre saw -V.A.G 1523/A-
Cut exhaust pipe at right angles at separating point -A-. When installing, position repair clamp at side markings -B-. Specified torque page 279
Engine must be cold.
Loosen bolts -3 and 4- on front clamp -1-. Align front clamp -1- to marking -A- on front exhaust pipe -2(-arrow- points forwards). Dimension -a- = page 279 The bolts must be on the right and the ends of the bolts must not protrude beyond the lower edge of the clamp.
3.3
Push rear silencer forwards into clamp until dimension -a- = 1517 mm is attained between mounting attachment points for body and rear silencer Item 2 (page 282) . -Arrow- points in direction of travel. Tighten clamp bolts in this position. Specified torque page 279 .
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Once clamp has been tightened, check distance -a- and cor rect if necessary.
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Align rear silencer horizontally.
3. Silencer (Touran)
283
4
4.1
Silencer (Passat)
Assembly overview - silencer, vehicles with front-wheel drive
1 - From front exhaust pipe 2 - Clamp Before tightening, align cold exhaust system free of tension page 285 Tighten bolted connec tions evenly. Specified torque page 279 3 - Front silencer 4 - Mounting Renew if damaged. 5 - 25 Nm Renew.
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6 - Separating point Marked by impressions on exhaust pipe. Centre and rear silenc ers are installed as a single component dur ing production. In cases of repair, the centre and rear silencer are sup plied separately, with a clamp for connecting. Cut through exhaust pipe at right angles us ing e.g. body saw V.A.G 1523- at separat ing point -arrow A- (wear eye protection) When installing, posi tion repair clamp at side markings -arrows B-. Evenly tighten threaded connections of clamp (repair clamp). Specified torque of the clamping sleeve (repair clamping sleeve) page 279 Before tightening, align cold exhaust system free of tension page 285
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8 - Rear silencer
284
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7 - Retaining ring Renew if damaged.
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4.2
Assembly overview - silencer, vehicles with four-wheel drive
1 - Clamp Before tightening, align cold exhaust system free of tension page 285 Tighten bolted connec tions evenly. Specified torque page 279 2 - Retaining ring Renew if damaged. 3 - Front mounting Renew if damaged. 4 - 25 Nm Renew. 5 - Centre mounting Renew if damaged. 6 - Rear left mounting Renew if damaged. 7 - Rear silencer 8 - Rear right mounting Renew if damaged. 9 - Securing bolt Specified torque Run ning gear, axles, steer ing; Rep. gr. 42 ; Rear suspension; Specified torques for rear axle . 10 - Front silencer
4.3
Test prerequisite Procedure
Engine must be cold
Loosen bolts -3 and 4- on front clamp -1-. Align front clamp -1- to marking -A- on front exhaust pipe -2(-arrow- points forwards). The bolts must be on the right and the ends of the bolts must not protrude beyond the lower edge of the clamp.
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Dimension -a- = page 279
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4. Silencer (Passat)
285
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Push front and rear silencer into clamp until dimension -a- (4 mm) is attained between mounting attachment points for body and rear silencer. -Arrow- points in direction of travel. Align rear silencer horizontally. With parts in this position, tighten bolted connections of clamp. Specified torque page 279 Once clamp has been tightened, check distance -a- and cor rect if necessary.

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286
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Exhaust gas recirculation system
Assembly overview - parts of exhaust gas recirculation page 287 . Schematic diagram of vacuum hoses page 240 . Note The exhaust gas recirculation system is actuated by the diesel
direct injection system control unit -J248- via the exhaust gas recirculation valve -N18- (electro-pneumatic) to the exhaust gas recirculation valve (mechanical). is located in the solenoid valve block.
The exhaust gas recirculation valve -N18- (electro-pneumatic) The cone-shaped plunger in the mechanical exhaust gas re Pulsed control enables every conceivable valve position. Renew self-locking nuts.
circulation valve ensures that various cross sectional openings are possible at different plunger lifts.
5.1
Assembly overview - exhaust gas recir culation

e ris
age Engine codes AZV, BKD, BKP, BMAsBVE and BWV k w Vol y page 287 db
ho Engine codes BMN, BMRutand BUZ
5.1.1
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Note
The exhaust gas recirculation system is actuated by the diesel
direct injection system control unit -J248- via exhaust gas re circulation valve -N18- (electro-pneumatic) to the exhaust gas recirculation valve (mechanical). is located in the solenoid valve block.
The exhaust gas recirculation valve -N18- (electro-pneumatic) The cone-shaped plunger in the mechanical exhaust gas re Pulsed control enables every conceivable valve position. Renew self-locking nuts.
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circulation valve ensures that various cross sectional openings are possible at different plunger lifts.
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5. Exhaust gas recirculation system
287
Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - 22 Nm 2 - Connecting pipe 3 - Seal Renew. 4 - Bypass flap When actuated, directs exhaust gas through ex haust gas recirculation cooler. 5 - To exhaust gas recircula tion valve page 244 6 - Radiator For exhaust gas recircu lation. 7 - Retainer For bypass flap and ex haust gas recirculation cooler. 8 - 10 Nm 9 - Retainer For engine cover. 10 - From exhaust manifold 11 - Connecting pipe Tightening sequence: 1. Attach to bypass flap 2. Attach to manifold 3. Tighten to bypass flap 4. Tighten to manifold
12 - 25 Nm
Note
5.1.2

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Before removing the exhaust gas recirculation cooler, first remove particulate filter page 274 .
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288
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 1 - 20 Nm 2 - Connecting pipe 3 - Seal Renew. 4 - 10 Nm 5 - From exhaust manifold 6 - 25 Nm 7 - Connecting pipe 8 - Radiator For exhaust gas recircu lation. With bypass flap. 9 - Vacuum hose 10 - Vacuum unit To switch-over of by pass flap.
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5. Exhaust gas recirculation system
289
28
1
Glow plug system

Optical characteristics of metal or ce ramic glow plugs
WARNING
The ceramic glow plugs page 290 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 there is no obvious damage. It is absolutely necessary to follow the installation instructions, otherwise the heater pin of the glow plug can break and cause engine damage. AG. Volkswagen AG d agen o
Optical characteristics of glow plugs
-A- = Metal glow plug, colour-coded -arrow-. -B- = Ceramic glow pin plug with support tube -arrow-, not colourcoded. Vehicles with 4 valves per cylinder head -C- = Metal glow plug, colour-coded -arrow-. -D- = Ceramic glow pin plug with support tube -arrow-, not colourcoded. Removing and installing metal glow plug page 290 Remove, install or check ceramic glow pin plugs page 292 .
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Vehicles with 2 valves per cylinder head
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1.1
Removing and installing metal glow plug
Special tools and workshop equipment required Special wrench, long reach -T50001r fo ng
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Note
Testing glow plugs with battery voltage is not permitted. This will destroy the glow plug.
290
Rep. gr.28 - Glow plug system
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 Procedure Note
Do not cant glow plugs when removing and installing. Remove any components hindering assembly.
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-. Remove cylinder head cover page 49 .
Pull connectors -1- off ceramic glow plugs. Remove and install glow plugs using socket -T50001- . Specified torque: 10 Nm
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1. Optical characteristics of metal or ceramic glow plugs
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291
1.2
Removing and installing ceramic glow plugs
Special tools and workshop equipment required Special wrench, long reach -T50001 Torque wrench (550 Nm) -V.A.G 1331 Multimeter -V.A.G 1715- or hand multimeter V.A.G 1526 A Auxiliary measuring set V.A.G 1594 Cn AG. Volkswagen AG do es n wage ot g olks yV ua db ran se tee ri ho t or ac au ss
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Test prerequisites Engine is cold Ignition switched off
Note
Do not cant ceramic glow plugs when removing and installing. Remove any components hindering assembly.
292
Rep. gr.28 - Glow plug system
AG.
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Procedure
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Golf 2004 , Golf Plus 2005 , Passat 2006 , Touran 2003 4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011 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-. Remove cylinder head cover page 49 .
Pull connectors -1- off ceramic glow plugs. Remove ceramic glow plugs using socket -T50001- . Installation is carried out in the reverseG. VolkswWhenG order. agen A installing, nA does wage note the following: no olks
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ra Before installing theised r drilling in cylinder head and the threads ntee tho must completely ucleaned of all deposits. or
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Never oil or grease thread of cylinder head bore or of ceramic glow plugs.
Screw ceramic glow plugs into cylinder head by hand using socket -T50001- . Then tighten the ceramic glow plugs. Specified torque: 12 Nm WARNING
Note
After installing and before the engine is started, always perform a resistance test on all ceramic glow plugs when engine is cold.
Specification: max. 1 If the specification is exceeded, renew the defective ceramic glow plug. Note
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If the defective ceramic glow plug is broken, remove all fragments from the engine, otherwise these can cause damage to the en gine.
AG.
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1. Optical characteristics of metal or ceramic glow plugs
293

Service: Golf 2004 Golf Plus 2005 Passat 2006 Touran 2003

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Service: Golf 2004 Golf Plus 2005 Passat 2006 Touran 2003

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es, in part or in w l purpos hole ercia , is n mm ot p co erm or te itte va ri d p

n AG. Volkswagen AG do es n wage ot g olks V ua by ran ed is tee or th or ac au ss

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4-cylinder diesel engine (2.0 l engine, 4 valve)

Service Department. Technical Information

BKD BMN BKP BMA BVE BMR BUZ BWV

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rrectness of i t to the co nf orm spec atio h re n in wit

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

urposes, in part or in wh ole, cial p is n mer ot p om erm or c te a itte riv du p or nl f e ng

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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20 - Fuel supply system . . .

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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

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Engine number page 1 Engine data page 1

Edition 02.2011 version 24.0 Engine code Manufac tured

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Rep. gr.00 - Technical data

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Removing and installing engine

Stepladder -VAS 5085 Engine bracket -T10012-

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1. Removing and installing engine

Before carrying out further work, disconnect battery earth

removed must be replaced in the same position when engine is installed.

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w Procedures for Golf, Golf Plus, Touran a olks yV

test or VAS 5052; Vehicle self-diagnosis .

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Rep. gr.10 - Removing and installing engine

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The very hot (danger of scalding)!

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1. Removing and installing engine

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The engine is lowered downwards with particulate filter fitted.

Rep. gr.10 - Removing and installing engine

Continuation for all vehicles:

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to prevent damage to bodywork.

Carefully lower engine with gearbox.

1. Removing and installing engine

Procedures for Passat

Remove feed-through for engine control unit wiring harness -arrow-.