Professional Documents
Culture Documents
Workshop Manual
Jetta 2005
Bora 2006
Golf Variant 2007
4-cylinder diesel engine with unit injector
Engine ID BKC BLS BRM BXE
Edition 05.2007
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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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1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Checking and adjusting assembly mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1.2 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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1.5 Removing and installing poly-V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Assembly overview - sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.3 Identification of upper crankshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.4 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4 Pistons and connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.4 Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Contents i
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.1 Engine oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.2 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.3 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Oil pump, oil sump - assembly overview, engine codes BKC, BLS, BXE . . . . . . . . . . . . . . 98
2.2 Oil pump, oil sump - assembly overview, engine codes BRM . . . . . . . . . . . . . . . . . . . . . . 100
2.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Oil filter bracket, oil pressure, oil cooler and oil supply line . . . . . . . . . . . . . . . . . . . . . . . . 106
3.1 Assembly overview - oil filter bracket and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2 Removing and installing oil filter bracket with oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.4 Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.5 Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1 Parts of the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.1 Parts of cooling system - body side, engine agencodes BLS, BRM
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1.2 Parts of cooling system - body side, by V engine codes BKC, BXE . . o. t .gu. . . . . . . . . . . . . . . . . .
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1.3 Parts of cooling system - engineoris side, engine codes BLS, BRM . . . . . n.te.e . . . . . . . . . . . . .
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1.4 Parts of cooling system - sengine
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1.5 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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1.7 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 130
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1.8 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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1.9 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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1.11 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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1.12 Checking oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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4 Repairing fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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4.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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4.2 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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4.3 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.4 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.2 Assembly overview - accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.3 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
ii Contents
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
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7.1 Vehicles with engine codes BKC, BXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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1.9 Removing and installing intake pipe with exhaust gas recirculation potentiometer G212 and
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exhaust gas recirculation valve N18 , engine codes BLS, BRM . . . . . . . . . . . . . . . . . . . . 233
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1.10 Dismantling and assembling intake pipe with with exhaust gas recirculation potentiometer
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G212 and exhaust gas recirculation valve N18 , engine codes BLS, BRM . . . . . . . . . . . . 234
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1.11 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 235
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1.12 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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1.13 Connection diagram for charge pressure control, engine codes BKC, BXE . . . . . . . . . . . . 238
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Connection diagram for solenoid valve block, engine codes BKC, BXE . . . . . . . . . . . . . . 238
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Contents iii
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
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iv Contents
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
00 Technical data
1 Technical data
Engine number page 1
Engine data page 1
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Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
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1. Technical data 1
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
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Do not press clutch pedal after removing slave cylinder.
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un
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an
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ility
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spec
es, in part or in w
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Note
a
com
tion in
r
thi
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iva
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t.
yi Co
Rep. Gr. 50 ; Noise insulation . ht. Cop py
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rig ht
Bring lock carrier into service position General body repairs,
py by
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exterior; Rep. Gr. 50 ; Lock carrier .
by lksw
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Prote AG.
Vehicles with air conditioner
Note
WARNING
pt
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ility
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ole,
spec
urposes, in part or in wh
t to the co
Unscrew nut -arrow- and take retainer for wiring harness off
threaded stud.
Vehicles with engine codes BKC, BXE
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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AG. Volkswagen AG d
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Remove air hose fromthoturbocharger.
ris To do this lift retaining nte
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clip -arrow- lightly. s au ra
c
s
ce
Remove right air duct pipe. To do this lift retaining clips
le
un
pt
-arrow- lightly.
an
d
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ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Remove connector -2- on radiator outlet coolant temperature
l purpos
sender -G83- .
Continuation for all models
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted
Remove locking screw -arrow- for front air duct pipe.
agen
Prote AG.
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un
pt
an
Pull off or disconnect all other electrical connections from en
d
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gine and gearbox as necessary and lay to side.
erm
ab
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from engine.
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Unscrew bolt -1 - first.
Unscrew bolts -2- and -3- and take pendulum support off.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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Insert engine support -T10012- in engine and gearbox jack -
by c lksw
cted agen
V.A.G 1383 A- .
Prote AG.
Note
Note
Note
ce
le
equipment required
un
pt
an
d
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erm
ab
ility
Engine and gearbox sup
ot p
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port -VW 540-
is n
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spec
urposes, in part or in wh
t to the co
V.A.G 1383 A-
Workshop crane -
rrectne
VAS 6100-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Procedure
Move engine/gearbox jack -V.A.G 1383 A- to a workbench.
Lower engine/gearbox assembly so that the gearbox is on the
workbench.
Remove engine/gearbox connecting bolts.
Press gearbox off engine.
WARNING agen
AG. Volkswagen AG d
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The hooks and locating pins must be secured with locking pins.
d ara
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pulley end.
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The holes in the hooks are counted up from the hook. spec
urposes, in part or in wh
t to the co
f inform
mer
Caution
atio
om
n
c
i
or
o
r
tions:
p
cum
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fo
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Note
AG. Volkswagen AG d
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or eo
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un
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rm
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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iva
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cum
fo
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
Note
Procedure
. Volkswagen AG
gen AG does
Install pendulum support
Vol
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a
not
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Install drive shafts
oris Running gear, axles, steering; Rep.ntGr.
e
ee
40 ; Servicing
au drive shafts; Removing and installing drive or a
th
shafts . ss c ce
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nl
pt
Remove front exhaust pipe page 251 .
du
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overview - Hydraulics .
spec
es, in part or in w
at
io
in t
or
his
e
do
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cum
or
en
ng
t.
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op
Install poly-V-belt page 29 . C py
t. rig
gh ht
yri
Install noise insulation General body repairs, exterior; Rep.
p by
co Vo
by lksw
Gr. 50 ; Noise insulation . Prote
cted AG.
agen
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pt
du
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Observe applicable safety precautions during road test.
erm
ab
ility
ot p
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, is n
h re
After this, perform vehicle system test again and if necessary,
hole
rectify faults.
spec
es, in part or in w
t to the co
1.4 Checking and adjusting assembly
mounting
rrectness of i
Checking settings page 19
l purpos
nform
ercia
1.4.1 Checking
m
at
om
ion
c
in t
or
his
e
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
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V gu
d by ara
ise nte
or eo
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aut ra
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ce
le
un
pt
an
d
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rm
ab
pe
ility
ot
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
do
cum
fo
en
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Remove air filter housing with air mass meter and connecting
n
t.
yi Co
pipe. Cop py
t. rig
gh ht
yri
Disconnect connector -2- on air mass meter -G70- . p by
o Vo
by c lksw
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Pull breather hose -1- and air duct hoses -3- and -5- off. Prote AG.
ce
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Unscrew bolt -4- and take off air filter housing.
nl
pt
du
an
itte
Continuation for all models
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ab
ility
Removing battery Electrical system; Rep. Gr. 27 ; Remov
ot p
wit
ing and installing battery; Vehicles with diesel engine .
, is n
h re
hole
spec
Remove battery tray -arrows-.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
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m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Fit support bracket -10 - 222 A- before the gas pressure damp
er for the front flap using adapter -10 - 222 A/8- , adapter - 10
- 222 A/3- and adapter -10 - 222 A/16- .
Attach trigger snap of spindles to lifting eyes. On the right side
use additionally the adapter -10 - 222 A/20-
Take up weight of engine evenly with both spindles (but do not
raise engine).
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Slide the engine with a lever between engine console -1- and
arm -2- until the following dimensions are set:
Between the engine support and the right longitudinal member
there must be a distance of -a- = 10 mm.
The side surface of the engine support -2- should be located
parallel to the support arm -1-. Dimension -x- must be identical
at top and bottom.
Note
ce
e
nl
pt
B = 40 Nm + 90 (1/4 turn) further
du
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erm
ab
Renew bolts.
ility
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C = 60 Nm + 90 (1/4 turn) further
, is n
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spec
Renew bolts.
es, in part or in w
t to the co
Gearbox assembly mounting
A = 40 Nm + 90 (1/4 turn) further
rrectness of i
Renew bolts.
l purpos
nform
ercia
Renew bolts.
m
at
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ion
c
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or
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ate
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for
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Pendulum support t. Cop py
rig
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A = 40 Nm + 90 (1/4 turn) further pyri by
Vo
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Renew bolts.
AG.
13 Crankshaft group
1 Dismantling and assembling engine
Assembly overview page 25
n AG. Volkswagen AG do
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Assembly overview - toothedyV
olks belt drive page 26 ot g
ua
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Assembly overviewhor-ispoly-V-belt drive page 27 tee
ut or
a ac
Assembly overview
ss - cylinder block page 28
ce
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nl
pt
Removing and installing poly-V-belt page 29
du
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Note
wit
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spec
example, by partial seizure of the crankshaft or conrod bearings)
es, in part or in w
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are found in the engine oil when performing repairs, clean the oil
passages of the oil cooler, the oil spray jets and the oil filter thor
oughly and renew the oil cooler in order to prevent further damage
from occurring later.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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1.1 Assembly overview
un
pt
an
d
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rm
ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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Prote AG.
ce
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T10052- .
un
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an
d
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page 92 .
pe
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6 - 10 Nm
wit
, is n
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Renew.
hole
spec
es, in part or in w
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8 - 25 Nm
9 - Sealing grommet
rrectness of i
Renew if damaged.
l purpos
nform
ercia
11 - Tensioning roller
m
a
com
tion in
12 - 20 Nm
r
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13 - Idler roller
s
iva
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rp
cum
14 - Coolant pump
fo
en
ng
t.
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Removing and installing
Co
op py
page 134 .
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ht ht
rig by
py
15 - Crankshaft toothed belt pulley
co Vo
by lksw
cted agen
Prote AG.
16 - 120 Nm + 90 (1/4 turn) further
Renew.
Use counter-hold tool -3099- to loosen and tighten.
Do not additionally oil or grease thread and shoulder.
Turning further can be done in several stages.
17 - 15 Nm
18 - Toothed belt guard lower part
19 - Belt pulley and vibration damper
Can only be installed in one position. Holes are offset.
ce
20 - 10 Nm + 90 (1/4 turn) further
le
un
pt
an
d
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21 - Cover
rm
ab
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ility
22 - Toothed belt
ot
wit
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Mark direction of rotation before removing.
h re
hole
spec
Check for wear.
es, in part or in w
Do not kink.
t to the co
Removing, installing and tensioning page 62 .
23 - 40 Nm + 180 (1/2 turn) further
rrectness of i
Renew.
l purpos
nform
ercia
25 - Engine support
m
a
com
tion in
r
te o
thi
1.3 Assembly overview - poly-V-belt drive
s
iva
do
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rp
cum
fo
en
ng
2 - 25 Nm
3 - Alternator
4 - Retainer
For alternator and air
conditioner compressor.
5 - Poly-V-belt tensioner
Swing with ring spanner
to slacken poly-V-belt.
6 - 25 Nm
7 - Air conditioner compressor
8 - 25 Nm
9 - Dowel sleeves
10 - Poly-V-belt
Mark direction of rota
tion before removing.
Check for wear.
Do not kink.
Removing and installing
page 29 .
1 - Cylinder block
Removing and installing
sealing flange and fly
wheel page 32 .
Removing and installing
crankshaft
page 48 .
Dismantling and assem
bling pistons and con
rods page 48 .
2 - Retainer
For wiring harness and
charge air pipe
3 - 15 Nm
4 - Seal
Renew.
5 - Oil filter bracket
Removing and installing AG. Volkswagen AG d
page 107 . lksw
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not
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Dismantling and eassem yV gu
db ara
nte
bling pageth106
oris
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6 - 15 Nm + 90 s(1/4 turn) fur
c
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un
pt
an
d
itte
Renew.
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erm
ab
diagonally.
spec
urposes, in part or in wh
7 - Retainer
t to the co
8 - 20 Nm
rrectne
9 - Connection
For thermostat.
ss
10 - 15 Nm
o
cial p
f inform
11 - O-ring
mer
atio
Renew.
om
n
c
12 - Thermostat
or
n thi
te
sd
a
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pr
cum
r
en
ng
t.
yi
Checking: heat thermostat in water.
Co
Cop py
t. rig
Opening begins at approx. 85C. opyri
gh by
Vo
ht
15 - Poly-V-belt tensioner
16 - 25 Nm
17 - Sump
Clean sealing surface before installing
Install with silicone sealant -D 176 404 A2- .
18 - 15 Nm
G. Volkswage
1.5 Removing
olks
wagand
en A installing poly-V-belt
n AG d
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not
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by ara
Special tools and
ris workshop equipment required
ed nte
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ut
Mandrel
ss -T10060A-
a ra
c
ce
le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing page 29
nform
ercia
Installing page 30
m
1.5.1 Removing
com
tion in
r
te o
cum
fo
t.
abruptly at front -arrows A- and then pull forwards out of rear
yi Co
op py
fastening -arrow B-. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Pull fuel filter out in -direction of arrow- and lay it with hoses to
side.
Mark direction of rotation of poly-V-belt.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
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ab
ility
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is n
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Lock tensioning element with retaining pin -T10060 A- . ole,
spec
urposes, in part or in wh
Remove poly-V-belt.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
1.5.2 Installing
t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note p by
co Vo
by lksw
cted agen
Prote AG.
Ensure, before installing poly-V-belt, that all ancillaries (alter
nator, air conditioner compressor) are secured tightly.
When fitting poly-V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
Lastly, place poly-V-belt over alternator.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
Note agen oes
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ara
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Servicing of couplingthor
is
5-speed manual gearbox 0A4; Rep. Gr.
nte
eo
30 ; Service coupling
s au or Direct shift gearbox 02E; Rep. Gr. 30 ; r ac
Removing and installing coupling .
s
ce
le
un
pt
an
d
itte
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rm
1 - Oil seal ab
pe
ility
ot
h re
grease sealing lip of oil
hole
seal
spec
es, in part or in w
Before installing, re
t to the co
tio
sleeves.
n in
r
te o
page 35
do
r
rp
cum
en
ng
ing compound -D
t.
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op
176 404 A2 - C py
ht. rig
page 35 rig ht
py by
co Vo
by lksw
3 - Cylinder block cted agen
Prote AG.
Removing and installing
crankshaft page 48
Dismantling and assem
bling pistons and con
rods page 52
4 - 60 Nm + 90 (1/4 turn) fur
ther
Renew.
5 - Flywheel
When removing and in
stalling flywheel, lock
with counter-hold tool
-3067- .
6 - Intermediate plate
Must seat on dowel sleeves.
Do not damage or bend when assembling.
7 - 15 Nm
Renew.
8 - Sealing flange with oil seal.
Renew complete with oil seal and sender wheel only.
Removing and installing page 38 .
9 - Engine speed sender -G28-
Loosen and tighten using commercially available ball-ended hex key socket.
Tightening torque: 5 Nm
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Removing page 34
Installing page 34
2.2.1 Removing
Remove toothed belt page 62 .
Remove crankshaft toothed belt pulley. To do this, lock tooth
ed belt pulley using counter-hold tool -3099- .
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
2.2.2 Installing
s
ce
e
nl
pt
du
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erm
ab
Note
ility
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The oil seal sealing lip must not be additionally oiled or greased.
h re
hole
spec
es, in part or in w
cloth.
Fit guide sleeve -T10053/1 - onto crankshaft journal.
rrectness of i
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Press seal with press sleeve -T10053- and central bolt to limit
stop.
Install crankshaft toothed belt pulley with new centre bolt.
Install and tension toothed belt page 62 .
pt
du
an
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A-
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
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Removing page 35 by c lksw
cted agen
Prote AG.
Installing page 36
2.3.1 Removing
Remove toothed belt page 62 .
Note
olkswagen AG
en AG. V
When bolting on counter-hold tool, place Vol
ktwo
swa washers between
g does
not
toothed belt pulley and counter-hold
ed tool.
by gu
ara
ris nte
utho eo
ra
Drain engine oil. ss
a c
ce
e
nl
pt
du
an
itte
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Remove sealing flange -belt pulley end-.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Drive out oil seal with sealing flange removed.
es, in part or in w
t to the co
Remove sealant residue on cylinder block with a flat scraper.
rrectness of i
rotary brush (wear eye protection).
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
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2.3.2 Installing
p by
co Vo
by lksw
cted agen
Prote AG.
Note
Note
Note
When fitting sealing flange with oil seal installed, use guide sleeve
-T10053/1- .
Note
n AG. Volkswagen AG do
lkswage es n
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byV ua
d ran
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tho
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ss
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nl
pt
du
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
atio
om
n in
or c
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te
sd
iva
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cu
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m
f
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Cop py
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37
co Vo
by lksw
2. Removing and installing sealing flange and flywheel
cted agen
Prote AG.
AG. Volkswagen AG d
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Jetta 2005 , Bora d by2006
V , Golf Variant 2007 t guar
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4-cylinder dieselho engine with unit injector - Edition 05.2007 e o
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2.4 Renewing crankshaft sealing flange - flywheel end
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erm
ab
Special tools and workshop
ility
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equipment required
wit
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Torque wrench -
ole,
spec
V.A.G 1331-
urposes, in part or in wh
t to the co
Tool insert 24 mm -V.A.G
1332/11-
Assembly device -T10134-
rrectne
Vernier gauge
ss
Three hexagon bolts -M6 x
o
cial p
f i
35 mm-
nform
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35 mm-
o
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.
Note
For the sake of clarity, the work is performed with the engine
removed.
The procedure is identical whether the engine is installed or
removed.
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an
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Note
rm
ab
pe
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wit
Sealing flange and sender wheel are pressed off the crankshaft
, is n
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with hexagon bolts -M6 x 35 mm- .
hole
spec
es, in part or in w
t to the co
rrectness of i
Screw three hexagon bolts -M6 x 35 mm- into the threaded
holes arrows -arrows- of the sealing flange.
l purpos
Screw the bolts alternately (max. 1/2 turn (180) per bolt) into
the sealing flange and press the sealing flange and the sender
nform
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Cop py
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by
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Prote AG.
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du
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erm
Note
ab
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The sealing flange with a PTFE seal is equipped with a sealing
h re
lip support ring. This support ring serves as a fitting sleeve and
hole
spec
must not be removed prior to installation.
es, in part or in w
t to the co
Sealing flange and sender wheel must not be separated or
turned after removal from packaging.
The sender wheel is held in its installation position on the as
rrectness of i
sembly device -T10134- by a locating pin. l purpos
Sealing flange and seal are one unit and must be replaced
together with the sender wheel only.
nf
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The assembly device -T10134- is held in its position relative
rm
m
atio
to the crankshaft by a guide pin inserted into a hole in the
om
crankshaft.
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A - Clamping surface
en
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B - Hexagon nut
C py
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C - Assembly housing
cop Vo
by lksw
cted agen
Prote AG.
D - Locating pin
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
G - Guide pin for petrol engines (red knob)
Note
Note
The sender wheel must not be taken out of the sealing flange or
turned.
Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
Place sealing flange with front side downwards on a clean flat
surface.
AG. Volkswagen AG d
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
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n
c
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or
n thi
te
sd
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pr
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fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
41
Prote AG.
2. Removing and installing sealing flange and flywheel
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
Note
pt
du
an
itte
y li
Push sealing flange and support ring for sealing lip -B- against
erm
ab
surface of assembly device - T10134- whilst tightening the
ility
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three knurled screws -A- so that locating pin cannot slide out
wit
, is n
spec
es, in part or in w
t to the co
Note
nf
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thi
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Screw hexagon nut -B- to end of threaded spindle.
C py
ht. rig
rig ht
py by
Press threaded spindle of assembly tool -T10134- in co Vo
by lksw
cted
-direction of arrow-, until hexagon nut -B- lies against assem
agen
Prote AG.
bly bell housing -A-.
Align flat side of assembly housing on sump side of crankcase
sealing surface.
ce
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un
pt
Note
an
d
itte
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erm
ab
Screw hexagon socket head bolts -A- into crankshaft flange (ap
ility
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectne
To guide sealing flange, screw two hexagon bolts -M7 x 35
mm- -A- into the cylinder block.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
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Cop py
t. rig
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pyri by
Vo
co
2.4.5 C - Bolting assembly tool -T10134- onto
by lksw
cted agen
Prote AG.
crankshaft flange
Push assembly bell housing -C- by hand in
-direction of arrow- until sealing lip support ring -B- contacts
crankshaft -A-.
Push guide pin for diesel engines (black knob) -D- into hole in
crankshaft. This ensures that the sender wheel reaches its fi
nal installation position.
Note
The guide pin for petrol engines (red knob) -F- must not be inser
ted in threaded hole of crankshaft.
Note
ce
e
nl
pt
du
an
itte
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erm
spec
t to the co
rrectness of i
l purpos
nf
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orm
m
atio
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n in
c
wheel.
or
thi
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sd
a
o
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cu
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en
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t.
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op
If dimension -a- is achieved:
C py
t. rig
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Tighten new securing bolts for sealing flange to 15 Nm using cop Vo
by lksw
alternate and diagonal sequence.
cted agen
Prote AG.
ce
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nl
pt
du
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erm
ab
ility
ot p
wit
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hole
spec
Secure assembly tool -T10134 - to crankshaft flange using
es, in part or in w
t to the co
Hand tighten both hexagon socket head bolts.
rrectness of i
Push assembly tool -T10134- by hand to sealing flange.
l purpos
nf
ercia
orm
m
atio
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n in
or c
thi
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sd
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Screw hexagon nut -E- onto threaded spindle by hand until it
o
m
f
en
lies against assembly bell housing -C-.
ng
t.
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Cop py
t. rig
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Prote AG.
n AG. Volkswagen AG do
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
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ion
c
in t
or
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ate
do
priv
c
Removing page 46
um
for
en
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t.
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Installing page 47
Co
Cop py
t. rig
gh
2.5.1 Removing
ht
pyri by
Vo
co lksw
by
cted agen
Fit counter-hold -3067- into the hole of the cylinder head.
Prote AG.
Note
Rotate the dual-mass flywheel -A- so that the bolts align with
the holes -arrows-.
When unscrewing the bolts, make sure that the bolt heads do
not come into contact with the dual-mass flywheel; the fly
wheel will otherwise be damaged as the bolts are screwed out.
2.5.2 Installing
Install in reverse order. In the process, note the following:
Use new bolts for securing.
olkswagen AG
en AG. V
Tighten bolts to 60 Nm ks+w 90 (1/4 turn).
ag does
not
Vol y gu
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nl
pt
du
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erm
ab
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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m
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or c
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f
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
3 Crankshaft
Assembly overview - crankshaft page 48
Crankshaft dimensions page 49
AG. Volkswagen AG d
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Marking of upper crankshaft bearing shells page 49 olksw not
byV gu
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Pulling needle bearing out of and driving into crankshaft horis nte
eo
page 49 aut ra
c
ss
3.1 Assembly overview - crankshaft
ce
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nl
pt
du
an
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erm
ab
1 - Bearing shells 1, 2, 4 and 5
ility
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For bearing cap without
h re
oil groove
hole
spec
For cylinder block with
es, in part or in w
t to the co
oil groove
Do not interchange
used bearing shells
rrectness of i
(mark)
l purpos
nf
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Renew.
orm
m
atio
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ance, tighten to 65 Nm
o
n in
or c
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3 - Bearing cap
o
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Bearing cap 1: Pulley
f
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t.
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end.
Co
Cop py
. rig
Bearing cap 3 with re
ht ht
rig by
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cesses for thrust wash co Vo
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ers. cted agen
Prote AG.
Bearing shell retaining
lugs in cylinder block
and bearing caps must
be above one another.
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 arrangement
6 - Crankshaft
Axial clearance new: 0.07...00.17 mm, wear limit: 0.37 mm
Check radial clearance with Plastigage new: 0.03...00.08 mm, wear limit: 0.17 mm.
Do not rotate crankshaft when checking radial clearance
Crankshaft dimensions page 49 .
7 - Thrust washer
For cylinder block, bearing 3
Note
ce
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un
pt
an
d
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rm
ab
3.4 Pulling needle bearing out of and driving
pe
ility
ot
into crankshaft
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Crankshaft 49
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Removing
Remove needle bearing with internal puller -Kukko 21/2-
-arrow-, adapter -T10055/3- and puller -T10055- .
Installing
Note
AG. Volkswagen AG d
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nl
pt
du
an
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erm
ab
ility
ot p
Installation depth: dimension -a- = 2 mm.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Crankshaft 51
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
1 - Piston rings
Offset gaps by 120
AG. Volkswagen AG d
Remove and install us lksw
agen oes
not
ing piston ring pliers d by
Vo gu
ara
e nte
TOP faces towards horis
eo
piston crown. aut ra
ss c
Checking ring gap
ce
le
un
pt
page 54
an
d
itte
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Checking ring-to-groove
erm
ab
clearance page 55
ility
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wit
is n
2 - Piston
h re
ole,
spec
urposes, in part or in wh
ber.
t to the co
Mark installation posi
tion and cylinder num
ber.
rrectne
Installation position and
allocation of piston to
ss
cylinder page 56
o
cial p
f i
Arrow on piston crown
nform
points to pulley end.
mer
atio
m
n
c
clamp.
i
or
n thi
e
sd
iva
renew piston.
pr
cum
r
fo
t.
yi Co
tion at TDC Cop py
page 53
t. rig
gh ht
pyri by
Vo
o
3 - Piston pin
by c lksw
cted agen
Prote AG.
If difficult to remove,
heat piston to 60C.
Remove and install with
drift -VW 222 A-
4 - Circlip
5 - Conrod
Mark cylinder number -arrows A- with coloured pen
Installation position: Marking -arrows B- faces towards pulley end.
With industrially cracked conrod bearing cap
6 - Ball socket
Note installation position.
Note type: upper bearing shell (closest to piston) is constructed from more wear-resistant material. Iden
tification: Black line on bearing surface in area of joint
Do not interchange used bearing shells
Note
10 - 25 Nm
AG. Volkswagen AG d
Insert without sealant. agen oes
olksw not
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11 - Conrod bolt, 30 Nm + 90 (1/4 turn)orfurther
ise nte
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th
u ra
Renew. ss a c
ce
e
pt
du
an
Use old bolt for measuring radial clearance
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
Special tools and workshop equipment required
es, in part or in w
t to the co
Measuring bridge -VW 382/7-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
en
ng
t.
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op py
End dimension plate -VW 385/17- t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Dial gauge
Test procedure
Note
pt
an
d
itte
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rm
ab
pe
ility
wit
, is n
h re
hole
sion
1st oversize mm 79.72 79.76
rrectness of i
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
Oil scraper ring 0.25...0.50 1.0
un
pt
an
d
itte
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Checking ring-to-groove clearance
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Special tools and workshop equipment required
urposes, in part or in wh
t to the co
Feeler gauges
Clean groove in piston before checking clearance.
rrectne
Piston ring New Wear limit
dimensions in mm
ss o
1st compression ring 0.06...0.09 0.25
cial p
f inform
2nd compression ring 0.05...0.08 0.25
mer
atio
Oil scraper ring 0.03...0.06 0.15
om
n
c
i
or
n
Checking cylinder bores
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Measuring the cylinder bores must not be done when the cylinder
block is mounted on a repair stand with adapter bracket -VW 540
- , as incorrect measurements would then be possible.
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Piston for cylinders 1 and 2: marked 1/2
es, in part or in w
t to the co
Piston for cylinders 3 and 4: marked 3/4
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
ot p
wit
, is n
When installing an exchange cylinder head with fitted cam
h re
shaft, the contact surfaces between the bucket tappets and hole
spec
the cam must be oiled before installing the cylinder head cov
es, in part or in w
er.
t to the co
The plastic protectors fitted to protect the open valves must
not be removed until immediately before fitting the cylinder
rrectness of i
head.
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
ted.
do
priv
cum
or
en
ng
t.
starting the engine. Hydraulic compensation elements must
yi Co
op py
settle (otherwise valves will strike pistons). t. C rig
gh ht
pyri by
After working on the valve gear, turn the engine carefully at
o Vo
by c lksw
cted
least 2 rotations to ensure that none of the valves make con
agen
Prote AG.
tact when the starter is operated.
Always renew gaskets and seals.
1. Cylinder head 57
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
ce
e
nl
pt
du
Removing, installing
an
itte
y li
and tensioning
erm
ab
page 62 .
ility
ot p
wit
, is n
3 - 10 Nm
h re
hole
Renew. spec
es, in part or in w
4 - 25 Nm
t to the co
5 - 100 Nm
rrectness of i
6 - Camshaft pulley
l purpos
7 - Hub
With sender wheel.
nf
ercia
Use counter-hold -
or
atio
tighten
om
n in
c
thi
e
T10052- .
t
sd
iva
o
r
cu
o
page 92 .
f
en
ng
t.
yi Co
op
8 - Rear toothed belt guard
C py
t. rig
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9 - Sealing grommet cop Vo
by lksw
cted agen
Renew if damaged. Prote AG.
ce
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un
22 - 10 Nm
pt
an
d
itte
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23 - Central connector
rm
ab
pe
ility
For unit injector.
ot
wit
, is n
h re
24 - From brake servo
hole
spec
25 - Tandem pump
es, in part or in w
t to the co
For fuel and vacuum supply.
Checking page 160 . rrectness of i
Removing and installing page 166 .
Must not be dismantled
l purpos
26 - Supply hose
nform
ercia
a
com
tio
thi
do
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rp
27 - Return hose
um
fo
en
g
t.
yi Co
op py
Blue or with blue marking t. C rig
gh ht
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Check for secure seating. cop Vo
by lksw
cted agen
Secure with spring-type clips Prote AG.
28 - Seal
Renew.
29 - Bolt/screw
30 - Cylinder head
Removing and installing page 79 .
If renewed, change coolant in entire system.
31 - Cylinder head gasket
Renew.
Note marking page 60
If renewed, change coolant in entire system.
1. Cylinder head 59
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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ss c
ce
le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Straight edge
es, in part or in w
t to the co
Feeler gauges
Max. permissible distortion: 0.05 mm.
rrectness of i
l purpos
Note
tion in
r
te o
Part No = -arrow 1-
thi
s
iva
do
cum
fo
en
g
Holes = -arrow 3-
n
t.
yi Co
Cop py
t. rig
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Note
cop Vo
by lksw
cted agen
Prote AG.
1.2 Removingageand
n AG. Vinstalling
olkswagen AG cylinder head
does
cover
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ar
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tho or
au ac
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
Special tools and workshop equipment required
Torque wrench -V.A.G 1331-
rrectness of i
Sealant, black -AMV 174 004 01-
l purpos
Removing
nf
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or
abruptly at front -arrows A- and then pull forwards out of rear
m
m
atio
fastening -arrow B-.
om
n in
or c
thi
te
sd
iva
cu
o
m
f
en
t.
yi Co
op py
Remove cylinder head cover. t. C rig
gh ht
pyri by
Vo
Installing
o
by c lksw
cted agen
Prote AG.
Install in reverse order. In the process, note the following:
Note
1. Cylinder head 61
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
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quence -113-.
rm
ab
pe
ility
Tighten the bolts in the sequence -1...13- to 10 Nm.
ot
wit
, is n
h re
Engine codes BKC, BXE
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
quence -113-.
a
com
tion in
Tighten the bolts in the sequence -1...13- to 10 Nm.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Torque wrench -
un
pt
an
V.A.G 1331-
d
itte
y li
rm
ab
Torque wrench -
pe
ility
V.A.G 1332-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 63
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Removing
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
Note
nl
pt
du
an
itte
y li
erm
Carefully seal openings of charge air duct, e.g. with a clean cloth
ab
ility
to prevent particles of dirt from entering.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Unbolt toothed belt covers (bottom and centre) -arrows-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 65
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
Fit support bracket -10 - 222 A- before the gas pressure damp AG. Volkswagen AG d
agen
er for the front flap using adapter -10 - 222 A/8- , adapter - 10 Volksw
oes
not
gu
- 222 A/3- and adapter -10 - 222 A/16- . ed by ara
n
is tee
or
Attach trigger snap of spindles to lifting eyes. On the rightauside
th or
ac
use additionally the adapter -10 - 222 A/20- ss
ce
le
un
pt
Take up weight of engine evenly with both spindles (but do not
an
d
itte
raise engine).
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
ti
engine and take engine mounting out completely.
on in
r
te o
thi
s
iva
do
Note
r
rp
cum
fo
en
ng
t.
yi
The assembly mounting may only be removed if the engine is
Co
op py
supported with support bracket -10 - 222 A- !
t. C rig
gh ht
pyri by
Vo
o
The engine bracket must be loosened only when the assembly by c lksw
cted agen
mounting has been removed. Prote AG.
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nf
ercia
orm
ment of camshaft pulley is on top. The marking on the rear toothed
m
atio
m
belt guard must align with the marking on the camshaft sender
o
n in
c
wheel -arrow-.
or
thi
te
sd
iva
o
r
cu
o
pin through the free elongated hole on left into hole in cylinder
f
en
ng
t.
yi
head.
Co
Cop py
t. rig
Lock crankshaft toothed belt pulley with crankshaft stop -
gh ht
pyri by
T10050 or T10100- . To do this, push crankshaft stop into teeth
o Vo
by c lksw
cted
of belt pulley from face side.
agen
Prote AG.
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.
1. Cylinder head 67
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
toothed belt tensioner can be locked in position using locking
ility
ot p
pin -T10115- .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
Now turn two-hole pin wrench -T10020 - clockwise onto top
rm
m
n in
c
Remove toothed belt first from coolant pump and then from
or
thi
e
remaining pulleys.
t
sd
iva
o
r
rp
cu
Installing
o
m
f
en
ng
t.
yi
Lock camshaft with pin -3359- .
Co
Cop py
ht. rig
Lock crankshaft with crankshaft stop -T10050 or T10100- .
rig ht
py by
co Vo
by lksw
The tensioning roller must be fitted with pin -T10115- and
cted agen
Prote AG.
locked right-hand.
Note
Note
Ensure that tensioning roller seats correctly in rear toothed beltn AG. Volkswagen AG do
guard -arrow-. olks
wage es n
ot
yV gu
db ara
ise nte
Loosen tensioning roller securing nut and pull
tho out locking
r
pin eo
-T10115- . s au ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Now turn carefully tensioning roller with two-hole pin wrench -
hole
spec
-arrow- in the base plate.
es, in part or in w
t to the co
Ensure that securing nut does not turn as well.
Hold tensioning roller in this position and tighten tensioning
rrectness of i
roller securing nut as follows: 20 Nm and 45 (1/8 turn) further.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
Fit counter-hold tool -T10172- with pins -T10172/4- as shown.
s
iva
do
Press counter-hold -T10172- in -direction of arrow- and hold
r
rp
cum
fo
en
ng
t.
yi Co
In this position, tighten camshaft toothed belt pulley securing Cop py
t. rig
bolts -1- to 25 Nm. gh ht
pyri by
Vo
co lksw
by
Remove locking pin -3359- and crankshaft stop -T10050 or Prote
cted AG.
agen
T10100- .
Turn crankshaft two rotations in engine direction of rotation
until crankshaft is just before TDC No. 1 cylinder.
1. Cylinder head 69
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
ce
le
un
pt
an
d
itte
y li
erm
ab
Fit counter-hold tool -T10172- with pins -T10172/4- as shown.
ility
ot p
wit
is n
h re
ole,
spec
In this position, tighten camshaft toothed belt pulley securing
urposes, in part or in wh
t to the co
Remove locking pin -3359- and crankshaft stop -T10050 or
T10100- .
rrectne
Turn crankshaft two rotations in engine direction of rotation
until crankshaft is just before TDC No. 1 cylinder.
ss o
cial p
f
Repeat check.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 71
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Removing
ss
atio
om
n
c
WARNING
i
or
n thi
te
sd
va
In extreme cases the fuel lines and the fuel can reach a
i
o
pr
cum
r
en
ng
Pull fuel supply hose -1- and fuel return hose -2- off fuel lines.
Pull off coolant line -3-.
Remove bolts -1-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
Disconnect fuel supply line
ss -3- and return line -2- by pulling c
release tabs.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 73
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
Remove upper toothed belt guard, to do this, loosen retainingen AG. Volkswagen AG
clips -arrows-. ag does
ksw not
Vol gu
by ara
Remove front right wheel housing liner. ed nte
oris eo
h
ut ra
Remove belt pulley with vibration damper. ss a c
ce
e
nl
pt
du
an
itte
y li
Turn crankshaft to TDC No. 1 cylinder.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Turn crankshaft until marking on crankshaft pulley and tooth seg
l purpos
nform
ercia
wheel -arrow-.
m
at
om
io
Lock hub using locking pin -3359- . To do this slide locking pin
n
c
in t
r
his
e
head.
at
do
priv
cum
en
g
t.
yi Co
op
pulley from face side. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Note
agen
Prote AG.
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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Turn eccentric of tensioning roller anti-clockwise -arrow- using
es, in part or in w
t to the co
locking tool -T10265- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
Now turn eccentric of tensioning roller clockwise -arrow- to
te
sd
a
o
r
rp
cu
o
Remove toothed belt first from coolant pump and then from
f
en
ng
t.
yi
remaining toothed belt pulleys.
Co
Cop py
t. rig
gh
Installing
ht
pyri by
Vo
o
by c lksw
Camshaft locked with locking pin -3359- .
cted agen
Prote AG.
Note
1. Cylinder head 75
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
Note
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
Tighten bolts -1- of camshaft toothed belt pulley to 25 Nm.
ility
ot p
h re
hole
t to the co
rrectness of i
l purpos
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
Loosen securing bolts -1- for camshaft toothed belt pulley.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 77
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
ce
e
nl
Remove locking pin -3359- and crankshaft stop -T10100- .
pt
du
an
itte
y li
Turn crankshaft two rotations in engine direction of rotation erm
ab
until crankshaft is just before TDC No. 1 cylinder.
ility
ot p
wit
, is n
h re
hole
spec
Install centre and lower parts of toothed belt guard.
es, in part or in w
t to the co
Install belt pulley vibration damper. Torque setting: 10 Nm +
90 (1/4 turn) further.
Install poly-V-belt page 29 .
rrectness of i
Install upper toothed belt guard.
l purpos
nf
ercia
orm
Install front right wheel housing liner.
m
atio
om
n in
Install coolant expansion tank.
or c
thi
te
sd
iva
o
r
rp
cu
-arrows-.
o
m
f
en
ng
t.
yi Co
Engage fuel filter in bracket. t. Cop py
rig
gh ht
yri
Bolt on filler neck for window wash system. p by
o Vo
by c lksw
cted agen
Fit engine cover. Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Special tools and workshop
ility
ot p
equipment required
wit
, is n
h re
Drip tray -V.A.G 1306- or
hole
spec
drip tray for workshop hoist
es, in part or in w
-VAS 6208-
t to the co
Torque wrench -
V.A.G 1331-
rrectness of i
Torque wrench -
l purpos
V.A.G 1332-
Diesel extractor -VAS
nf
ercia
5226- or hand-operated
or
vacuum pump with acces
m
m
atio
sories -V.A.G 1390- and
om
n in
or c
thi
te
V.A.G 1390/1 -
sd
iva
o
r
rp
cu
Retainer -T10014- (only ve
o
m
f
en
ng
hicles 05.05)
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 79
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
Note
All cable ties which are opened or cut through when cylinder head
is removed must be replaced in the same position when cylinder
head is installed.
Caution
Removing page 80
Installing page 82
1.4.1 Removing
Note
pt
du
an
itte
y li
ab
ility
ot p
Remove air filter housing with air mass meter and connecting
wit
, is n
pipe.
h re
hole
spec
es, in part or in w
t to the co
Pull breather hose -1- and air duct hoses -3- and -5- off.
l purpos
orm
m
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
pt
an
y li
rm
ab
pe
ility
Remove securing bolts for rear toothed belt guard -2- and
ot
wit
-4- .
, is n
h re
hole
a
com
tio
Note
n in
r
te o
thi
s
Both lifting eyes for the support are located on the cylinder head,
iva
do
r
cum
fo
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
81
cted agen
Prote AG.
1. Cylinder head
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Maintain sequence when loosening cylinder head bolts.
es, in part or in w
t to the co
Lift cylinder head slightly and remove from engine past toothed
belt guard.
rrectness of i
Note
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
1.4.2 Installing
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Note py by
co Vo
by lksw
cted agen
Prote AG.
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 made on the surfaces. When using abrasive
paper do not use a grade less than 100.
Carefully remove remains of emery and abrasives.
Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
Note
ce
le
un
1- Tighten initially with torque wrench:
pt
an
d
itte
y li
Stage I = 35 Nm
erm
ab
ility
ot p
Stage II = 60 Nm
wit
is n
h re
2- Turn further with rigid wrench:
ole,
spec
urposes, in part or in wh
t to the co
Stage IV = 1/4 turn (90)
rrectne
Note
ss o
cial p
f
It is not necessary to retighten cylinder head bolts after repairs.
inform
mer
atio
Further installation is carried out in the reverse order. In the proc
om
n
ess, note the following:
c
i
or
n thi
te
sd
va
o
pr
cum
r
that the cam lobs -arrows- for cylinder No. 1 point evenly up
fo
en
ng
Note
1. Cylinder head 83
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Test prerequisites
Engine oil temperature min. 30C. rrectne
Test procedure
s
f inform
mer
Note
atio
om
n
c
i
or
sd
iva
o
pr
cum
r
fo
t.
yi Co
extension and socket -3220- . t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Note
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 85
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
2 Valve gear
n AG. Volkswagen AG do
lkswage es n
o ot g
Note d byV ua
ran
ir se tee
tho
or
When installing an exchange
ss
au
cylinder head with fitted cam ac
shaft, the contact surfaces between the bucket tappets and
ce
e
nl
the cam must be oiled before installing the cylinder head cov
pt
du
an
er.
itte
y li
erm
ab
The plastic protectors fitted to protect the open valves must
ility
ot p
wit
, is n
head.
h re
hole
spec
If the cylinder head is renewed, all the coolant in the system
es, in part or in w
t to the co
Cylinder heads with cracks between the valve seats may be
used without reducing engine life, provided the cracks are
rrectness of i
small and not more than 0.5 mm wide.
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
c
tact when the starter is operated.
um
for
en
ng
t.
Always renew gaskets and seals.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
Renewing valve stem seals page 90
un
pt
an
d
itte
y li
Removing and installing camshaft page 92
erm
ab
ility
ot p
Removing and installing camshaft seal page 95
wit
is n
h re
2.1 Assembly overview - valve gear
ole,
spec
urposes, in part or in wh
t to the co
1 - 20 Nm + 90 (1/4 turn) fur
ther
rrectne
Renew.
Note sequence for loos
s
ening and tightening
s o
cial p
page 92
f inform
mer
atio
m
Do not interchange.
o
n
c
i
or
n
3 - Cylinder head bolt
thi
te
sd
va
Renew.
i
o
pr
cum
r
fo
en
ng
t.
yi
ening and tightening
Co
op py
page 79 t. C rig
gh ht
yri by
Before installing, insert
op Vo
by c lksw
washers cted agen
Prote AG.
Item 4 (page 87) in
cylinder head.
4 - Washer
For cylinder head bolts.
Insert in cylinder head
before installing bearing
caps
5 - Bucket tappet
Do not interchange.
With hydraulic valve
clearance compensa
tion.
Place down with contact
surface facing down
wards
Before installing check
camshaft axial clear
ance page 88
Oil contact surface.
Before removing, remove camshaft bearing caps
6 - Cotters
7 - Valve spring plate
8 - Outer valve spring
Removing and installing, cylinder head removed: using valve spring compressor -2037- .
Removing and installing, cylinder head installed: page 90
9 - Inner valve spring
Removing and installing, cylinder head removed: using valve spring compressor -2037- .
Removing and installing, cylinder head installed: page 90
2. Valve gear 87
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
ce
le
pt
an
d
itte
18 - Bearing cap
y li
rm
ab
pe
To install seal bearing cap contact surfaces 1 and 5 seal with sealant, black -AMV 174 004 01- wit
, is n
h re
page 89
hole
spec
t to the co
Renew.
rrectness of i
a
com
tio
Dial gauge
n in
r
te o
thi
Check with bucket tappets removed and with first, third and last
s
iva
do
cum
fo
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
ce
e
nl
is permitted.
pt
du
an
itte
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erm
ab
Dimension Inlet valve Exhaust valve
ility
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, is n
a mm 35.95 31.45
h re
hole
b mm 6.980 6.956
spec
es, in part or in w
c mm 89.95 89.95
t to the co
45 45
rrectness of i
2.5 Checking valve guides
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Dial gauge
2. Valve gear 89
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
Test procedure
Insert new valve into guide. The end of the valve stem must
be flush with the guide. Due to differences in stem diameters,
use only an inlet valve in inlet guide and an exhaust valve in
exhaust guide.
Determine rock. Wear limit: max. 1.3 mm.
Cylinder head must be renewed if rock exceeds wear limit.
ce
le
pt
an
d
itte
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Puller -3047 A-
rm
ab
pe
ility
Valve stem seal fitting tool
ot
wit
, is n
-3129-
h re
hole
spec
Valve lever -VW 541/1A-
es, in part or in w
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing page 90
Installing page 91
2.6.1 Removing
(with cylinder head installed)
ce
le
un
pt
Set piston of respective cylinder to top dead centre (TDC).
an
d
itte
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rm
ab
Insert valve assembly device -2036- and adjust mounting to
pe
ility
height of studs.
ot
wit
, is n
h re
Remove valve springs using lever -VW 541/1A- and thrust
hole
spec
piece -VW 541/5- .
es, in part or in w
t to the co
Note
rrectness of i
The valves are supported by the piston crown.
l purpos
nform
mercia
a
Pull off valve stem seals using puller -3047 A- .
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.6.2 Installing
Place the plastic sleeve -A- supplied on the appropriate valve
stem. This will prevent the new valve stem seal -B- being
damaged.
Insert new valve stem seal in fitting tool -3129- .
Lubricate sealing lip of valve stem seal and carefully push on
valve guide.
Further installation is carried out in the reverse order.
2. Valve gear 91
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing page 92
Installing page 94
2.7.1 Removing
Remove toothed belt page 62 .
Remove securing bolts for camshaft toothed belt pulley -1-.
Pull camshaft toothed belt pulley off hub.
n AG. Volkswagen AG do
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Apply puller -T10052- and screw securing bolts -1-byinto Vo hub.
l ot g
ua
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ir se
Put the hub under pressure by tightening up theth puller until the
o tee
or
hub loosens from the camshaft taper. ss
au ac
ce
e
nl
pt
du
an
itte
Note
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
Remove cylinder head cover.
rrectness of i
tipped pen to avoid confusion and therefore the injection pump
basic setting.
l purpos
nform
mercia
at
Note
om
ion
c
in t
or
First loosen both outer and then inner securing bolts respectively.
his
ate
do
priv
cum
or
en
ng
t.
yi Co
Cop py
t. rig
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yri
First remove bearing caps 5, 1 and 3. Then loosen bearing p by
co Vo
caps 2 and 4 alternately and diagonally.
by lksw
cted agen
Prote AG.
Remove camshaft.
2. Valve gear 93
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
2.7.2 Installing
Note
Note
pt
an
d
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erm
ab
ility
ot p
Install rocker shafts and tighten inner -2- and then the outer wit
is n
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
i
or
n thi
e
sd
iva
o
pr
cum
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
le
un
pt
an
d
itte
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rm
ab
Note
pe
ility
ot
wit
, is n
h re
hole
spec
(otherwise valves will strike pistons).
es, in part or in w
t to the co
2.8 Removing and installing camshaft oil seal
rrectness of i
l purpos
nform
ercia
a
com
ti
Oil seal extractor -3240- on in
r
te o
thi
1331-
do
r
rp
cum
fo
t.
yi
1332-
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Valve gear 95
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
Removing page 96
Installing page 96
2.8.1 Removing
Remove toothed belt page 62 .
Remove camshaft pulley and hub page 92 .
Unscrew inner part of oil seal extractor - 3240- two turns (ap
prox. 3 mm) out of outer part and lock with knurled screw.
Lubricate threaded head of oil seal extractor -3240- , place it
in position and exerting firm pressure screw it into oil seal as
far as possible. AG. Volkswagen n AG do
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Loosen knurled screw and turn innerypart Vol against camshaft ot g
ua
until the oil seal is pulled out. rised b ran
tee
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e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
2.8.2 Installing
es, in part or in w
t to the co
Note
rrectness of i
The oil seal sealing lip must not be additionally oiled or greased.
l purpos
at
om
io
in t
or
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e
do
riv
cum
for
en
g
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
17 Lubrication
1 Engine oil
Note
The oil level must not be above the max. mark, danger of damage
to catalytic converter!
pt
Wait a few minutes after switching off the engine to allow the
an
d
itte
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ab
pe
ility
Test procedure
ot
wit
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Pull out the dipstick, wipe off with a clean cloth and insert it
hole
Pull out the dipstick again and read off the oil level.
t to the co
1 - Max. mark
l purpos
2 - Min. mark
a - Area above grooved section up to max. mark: Do not top up
nform
ercia
tion in
thi
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Engine oil 97
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
Caution
AG. Volkswagen AG d
agen o
Finding metal shavings or a large Vquantity
olks
w
of small metal pares not g
ticles during engine repair could d by indicate that the crankshaft ua
ran
ise
bearings or conrod bearings hor
are damaged. To prevent this tee
ut or
from causing further damage,
ss
a perform the following repairs: ac
ce
e
pt
du
an
itte
y li
Replace oil cooler.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Oil pump, oil sump - assembly overview, engine codes BKC, BLS,
es, in part or in w
BXE page 98
t to the co
Oil pump, oil sump - assembly overview, engine code BRM
page 100
rrectness of i
Removing and installing sump page 101
l purpos
nform
ercia
2.1 Oil pump, oil sump - assembly overview, engine codes BKC, BLS, BXE
m
at
om
ion
c
1 - 15 Nm
in t
or
his
ate
2 - Sealing flange
do
priv
cum
or
en
ng
t.
yi
Must seat on dowel
Co
op py
sleeves.
t. C rig
gh ht
yri by
Removing and installing cop Vo
by lksw
cted
page 35
agen
Prote AG.
7 - Dowel sleeves
8 - O-ring
Renew.
9 - 15 Nm
10 - Suction line
Clean strainer if soiled
11 - Baffle plate
12 - 15 Nm
13 - 15 Nm
14 - Sump
Clean sealing surface before installing
Install with silicone sealant -D 176 404 A2-
Removing and installing page 101 . AG. Volkswagen AG d
agen oes
olksw not
15 - Oil drain plug, 30 Nm d byV gu
ara
ise nte
With attached seal. hor eo
aut ra
Renew. ss c
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nl
16 - 10 Nm
pt
du
an
itte
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17 - Oil level and oil temperature gauge -G266 -
erm
ab
ility
ot p
wit
, is n
h re
18 - Oil seal
hole
spec
Renew.
es, in part or in w
t to the co
19 - Oil pump
With 12 bar pressure relief valve.
rrectness of i
Before installing, check that both dowel sleeves Item 7 (page 98) are fitted for centralising oil pump/
cylinder block.
l purpos
nf
ercia
orm
21 - Retainer
m
atio
om
For Oil level and oil temperature sender -G266- wiring harness
n in
or c
thi
e
sd
iva
o
r
rp
cu
Renew.
o
m
f
en
ng
t.
yi
23 - Chain
Co
Cop py
ht. rig
ht
24 - 25 Nm
rig by
copy Vo
by lksw
Insert without sealant. cted agen
Prote AG.
Note
2.2 Oil pump, oil sump - assembly overview, engine codes BRM
AG. Volkswagen AG d
1 - 15 Nm agen oes
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2 - Sealing flange orise nte
th eo
With oil seals au ra
c
s
Must seat on dowel
ce
le
un
pt
sleeves.
an
d
itte
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Removing and installing
rm
ab
pe
page 35
ility
ot
wit
Install with silicone seal
, is n
h re
ant -D 176 404 A2-
hole
spec
page 35
es, in part or in w
t to the co
grease the oil seal seal
ing lip.
rrectness of i
Before installing, re
move oil residue from
l purpos
nform
ercia
a
page 33
com
tion in
r
te o
do
r
rp
en
g
t.
yi Co
gage Cop py
ht. rig
rig ht
4 - Oil dipstick py by
co Vo
by lksw
cted
The oil level must not be
agen
Prote AG.
above the max. mark!
Markings page 97
5 - Dipstick guide
6 - Guide tube
7 - Dowel sleeves
8 - O-ring
Renew.
9 - 15 Nm
10 - Suction line
Clean strainer if soiled
11 - Baffle plate
12 - 15 Nm
13 - 15 Nm
14 - Sump
Clean sealing surface before installing
Install with silicone sealant -D 176 404 A2-
Removing and installing page 101
15 - Oil drain plug, 30 Nm
With attached seal.
Renew.
16 - 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.
17 - Oil pump chain sprocket
18 - 20 Nm + 90 (1/4 turn) further
n AG. Volkswagen AG do
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Renew. yV
olks ot g
d b ua
ran
19 - Chain ir se tee
tho
u or
a ac
20 - 25 Nm ss
ce
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pt
du
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21 - Oil spray jet
erm
ab
ility
For piston cooling
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
2.3 Removing and installing sump
rrectness of i
l purpos
nform
ercia
at
om
io
Tool insert 5 mm -3249-
n
c
in t
or
his
e
do
riv
1331-
p
cum
for
en
g
t.
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op
-VAS 6208 - C py
t. rig
gh ht
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Silicone sealant -D 176 404
p by
co Vo
by lksw
A2- Prote
cted AG.
agen
2.3.1 Removing
Remove engine cover. To do this, pull engine cover upwards
abruptly at front -arrows A- and then pull forwards out of rear
fastening -arrow B-.
Remove intake hose air filter/exhaust turbocharger.
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Remove both bolts -arrows- from upper charge air pipe -A-.
Remove noise insulation General body repairs, exterior;
Rep. Gr. 50 ; Noise insulation .
Remove the bolt -arrows- of the charge air pipe -A- from the
oil sump.
If fitted, pull connector off oil level and oil temperature sender
-G266- .
Drain engine oil.
Note
pt
du
an
itte
ab
ility
ot p
spec
nform
mercia
at
om
ion
c
2.3.2 Installing
in t
or
his
ate
do
priv
cum
for
Note
en
ng
t.
yi Co
Cop py
. rig
Observe the use-by date of the sealing compound.
ht ht
rig by
copy Vo
lksw
The sump must be installed within 5 minutes of applying sili
by
cted agen
Prote
cone sealing compound.
AG.
ce
e
pt
du
excess sealing compound will enter the oil sump and may
an
itte
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block the oil suction line strainer.
erm
ab
ility
ot p
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block.
h re
hole
spec
If gearbox is installed, sump must rest against gearbox.
es, in part or in w
t to the co
Apply silicone sealing compound bead as shown to the clean
sealing surface of the sump. (The figure shows the position of
rrectness of i
the sealant bead on the cylinder block.)
l purpos
nform
mercia
at
om
Note ion
c
in t
or
his
ate
When installing sump with engine out of vehicle, ensure that sump
do
priv
en
ng
t.
yi Co
op
Tighten sump bolts diagonally to 15 Nm.
C py
t. rig
gh ht
yri by
Tighten sump to gearbox bolts to 45 Nm. cop Vo
by lksw
cted agen
Prote AG.
Note
After fitting sump assembly, the sealant must dry for approx. 30
minutes. Then (and only then) fill the engine with engine oil.
2.4.1 Removing
Remove the oil sump and the baffle plate page 101 .
ce
le
un
pt
Remove bolts -2-.
an
d
itte
y li
rm
ab
Pull sprocket off oil pump shaft.
pe
ility
ot
Remove bolts -1- and -3- and remove oil pump.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
2.4.2 Installing
m
a
com
t
Install in reverse order. In the process, note the following:
ion in
r
te o
thi
s
iva
do
r
cum
fo
shaft.
en
ng
t.
yi Co
op
Install sump page 101 . C py
t. rig
gh ht
yri by
Torque settings cop Vo
by lksw
cted agen
Prote AG.
Component Nm
Sprocket to oil 20 + 901)
pump shaft
Oil pump to cyl 15
inder block
1) Renew bolt.
ce
le
un
pt
1 - Oil filter bracket
an
d
itte
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erm
ab
ility
ot p
ther
wit
is n
Renew.
h re
ole,
spec
First fit upper left and
urposes, in part or in wh
t to the co
then tighten all four bolts
diagonally.
rrectne
3 - Seal
Renew.
ss
4 - Oil seal
o
cial p
f in
Renew.
form
mer
atio
5 - Pipe union, 35 Nm
om
n
c
i
6 - Oil supply line, 22 Nm
or
n thi
te
sd
a
To turbocharger
iv
o
pr
cum
r
en
ng
page 114 .
t.
yi Co
Cop py
7 - Cap, 25 Nm
t. rig
gh ht
pyri by
Loosen and tighten with
co Vo
by lksw
cted agen
socket -T10125 - Prote AG.
8 - Oil seal
Renew.
9 - Oil filter element
Ensure that "Top" is up
permost when fitting.
10 - Plug, 10 Nm
If sealing ring is leaking,
nip open and renew.
11 - Oil pressure switch -F1-
0.7 bar switch: brown.
Tighten to 20 Nm torque
If sealing ring is leaking, nip open and renew.
Checking page 112 .
12 - Plug, 25 Nm
13 - Seal
Renew.
14 - Oil cooler
Ensure clearance to adjacent components.
See note page 98 .
Checking oil cooler for leaks page 140
15 - Seal
Renew.
16 - Retainer
17 - 10 Nm
3.2 Removing and installing oil filter bracket with oil cooler
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Oil filter bracket, oil pressure, oil cooler and oil supply line 107
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
3.2.1 Removing
Remove engine cover. To do this, pull engine cover upwards
abruptly at front -arrows A- and then pull forwards out of rear
fastening -arrow B-.
Vehicles with engine codes BKC, BXE
Remove air filter housing with air mass meter and connecting
pipe. agen
AG. Volkswagen AG d
oes
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d b ara
rise nte
tho eo
au ra
ss c
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le
un
pt
an
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erm
ab
Disconnect connector -2- on air mass meter -G70- .
ility
ot p
wit
is n
Pull breather hose -1- and air duct hoses -3- and -5- off.
h re
ole,
spec
urposes, in part or in wh
t to the co
Remove air cleaner housing with air mass meter.
rrectness o
cial p
f inform
mer
atio
m
n
c
i
or
n
Pull breather hose -1- off and unhook from bracket -arrow-.
thi
te
sd
iva
o
pr
cum
r
fo
5024A- and pull intake hose off air mass meter -G70- .
en
ng
t.
yi Co
Pull intake manifold -5- off the air duct. Cop py
t. rig
gh ht
yri
Unscrew bolt -4- and take off air filter housing. p by
co Vo
by lksw
cted agen
Continuation for all models
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
Remove lower left air duct hose from front air duct pipe. To do
ole,
spec
urposes, in part or in wh
t to the co
Vehicles with engine codes BKC, BXE
Remove bolts -1-.
rrectne
Unclip coolant hose on air duct pipe -arrow-.
Vehicles with engine codes BLS, BRM
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
Remove both bolts -arrows- from upper charge air pipe -A-.
t
sd
iva
o
pr
cum
Remove the bolt -arrows- of the charge air pipe -A- from the
r
fo
en
ng
oil sump.
t.
yi Co
Cop py
Continuation for all models
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Oil filter bracket, oil pressure, oil cooler and oil supply line 109
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
Disconnect connector -arrow- on engine speed sender -G28- .
un
pt
an
d
itte
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Free wiring on wiring retainer.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f
Disconnect connector on oil pressure switch -F1- -1-.
inform
mer
atio
om
n
Remove oil supply pipe to turbocharger on retainer -3- and on
c
i
or
n
oil filter bracket -2-.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3.2.2 Installing
Install in reverse order. In the process, note the following:
Note
ce
le
un
pt
-A-.
an
d
itte
y li
rm
Fill up cooling system if the oil cooler has been renewed (use
ab
pe
ility
fresh coolant if necessary) page 127 .
ot
wit
, is n
h re
hole
spec
Torque settings
es, in part or in w
t to the co
Component Nm
Oil filter bracket to cylinder block 15 + 902)
rrectness of i
Oil pressure switch to oil filter bracket 20
l purpos
nform
ercia
a
com
tio
2) Renew bolts.
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Oil filter bracket, oil pressure, oil cooler and oil supply line 111
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Test procedure
Note
Functional check and servicing the optical and acoustic oil pres
sure warning Current flow diagrams, Electrical fault finding and
Fitting locations,Guided functions with Vehicle diagnosis, test
ing and information system -VAS 5051B - .
ce
le
un
Start engine and increase speed slowly.
pt
an
d
itte
y li
At 0.55...0.85 bar the LED must light up, otherwise renew oil
rm
ab
pe
pressure switch.
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
At higher engine speed, oil pressure must not exceed 7.0 bar. If
necessary renew oil filter bracket.
rrectness of i
3.4 Assembly overview - oil supply line to turbocharger
l purpos
1 - Retaining clamp
nform
ercia
2 - 25 Nm
m
a
com
tio
3 - Oil supply line
n in
r
te o
To turbocharger
thi
s
iva
do
4 - 10 Nm
r
rp
cum
fo
en
g
5 - Retainer
n
t.
yi Co
Cop py
6 - Union nut, 22 Nm
t. rig
gh ht
pyri by
Vo
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by c
7 - 10 Nm
lksw
cted agen
Prote AG.
8 - Union nut, 22 Nm
3. Oil filter bracket, oil pressure, oil cooler and oil supply line 113
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
. Volkswagen AG
gen AG
3.5 Removing and installing yoilVol supply line
a does
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gu
to turbocharger d b ara
ise nte
or h eo
ut ra
Special tools and workshop equipment
ss
a
required c
ce
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nl
Torque wrench -V.A.G 1331-
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3.5.1 Removing
Remove engine cover. To do this, pull engine cover upwards
abruptly at front -arrows A- and then pull forwards out of rear
fastening -arrow B-.
Vehicles with engine codes BKC, BXE
Remove air filter housing with air mass meter and connecting
pipe.
ce
le
un
pt
an
d
itte
y li
Unclip coolant hose on air duct pipe -arrow-.
rm
ab
pe
ility
Vehicles with engine codes BLS, BRM
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Remove both bolts -arrows- from upper charge air pipe -A-.
rrectness of i
Remove the bolt -arrows- of the charge air pipe -A- from the
l purpos
oil sump.
Continuation for all models
nform
ercia
a
com
tion in
Loosen oil supply line union nuts on oil filter bracket and tur
r
te o
thi
bocharger.
s
iva
do
r
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Oil filter bracket, oil pressure, oil cooler and oil supply line 115
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
3.5.2 Installing
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
19 Cooling
1 Parts of the cooling system
WARNING
ce
le
un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
When the engine is warm, the cooling system is under pres
es, in part or in w
clips.
m
a
com
thi
do
r
rp
en
ng
t.
yi
The arrows on the coolant pipes and on the ends of the hoses
Co
op py
must be aligned with each other.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Carry out leak test of cooling system with cooling system tester -
V.A.G 1274- and the adapter -V.A.G 1274/8- and adapter -
V.A.G 1274/9- .
Parts of cooling system - body side, engine codes BLS, BRM
page 118
Parts of cooling system - body side, engine codes BKC, BXE
page 119
Parts of cooling system - engine side, engine codes BLS, BRM
page 120
Parts of cooling system - engine side, engine codes BKC, BXE
page 123
Coolant hose schematic diagram page 125
Draining and filling coolant page 127
Removing and installing radiator fan - V7- and radiator fan 2 -
V177- page 130
Removing and installing radiator page 132
Removing and installing coolant pump page 134
Removing and installing thermostat page 136
Checking cooling system for leaks page 138
Checking oil cooler for leaks page 140
1.1 Parts of cooling system - body side, engine codes BLS, BRM
1 - Radiator
Removing and installing
page 132 .
AG. Volkswagen AG d
If renewed, change agen oes
olksw not
coolant in entire system. d by
V gu
ara
ise nte
r
2 - O-ring ut
ho eo
ra
a c
Renew if damaged. ss
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nl
pt
du
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ab
wit
, is n
4 - Cap
h re
hole
5 - Connector
nf
ercia
6 - 3 Nm
rm
m
atio
m
7 - Expansion tank
o
n in
or c
sd
iva
G32-
r
rp
cu
o
m
f
t.
yi Co
tem tester -V.A.G 1274 - Cop py
and adapter -
t. rig
gh ht
yri
V.A.G 1274/8-
p by
o Vo
by c lksw
page 138 Prote
cted AG.
agen
1.2 Parts of cooling system - body side, engine codes BKC, BXE
pt
If renewed, change
an
d
itte
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ab
ility
ot p
4 - Cap
wit
is n
bar
5 - Connector
ss o
cial p
6 - 3 Nm
inform
mer
7 - Expansion tank
atio
m
n
c
n thi
e
G32-
t
sd
iva
o
r
cum
r
fo
t.
yi
and adapter -
Co
op py
V.A.G 1274/8-
t. C rig
gh ht
yri
page 138 p by
co Vo
by lksw
cted agen
Prote AG.
ce
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un
pt
an
d
itte
9 - 5 Nm
y li
erm
ab
10 - Fan support
ility
ot p
wit
is n
11 - Radiator fan 2 -V177-
h re
Only vehicles with optional equipment. ole,
spec
urposes, in part or in wh
Removing and installing page 130 .
t to the co
12 - Radiator fan -V7-
With radiator fan control unit -J293-
rrectne
Removing and installing page 130 .
ss
13 - Connector
o
cial p
f in
14 - Lower coolant hose
form
mer
atio
om
n
15 - Securing clip
c
i
or
n thi
e
sd
iva
o
pr
c
16 - Radiator outlet coolant temperature sender -G83-
um
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
1.3 Parts of cooling system - engine side, engine codes BLS, BRM
py by
co Vo
by lksw
cted agen
Prote AG.
1 - 10 Nm
2 - To exhaust gas recircula
tion cooler
Coolant hose schematic
diagram page 125 .
3 - Coolant pipe
Coolant hose schematic
diagram page 125 .
4 - Coolant pipe
Coolant hose schematic
diagram page 125 .
5 - To heat exchanger
Coolant hose schematic
diagram page 125 .
6 - To auxiliary heater
Coolant hose schematic
diagram page 125 .
7 - O-ring
Renew.
8 - Securing clip
Check for secure seat
ing.
9 - Coolant temperature send
er -G62-
With coolant tempera
ture gauge sender -G2-
10 - To exhaust gas recircula
tion cooler
Coolant hose schematic
diagram page 125 .
11 - Connection
AG. Volkswagen AG d
agen
12 - 10 Nm Volksw
oes
not
gu
by ara
d
13 - Connecting hoseorise nte
eo
th
u ra
14 - T-piece ss a c
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nl
15 - To top of radiator
pt
du
an
itte
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Coolant hose schematic diagram page 125 .
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
17 - Gearbox oil cooler
Vehicles with direct shift gearbox only
rrectness of i
18 - To heat exchanger
Coolant hose schematic diagram page 125 .
l purpos
19 - 40 Nm
nf
ercia
orm
m
atio
om
n in
Coolant hose schematic diagram page 125 .
or c
thi
te
sd
21 - Coolant pipe
iva
o
r
rp
cu
Coolant hose schematic diagram page 125 .
o
m
f
en
ng
t.
yi
22 - 15 Nm
Co
Cop py
t. rig
gh
23 - Coolant hose
ht
pyri by
Vo
co lksw
by
To oil cooler for engine oil Prote
cted AG.
agen
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un
pt
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d
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ab
40 - T-piece
ility
ot p
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41 - To top of radiator
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.4 Parts of cooling system - engine side, engine codes BKC, BXE
ce
e
nl
pt
du
an
10 - To heat exchanger
itte
y li
erm
ab
Coolant hose schematic
ility
ot p
h re
11 - 40 Nm
hole
spec
12 - T-piece
es, in part or in w
t to the co
13 - To bypass flap.
Coolant hose schematic diagram page 125 .
rrectness of i
14 - T-piece
l purpos
15 - To top of radiator
Coolant hose schematic diagram page 125 .
nform
ercia
16 - 15 Nm
m
at
om
io
in t
or
do
riv
18 - Coolant pipe
p
cum
for
en
g
19 - To bottom of radiator
n
t.
yi Co
op py
Coolant hose schematic diagram page 125 .
. C rig
ht ht
rig by
py Vo
20 - Connection
co lksw
by
cted agen
Prote
For thermostat.
AG.
21 - Thermostat
Removing and installing page 136 .
Note installation position page 136 .
Checking: heat thermostat in water.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
le
pt
an
d
itte
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5 - Cylinder head/cylinder
erm
ab
block
ility
ot p
wit
is n
6 - Oil cooler
h re
ole,
spec
urposes, in part or in wh
t to the co
tomatic gearbox
7 - Coolant hose (top)
rrectne
8 - Radiator
s
9 - Lower coolant hose
s o
cial p
f
10 - Oil cooler
inform
mer
atio
m
n
c
i
or
n
mostat
thi
te
sd
va
12 - Auxiliary heater
i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1 - Expansion tank
2 - Cylinder head/cylinder
block
3 - Exhaust gas recirculation
cooler
4 - Heater unit heat exchanger
5 - Oil cooler
For automatic transmis
sion fluid
Only models with an au
tomatic gearbox
6 - Coolant hose (top)
7 - Radiator
8 - Lower coolant hose
AG. Volkswagen AG d
agen
9 - Oil cooler Volksw
oes
not
gu
by ara
For engine oil. rised
nte
ho eo
ut
10 - Coolant pump and ther
ss a ra
c
mostat
ce
le
un
pt
an
11 - Auxiliary heater
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Draining page 127 cted agen
Prote AG.
1.6.1 Draining
Note
WARNING
Raise retaining clip -arrow- slightly and pull coolant hose from
radiator.
Continuation for all models
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
To drain coolant from engine also remove coolant oris hose at oil
e nte
eo
cooler -arrow-. aut
h
ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
ot p
wit
, is n
Only use coolant additive G 12 in accordance with
h re
hole
TL VW 774 F. Identification: coloured lilac.
spec
es, in part or in w
G 12 purple (in accordance with TL VW 774 F) can be mixed
t to the co
with the previous coolant additive G 12 red!
G 12 and coolant additives marked In accordance with TL
rrectness of i
VW 774 F prevent frost and corrosion damage, scaling and
also raise boiling point of coolant. Therefore, the cooling sys
l purpos
tem must be filled all year round with frost and corrosion
protection additives.
nform
ercia
at
om
io
ical climates.
n
c
in t
or
his
Frost protection is required down to about -25C (in countries
ate
do
riv
cum
for
en
ng
t.
yi
ter even in warmer seasons and in warmer countries. The
Co
Cop py
antifreeze percentage must be at least 40%.
t. rig
gh ht
pyri by
Vo
o
If for climatic reasons greater frost protection is required, the
c by lksw
cted agen
amount of G 12 can be increased, but only up to 60% (frost
Prote AG.
ce
le
un
pt
Continuation for all models
an
d
itte
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Connect coolant hoses to oil cooler.
rm
ab
pe
ility
ot
Install noise insulation General body repairs, exterior; Rep.
wit
, is n
Gr. 50 ; Noise insulation .
h re
hole
spec
Filling with cooling system charging unit -VAS 6096-
es, in part or in w
t to the co
Screw adapter for cooling system tester -V.A.G 1274/8- onto
expansion tank.
rrectness of i
Fill coolant circuit using cooling system charging unit -
VAS 6096- manual for cooling system charging unit
l purpos
VAS 6096 .
Filling without cooling system charging unit -VAS 6096-
nform
mercia
a
com
tio
expansion tank -arrow-.
n in
r
te o
thi
Fit expansion tank cap.
s
iva
do
r
rp
c
Switch off heater and air conditioner.
um
fo
en
ng
t.
yi
Start engine and maintain an engine speed of about 2000 rpm
Co
op py
for approx. 3 minutes. t. C rig
gh ht
pyri by
Run engine until radiator fan cuts in.
co Vo
by lksw
cted agen
Prote AG.
WARNING
1.7.1 Removing
Drain off coolant page 127 .
Remove lower radiator connection (quick release coupling).
Unclip lower coolant hose out of the air ducting.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
differs from the figure.
Remove nuts -arrows- and remove fans.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
1.7.2 Installing
f
en
ng
t.
yi Co
op py
Install in reverse order of removal. In the process, note the fol t. C rig
gh ht
lowing: pyri by
Vo
co lksw
by
cted agen
Torque settings: Prote AG.
Component Nm
Radiator fan to cowling 5
Cowling to radiator 5
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Removing page 132 cop Vo
by lksw
cted agen
Prote
Installing page 133
AG.
1.8.1 Removing
Bring lock carrier into service position General body repairs,
exterior; Rep. Gr. 50 ; Lock carrier .
Drain off coolant page 127 .
ce
le
un
pt
Detach connector -2-.
an
d
itte
y li
rm
ab
Remove coolant connection. To do this lift retaining clips -1-
pe
ility
lightly.
ot
wit
, is n
h re
Continuation for all models
hole
spec
Disconnect coolant connection to upper radiator (quick re
es, in part or in w
t to the co
lease coupling).
Remove cowling with radiator fans page 130 .
rrectness of i
l purpos
Note
nform
ercia
ses, ensure that pipes and hoses are not stretched, kinked or
m
bent.
a
com
tion in
r
te o
thi
Remove bolts -arrows- from radiator mounting.
s
iva
do
r
rp
cum
Swing radiator slightly towards rear.
fo
en
ng
t.
yi Co
Unscrew condenser securing bolts. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.8.2 Installing
Install in reverse order. In the process, note the following:
Renew coolant if a new radiator has been installed.
Fill with coolant page 127 .
Torque settings:
Component Nm
Radiator mounting to lock carrier 5
Condenser to radiator 5
Cowling to radiator 5
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
1.9.1 Removing
ss
Caution
o
cial p
f inform
mer
tions:
c
i
or
n thi
te
o
r
cum
r
fo
t.
yi Co
op
To avoid damages to the wiring ensure sufficient clear C py
t. rig
ance to all moving or hot components.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
1.9.2 Installing
Install in reverse order. In the process, note the following:
Moisten new O-ring -3- with coolant.
AG. Volkswagen AG d
Note agen oes
olksw not
y V gu
d b ara
ise nte
The coolant pump plug faces
thor downwards. eo
au ra
ss c
Insert coolant pump -2- in cylinder block and tighten securing
ce
e
nl
pt
du
y li
erm
h re
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
Refractometer -T10007-
pt
du
an
itte
y li
Drip tray -V.A.G 1306- or
erm
ab
drip tray for workshop hoist
ility
ot p
-VAS 6208-
wit
, is n
h re
Torque wrench -
hole
spec
V.A.G 1331-
es, in part or in w
t to the co
Spring-type clip pliers -VAS
5024A-
rrectness of i
Adapter set -V.A.G 1274/8-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.10.1 Removing
WARNING
Note
1.10.2 Installing
Install in reverse order. In the process, note the following:
AG. Volkswagen AG d
agen
Moisten new O-ring -3- with coolant. olksw
oes
not
byV gu
ara
d
rise 1
Insert thermostat -4- into connection -2- andhoturn /4 turn (90) nte
eo
t
to right. s au ra
c
s
ce
le
un
pt
an
d
Note
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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le
un
pt
1.11 Checking cooling system for leaks
an
d
itte
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rm
ab
pe
ility
Special tools and workshop
ot
wit
, is n
equipment required
h re
hole
spec
Cooling system tester -
es, in part or in w
V.A.G 1274-
t to the co
Adapter for cooling system
-V.A.G 1274/8-
rrectness of i
Adapter for cooling system
l purpos
-V.A.G 1274/9-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Test prerequisites
Engine at operating temperature.
Test sequence:
WARNING
ce
e
nl
Checking pressure relief valve in filler cap
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
Fit coolant system tester -V.A.G 1274- onto sealing cap using es, in part or in w
t to the co
adapter -V.A.G 1274/9- .
Use hand pump on cooling system tester -V.A.G 1274- to cre
rrectness of i
ate a pressure of max. 1.4 bar.
l purpos
nf
ercia
o
Renew sealing cap.
rm
m
atio
m
n in
or c
thi
Pressure relief valve must open.
te
sd
iva
o
r
cu
o
m
f
en
ng
t.
Renew sealing cap. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
t.
yi Co
op
Torque wrench -V.A.G 1331-
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Not illustrated
Expansion tank -1K0 121 407 A or 6Q0 121 407 A or 1J0 121
407 B-
Plug -191 211 343-
ce
e
nl
Rep. Gr. 50 ; Noise insulation .
pt
du
an
itte
y li
Clamp supply and return lines off oil cooler using hose clamps
erm
ab
to 25 mm -3094- .
ility
ot p
wit
, is n
h re
VAS 5024A- .
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Collect escaping coolant with drip tray - V.A.G 1306- or drip tray
-VAS 6208- .
l purpos
nform
ercia
at
om
ion
c
in t
or
tank -1-.
his
ate
do
riv
cum
for
en
ng
t.
Fill expansion tank up to Max marking.
yi Co
Cop py
t. rig
Attach cooling system tester -V.A.G 1274- with cooling system gh ht
yri by
tester adapter -V.A.G 1274/8- to expansion tank. cop Vo
by lksw
cted agen
Prote AG.
Use hand pump on tester to create a pressure of about 1.6 bar.
Watch pressure drop on pressure gauge. A pressure drop
within 10 minutes is not permitted.
If pressure drops:
Renew oil cooler page 106 .
Carry out installation in the reverse sequence, noting the follow
ing:
Check coolant level, if necessary replenish coolant
page 127 .
ce
e
nl
pt
All wirings (e.g. for fuel, hydraulic system, coolant and re
du
an
itte
frigerant liquid, brake liquid, vacuum) and electrical wir
y li
erm
ab
ings must be installed in the original way.
ility
ot p
wit
Ensure that there is sufficient clearance to all moving or
, is n
h re
hot components.
hole
spec
The fuel and the fuel lines in the fuel system can become
es, in part or in w
t to the co
very hot (danger of scalding)!
The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
rrectness of i
carefully loosen connection to release the pressure!
l purpos
nf
ercia
orm
m
atio
The fuel pump is activated when switching on the ignition and by
om
n in
the driver's door contact switch. For safety reasons, the connector
or c
thi
-arrow- must be removed from the fuel delivery unit before open
te
sd
a
o
r
rp
cu
o
m
When removing and installing fuel gauge sender or fuel pump
f
en
ng
t.
yi
(fuel delivery unit) from a full or partly full fuel tank, observe the
Co
op py
following: t. C rig
gh ht
pyri by
Vo
Before beginning work, place an extraction hose close to
co lksw
by
cted agen
sender opening in fuel tank to extract escaping fuel fumes and Prote AG.
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!
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
Note
an
d
itte
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erm
ab
Hose connections are secured with either spring-type or
ility
ot p
clamp-type clips.
wit
is n
h re
Always renew clamp-type clips with spring-type clips.
ole,
spec
urposes, in part or in wh
t to the co
1921- are recommended for installation of spring-type clips.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
Assembly overview - fuel tank page 145
y li
erm
ab
ility
Emptying fuel tank page 147
ot p
wit
, is n
Removing and installing fuel tank page 149
h re
hole
spec
Removing and installing fuel delivery unit page 152
es, in part or in w
t to the co
Removing and installing fuel gauge sender page 154
Checking fuel pump page 154
rrectness of i
3.1 Assembly overview - fuel tank
l purpos
1 - Cap
nform
ercia
2 - 1.5 Nm
m
at
om
ion
3 - Earth connection
c
in t
or
his
e
do
riv
ing.
p
cum
for
en
g
4 - 10 Nm
n
t.
yi Co
op py
5 - Cable guide
. C rig
ht ht
rig by
py Vo
6 - Fuel tank
co lksw
by
cted agen
Prote
Removing and installing
AG.
page 149 .
7 - 25 Nm
Renew.
8 - Clamping washer
9 - Securing strap
Note installation posi
tion.
10 - Heat shield
For fuel tank.
11 - Oil seal
Renew.
Moisten with fuel when
installing.
12 - Fuel delivery unit
With fuel gauge sender
-G -
Note installation posi
tion in fuel tank
page 146
Removing and installing
page 152 .
Checking fuel pump page 154 .
Removing and installing fuel gauge sender -G- page 154 .
Clean strainer if soiled
13 - Locking ring, 110 Nm
Remove and install using fuel tank sender wrench -T10202-
14 - Supply line
To fuel filter Item 1 (page 158) .
ce
le
Clipped onto fuel tank.
un
pt
an
d
itte
Check for secure seating.
y li
erm
ab
To pull off, press release buttons on connecting piece
ility
ot p
wit
is n
16 - Tank flap unit
h re
ole,
Removing and installing General body repairs, exterior; Rep. Gr. 55 ; Tank flap unit .
spec
urposes, in part or in wh
t to the co
Installation position of fuel delivery unit:
rrectne
The tab -2- on the fuel delivery unit must lie between the tongues
-1- and -3-.
ss o
cial p
f in
Note
form
mer
atio
The -arrow- points in direction of travel.
om
n
c
i
or
n
The fuel delivery unit can only be installed in this position.
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
Insert -T10202-
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Caution
Note
G. Volkswagen AG d
A ball valve -2- is located at the lower end of filler neck in fuel tank wage
nA oes
olks not
-1-, which must not be damaged by the extraction hose -3-. by
V gu
ara
Therefore push hose into filler neck only as far as marking oris
ed nte
-arrow-. au
th eo
ra
ss c
ce
le
pt
an
d
itte
y li
Carefully pull out extraction hose.
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
urposes, in part or in wh
t to the co
vacant to open the fuel delivery unit without danger.
If you have to empty the fuel tank completely page 148 . rrectnes
f inform
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
Remove cover -1- from fuel delivery unit. The arrow -2- points
pt
du
an
in direction of travel.
itte
y li
erm
ab
ility
ot p
WARNING
wit
, is n
h re
hole
The fuel and the fuel lines in the fuel system can become
spec
very hot (danger of scalding)!
es, in part or in w
t to the co
The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
rrectness of i
Wear eye and hand protection when performing any type
l purpos
nform
mercia
at
Remove connector -1-, the supply line -2- and the return pipe
om
ion
-3- from the fuel delivery unit. Press locking ring inwards to
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
Fuel tank should be no more than1/4full.
Note
If necessary, take the adapter for the rim lock out of the lug
gage compartment.
Open fuel flap and remove fuel tank cap.
With ignition switched off, disconnect battery earth wire
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
Unscrew tank flap unit securing bolt and remove tank flap unit
General body repairs, exterior; Rep. Gr. 55 ; Tank flap unit .
Remove seat bench General body repairs, interior; Rep.
Gr. 72 ; Rear seat; Removing and installing seat bench .
Remove cover -1- from fuel delivery unit. The arrow -2- points
in direction of travel.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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!
Separate the black supply line and the blue return hose
-arrows- on front right of fuel tank.
Note
In vehicles with additional heater, disconnect connector of the agen AG. Volkswagen AG do
metering pump and unclip cable Additional heater; Rep.VGr.olks
w es n
ot g
82 ; Fuel supply system of additional heaters ThermoseTop
d by
V; ua
ran
Removing and installing metering pump -V54- . thori tee
o
au ra
c
ss
ce
e
nl
pt
Note
du
an
itte
y li
erm
ab
Press locking ring inwards to release fuel lines.
ility
ot p
wit
A second mechanic is required to assist when supporting the
, is n
h re
fuel tank.
hole
spec
es, in part or in w
t to the co
Remove tensioning strap and securing bolts -arrows-.
Slowly lower fuel tank. rrectness of i
Installing
Installation is performed in the reverse sequence. In the process,
nf
ercia
atio
m
n in
or c
thi
sd
a
o
r
rp
cu
o
m
f
t.
yi Co
op
Check earth connection on fuel tank and body to filler neck.
C py
ht. rig
rig ht
py by
After installing fuel tank, check that the supply and return lines co Vo
by lksw
cted
are still clipped onto the fuel tank.
agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3.4.1 Removing
Fuel tank should be no more than3/4full.
Note
Remove cover -1- from fuel delivery unit. The arrow -2- points
in direction of travel.
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 the connector -1-, the black supply line -2- and the
blue return pipe -3- from the fuel delivery unit. Press locking
ring inwards to release fuel lines.
an
itte
y li
ab
wit
, is n
h re
hole
spec
es, in part or in w
3.4.2 Installing
t to the co
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Insert new fuel delivery unit seal dry into fuel tank opening.
Moisten inner edges of seal with fuel only when installing fuel
delivery unit.
When inserting fuel delivery unit, ensure that fuel gauge send
er is not bent.
Check installation position of the fuel delivery unit: Tab -2- on
the fuel delivery unit must be between cogs -1- and -3-. The
-arrow- points in direction of travel.
Tighten lock ring to 110 Nm.
Do not interchange the black supply line and the blue return
line (arrows on the flange of the fuel delivery unit).
Ensure that fuel lines are tight.
After installing the fuel delivery unit, check that the supply and
return lines are still clipped onto the fuel tank.
Follow procedure after reconnecting battery Electrical sys
tem; Rep. Gr. 27 ; Disconnecting and reconnecting battery .
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
Auxiliary measuring set -V.A.G 1594C-
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
o
pr
cum
5051B-
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Test prerequisites
Fuses must be OK.
The battery voltage must be at least 11.5 V.
All electrical consumers, e.g. lights and rear window heating,
must be switched off.
Checking function and voltage supply page 155
Check the current draw of the fuel pump page 156
Note
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
Pull off connector -1-. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
-V.A.G 1594C- .
m
at
ion
c
in t
r
his
ate
do
riv
cum
for
en
t.
yi Co
Current flow diagrams, Electrical fault finding and Fitting lo Cop py
cations.
t. rig
gh ht
pyri by
Vo
co
LED lights up briefly (voltage supply OK.):
by lksw
cted agen
Prote AG.
Remove fuel delivery unit page 152 .
Check that the electrical wires between flange and fuel pump
are connected and for continuity.
If no open circuit can be found
Renew fuel delivery unit page 152 .
Remove cover -1- from fuel delivery unit. The arrow -2- points
in direction of travel.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
Renew fuel delivery unit page 152 .
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 - Supply line
From fuel tank
Item 14 (page 145) .
White or with white
marking.
Check for secure seat
ing.
2 - 8 Nm
3 - Return line
To fuel cooler
Check for secure seat
ing.
Blue or with blue mark
ing
4 - Sealing plug for water evac
uation, 4 Nm
Remove and evacuate
approx. 100 cm3 liquid
using diesel extractor -
VAS 5226- or hand-op
erated vacuum pump AG. Volkswagen AG d
with accessories -V.A.G agen oes
olksw not
1390- and water drain ed by
V gu
ara
age container -V.A.G horis nte
eo
1390/1- s aut ra
c
s
5 - Oil seal
ce
e
nl
pt
du
an
Renew.
itte
y li
erm
ab
6 - Return line
ility
ot p
wit
h re
Blue marking
hole
spec
t to the co
ing.
7 - Upper part of fuel filter
rrectness of i
9 - Oil seal
Renew.
nf
ercia
10 - Filter insert
rm
m
atio
m
n in
or c
11 - Oil seal
thi
te
sd
iva
Renew.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
158
agen
Prote AG.
Rep. Gr.20 - Fuel supply system
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
en
ng
t.
Installing page 160
yi Co
Cop py
ht. rig
4.2.1 Removing
rig ht
py by
co Vo
by lksw
cted agen
Note safety precautions before beginning work page 142 .
Prote AG.
Note
The fuel cooler is located in the return line to fuel tank. It is located
on the vehicle underbody.
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! Then release
pressure by carefully loosening the connection.
Wear eye and hand protection when performing any type
of repair work on the fuel system!
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
4.2.2 Installing
es, in part or in w
t to the co
a
com
tio
thi
s
do
r
rp
cum
fo
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Vehicle diagnosis, testing and information system -VAS
rrectness of i
5051B-
l purpos
nform
ercia
at
om
i
Unit injectors OK
on
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
Procedure
yi Co
Cop py
t. rig
Remove engine cover. To do this, pull engine cover upwards gh ht
yri by
abruptly at front -arrows A- and then pull forwards out of rear cop Vo
by lksw
cted
fastening -arrow B-.
agen
Prote AG.
ce
e
nl
pt
WARNING
du
an
itte
y li
erm
ab
The fuel and the fuel lines in the fuel system can become
ility
ot p
wit
, is n
h re
The fuel system is also under pressure! Before opening
hole
spec
the system, place cloths around the connections. Then
es, in part or in w
t to the co
Wear eye and hand protection when performing any type
of repair work on the fuel system!
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
pt
an
d
itte
y li
If specification is now obtained:
rm
ab
pe
ility
Pressure loss at unit injectors.
ot
wit
, is n
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Renew O-rings on unit injectors page 219 .
hole
spec
If the specification is not attained:
es, in part or in w
t to the co
Renew tandem pump page 166 .
rrectness of i
Note
l purpos
a
com
tio
thi
s
iva
do
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rp
cum
Note
fo
en
ng
t.
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op
The tandem pump must be checked for internal leaks between
C py
t. rig
gh
fuel side and oil side after reinstalling a used tandem pump, for
ht
pyri by
Vo
o
example after renewing or repairing a cylinder head and/or when
c by lksw
cted agen
installing a "short" engine. When leaking it is possible for the fuel Prote AG.
to mix with the oil, which may cause the engine to fail.
AG. Volkswagen AG d
agen oes
olksw not
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au ra
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
Procedure
spec
es, in part or in w
t to the co
WARNING
The fuel and the fuel lines in the fuel system can become
rrectness of i
very hot (danger of scalding)!
l purpos
nform
ercia
at
om
io
of repair work on the fuel system!
n
c
in t
or
his
ate
do
riv
Pull fuel supply hose (white marking) Item 26 (page 59) and
p
cum
for
fuel return hose (blue marking) Item 27 (page 59) off tandem
en
ng
t.
yi
pump.
Co
Cop py
t. rig
gh
Seal fuel return union on tandem pump with a plug. Secure
ht
pyri by
Vo
o
sealing plug with a spring-type clip.
c by lksw
cted agen
Prote AG.
Prepare this as follows:
Unscrew pressure regulating valve -2- and close valves -3-
and -4-.
Connect test connection -5- charge air system tester -V.A.G
1687- to fuel supply union of tandem pump using a commer
cially available compressed air connection 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.
Note
If there is water in the sight glass, drain at water drain screw -6-.
Caution
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.
Volkswage n AG n AG d
wage oes
Volks not
gu
by ara
ed nte
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th
au ra
c
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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te
sd
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cu
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m
f
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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au ra
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ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
at
om
io
in t
or
his
4.4.1 Removing
ate
do
priv
cum
or
en
ng
pipe.
ce
e
pt
du
an
itte
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erm
ab
ility
Remove air cleaner housing with air mass meter.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Disconnect connector -2- on air mass meter -G70- .
l purpos
Pull breather hose -1- off and unhook from bracket -arrow-.
Release spring-type clip -3- with spring-type clip pliers -VAS
nform
ercia
5024A- and pull intake hose off air mass meter -G70- .
m
at
Pull intake manifold -5- off the air duct.
om
ion
c
in t
r
his
ate
do
riv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Carefully cut through cable tie -1-. Prote
cted AG.
agen
Remove both bolts -arrows- from upper charge air pipe -A-.
Remove noise insulation General body repairs, exterior;
Rep. Gr. 50 ; Noise insulation .
Remove the bolt -arrows- of the charge air pipe -A- from the
oil sump.
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!
Pull supply hose (white marking) and return hose (blue mark
ing) off fuel lines.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
Pull vacuum line from brake servo -1- off tandem pump -4-. nl
pt
du
an
itte
y li
Pull supply hose -2- (white marking) and return hose -3- (blue
erm
ab
marking) off tandem pump -4-.
ility
ot p
wit
, is n
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hole
spec
Remove tandem pump -4- from cylinder head.
es, in part or in w
t to the co
rrectness of i
l purpos
4.4.2 Installing
nform
mercia
at
Install in reverse order. In the process, note the following:
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
g
t.
yi Co
op
shaft. C py
t. rig
gh ht
yri
Always renew tandem pump seals.
p by
co Vo
by lksw
cted agen
Prote AG.
Install tandem pump and tighten top securing bolts to 20 Nm.
Tighten bottom securing bolts to 10 Nm.
Attach return hose (blue marking) to return connection -3- of
tandem pump.
Connect supply line (white marking) to the supply connection
-2- and the vacuum line of brake servo -1- to the tandem pump
-4-.
Connect supply hose (white marking) to the fuel filter.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
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ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
the engine control unit moves the throttle valve exactly as pre
an
d
itte
y li
scribed by the accelerator pedal position sender. That is, when
rm
ab
the accelerator is depressed halfway, the throttle valve positioner
pe
ility
opens the throttle valve by the same amount. The throttle is then
ot
wit
, is n
h re
hole
spec
When the engine is running (under load), the engine control unit
es, in part or in w
t to the co
erator pedal position sender.
This means that the throttle valve can already be completely open
rrectness of i
even though the accelerator pedal is only depressed half way.
This has the advantage of preventing throttling losses at the throt
l purpos
tle valve.
After evaluating the torque requirements of various components
nform
ercia
a
com
ti
thi
cum
fo
t.
yi
determining, controlling or monitoring the position of the throttle
Co
op py
valve, e.g. accelerator pedal position sender, the throttle valve
t. C rig
gh ht
yri
control module, the EPC warning lamp, the engine control unit p by
co Vo
and so on.
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Prote AG.
1 - Connector
Black, 6-pin AG. Volkswagen AG d
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2 - Accelerator spedal
ed b position ara
nte
sender -G79- hoand
ri
accelerator eo
ut
pedal position
ss a sender 2 -G185- ra
c
Not adjustable
ce
e
nl
pt
du
an
The accelerator position
itte
y li
sender passes the posi
erm
ab
tion of the accelerator
ility
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wit
, is n
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unit.
hole
spec
-A- Openings for re
es, in part or in w
t to the co
release tool - T10240-
Removing and installing
page 171 .
rrectness of i
3 - 10 Nm
l purpos
4 - Cap
nf
ercia
orm
m
atio
om
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or c
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
ce
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un
pt
Removing
an
d
itte
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Remove steering column cover -arrows-.
erm
ab
ility
ot p
Lever out cap Item 4 (page 171) using a screwdriver.
wit
is n
h re
ole,
Remove securing bolt Item 3 (page 171) .
spec
urposes, in part or in wh
Release accelerator pedal module
t to the co
rrectness o
cial p
f inform
mer
atio
m
n
c
i
or
n
remove accelerator pedal module.
thi
te
sd
va
o
pr
cum
erator pedal module.
r
fo
en
ng
t.
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Installing . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Fit connector -2- to the accelerator pedal module -5- and slide
the rubber grommet -1- onto the connector again.
Press accelerator pedal module onto securing pins -6-.
Insert centring pin -7- into hole in floor of vehicle.
Secure accelerator pedal module with the bolt -3- and fit cover
cap -4-.
Install steering column trim.
If the accelerator pedal module has been renewed, adapt the
accelerator pedal module to the engine control unit Vehicle
diagnosis, testing and information system -VAS 5051B- Gui
ded functions.
If the accelerator pedal module has been renewed on vehicles
with automatic gearbox or direct shift gearbox, the kick-down
function must be programmed Vehicle diagnosis, testing
and information system -VAS 5051B- Guided functions.
Tightening torque:
Component Nm
Accelerator pedal module to body 10
21 Turbocharging/supercharging
1 Charge air system with turbocharger
AG. Volkswagen AG d
Observe safety precautions page 173 agen oes
olksw not
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by ara
Observe rules for cleanliness page 173 rised
nte
ho eo
ut
Charge air system with turbocharger,
ss a engine codes BKC, BXE ra
c
page 175
ce
e
nl
pt
du
an
Charge air system with turbocharger, engine codes BLS, BRM
itte
y li
page 185
erm
ab
ility
ot p
wit
, is n
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Removing and installing charge air cooler page 202
hole
spec
es, in part or in w
t to the co
1.1 Safety precautions
rrectness of i
Caution
l purpos
nform
ercia
tions:
m
at
om
i
Route all the various lines (e.g. for fuel, hydraulics, cool
on
c
in t
ant, refrigerant, brake fluid and vacuum) and electrical
or
his
e
do
priv
c
Ensure that there is sufficient clearance to all moving or
um
for
en
g
hot components.
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
Observe following if test and measuring instruments are required
o
by c lksw
cted agen
during a road test: Prote AG.
WARNING
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
wit
, is n
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Charge air system must be free of leaks.
hole
spec
Renew self-locking nuts.
es, in part or in w
t to the co
Before screwing on oil supply line, fill turbocharger at connec
tion with engine oil.
rrectness of i
After installing turbocharger, run engine for about 1 minute at
idling speed to insure that oil is supplied to turbocharger.
l purpos
orm
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Charge air system with turbocharger, engine codes BKC, BXE 175
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
1 - 10 Nm
2 - Union nut, 22 Nm
3 - Oil supply line
Before installing oil sup
ply line, ensure that it is
not blocked.
Before installing, fill tur
bocharger with engine
oil through oil supply line
connection.
Removing and installing
page 114 .
4 - Union nut, 22 Nm
5 - Seal
Renew.
Note installation posi
tion.
6 - Washer
7 - 25 Nm
Renew.
8 - Support
Between turbocharger
and cylinder block
9 - 40 Nm
First hand tighten all
bolts.
10 - Connecting pipe AG. Volkswagen AG d
agen oes
Air filter/turbocharger olksw not
V gu
d by ara
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11 - Connector horis
eo
aut ra
12 - Seal ss c
ce
e
nl
Renew.
pt
du
an
itte
y li
13 - Oil seal
erm
ab
ility
ot p
Renew.
wit
, is n
h re
14 - Pipe union, 40 Nm
hole
spec
t to the co
To cylinder block.
Tighten union nut to 30 Nm
rrectness of i
16 - 17 Nm
l purpos
17 - Vacuum hose
To solenoid valve block.
nf
ercia
18 - Turbocharger
rm
m
atio
n in
c
To remove turbocharger take right-hand drive shaft off Running gear, axles, steering; Rep. Gr. 40 ;
or
thi
e
sd
iva
o
r
rp
cu
19 - 20 Nm
o
m
f
en
ng
Renew. by c lksw
cted agen
Prote AG.
21 - Heat shield
22 - Seal
Renew.
Note installation position.
23 - Clamp, 7 Nm
24 - Front exhaust pipe
25 - Retainer
For oil supply line Item 3 (page 176) .
Before installing, secure oil supply pipe.
26 - 22 Nm
Renew.
27 - Connecting pipe
To bypass flap.
28 - Pipe union, 30 Nm
Renew.
Coat threads and bolt head contact surface with hot bolt paste -G 052 112 A3- .
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Charge air system with turbocharger, engine codes BKC, BXE 177
. Volkswagen AG
gen AG does
Jetta 2005 , Bora 2006 , Golf Variant 2007 olks
wa not
yV gu
4-cylinder diesel engine with unit injector - Edition 05.2007
ise
d b ara
nte
r
ho eo
aut ra
ss c
Caution
ce
e
nl
pt
du
an
itte
y li
If mechanical damage is found on the turbocharger, e.g. a bro
erm
ab
ken compressor wheel, it is not sufficient to replace the turbo
ility
ot p
charger. To prevent further damage, carry out the following
wit
, is n
repairs:
h re
hole
spec
Check air cleaner housing, air filter insert and intake hoses
es, in part or in w
for dirt.
t to the co
Check entire charge air duct and charge air cooler for for
eign bodies.
rrectness of i
If foreign bodies are found in the charge air system, the charge
l purpos
air duct must be cleaned and the charge air cooler renewed if
necessary.
nform
mercia
Removing page 178
at
om
ion
c
in t
or
his
ate
2.2.1 Removing
do
priv
cum
for
en
g
t.
yi Co
op
abruptly at front -arrows A- and then pull forwards out of rear C py
t. rig
fastening -arrow B-. gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Disconnect connector -arrow- on intake manifold flap motor -
ility
ot p
V157- .
wit
, is n
h re
Remove bolts -1 3- and take intake manifold flap motor -
hole
spec
V157- off.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
valve -N18- .
in t
or
his
ate
cum
or
en
ng
t.
yi
clip pliers -VAS 5024A- .
Co
Cop py
t. rig
Remove bolts -2- and -5- and take air duct pipe off.
gh ht
pyri by
Vo
o
by c lksw
Free vacuum hoses -arrow-. cted agen
Prote AG.
2. Charge air system with turbocharger, engine codes BKC, BXE 179
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Remove bolts -1- and -2-.
es, in part or in w
t to the co
Remove right air duct pipe. To do this lift retaining clips
-arrow- lightly.
Take right-hand drive shaft off gearbox flange Running
rrectness of i
gear, axles, steering; Rep. Gr. 40 ; Servicing drive shaft; Re
l purpos
nform
mercia
at
Note
om
ion
c
in t
or
his
e
do
priv
cum
for
en
ng
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
Remove oil supply pipe on exhaust manifold -arrows- and
ce
e
nl
pt
place to side.
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Charge air system with turbocharger, engine codes BKC, BXE 181
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
2.2.2 Installing
Install in reverse order. In the process, note the following:
Note
ce
le
un
pt
an
d
itte
y li
Install exhaust system and align free of stress page 248 .
rm
ab
pe
ility
When installing air pipes with plug-in connectors, ensure that
ot
wit
, is n
h re
-A-.
hole
spec
es, in part or in w
t to the co
Observe installation sequence of the oil supply pipe
page 114 .
rrectness of i
Install pendulum support page 23
l purpos
Note
m
a
com
tion in
thi
idling speed and do not rev up immediately, this ensures that the
s
iva
do
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
1 - 8 Nm
Location page 184
2 - Retainer
Note installation posi
tion.
n AG. Volkswagen AG do
3 - Charge air cooler lkswage es n
o ot g
byV ua
4 - Seal ir se
d ran
tee
tho
or
5 - O-ring au ac
ss
Renew if damaged.
ce
le
un
pt
an
d
6 - Connecting hose
itte
y li
erm
ab
7 - 8 Nm
ility
ot p
wit
is n
8 - Connecting pipe
h re
ole,
spec
9 - Silencer
urposes, in part or in wh
t to the co
10 - From turbocharger
11 - From air filter
rrectne
12 - Connector
13 - Hose clip ss o
cial p
14 - To intake manifold
inform
mer
15 - To turbocharger
atio
om
16 - Vacuum reservoir
n
c
i
or
n thi
e
17 - Sleeve
t
sd
iva
o
pr
cum
18 - Grommet
r
fo
en
ng
t.
yi
19 - 15 Nm
Co
Cop py
t. rig
gh
20 - Oil seal
ht
pyri by
Vo
co lksw
by
Renew if damaged. Prote
cted AG.
agen
2. Charge air system with turbocharger, engine codes BKC, BXE 183
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
184
cted agen
Prote
Rep. Gr.21 - Turbocharging/supercharging
AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
is Jetta 2005 , Bora 2006 , Golf Variant nte
hor e o2007
ut
4-cylinder
ss a diesel engine with unit injector - Edition 05.2007
ra
c
ce
le
un
pt
an
d
3 Charge air system with turbocharger,
itte
y li
erm
ab
engine codes BLS, BRM
ility
ot p
wit
is n
h re
Observe safety precautions page 173
ole,
spec
urposes, in part or in wh
Observe rules for cleanliness page 173
t to the co
Hoses with quick release coupling page 200
Turbocharger - Assembly overview, engine codes BLS (without
rrectne
diesel particulate filter), BRM page 185
Removing and installing turbocharger, engine codes BLS (without
ss
diesel particulate filter), BRM page 188
o
cial p
f in
Turbocharger - Assembly overview, engine code BLS (with diesel
form
mer
atio
om
n
c
i
or
n
diesel particulate filter) page 196
thi
te
sd
iva
o
Parts of charge air cooling - Assembly overview, engine codes
pr
cum
r
fo
en
ng
t.
yi Co
op
Removing and installing charge air cooler page 202 C py
t. rig
gh ht
yri
Checking charge air system for leaks page 204
p by
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by c lksw
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3.1 Turbocharger - Assembly overview, en
AG.
Note
3. Charge air system with turbocharger, engine codes BLS, BRM 185
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
1 - Union nut, 22 Nm
2 - 10 Nm
3 - Oil supply line
Before installing oil sup
ply line, ensure that it is
not blocked.
Before installing, fill tur
bocharger with engine
oil through oil supply line
connection.
Removing and installing
page 114 .
4 - Pipe union, 30 Nm
Renew.
Coat threads and bolt
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hole
spec
7 - Heat shield
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With retainer for lambda
probe wiring harness
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8 - Seal
Renew.
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9 - Clamp, 7 Nm
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11 - 25 Nm
s
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12 - 25 Nm
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Renew.
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Cop py
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13 - Connecting pipe
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co
To exhaust gas recirculation cooler.
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14 - Seal
Renew.
15 - Seal
Renew.
Note installation position.
16 - Turbocharger
Can only be renewed completely with exhaust manifold and loading shovel position sender -G500-
17 - Banjo bolt, 60 Nm
Renew.
18 - O-ring
Renew.
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pt
du
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21 - Air duct
erm
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To air filter
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22 - Heat shield
23 - Connecting pipe
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24 - Hose clip
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25 - Connecting hose
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26 - 8 Nm
m
at
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om
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27 - Vacuum hose
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28 - 4 Nm
p
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for
29 - O-ring
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Renew. C py
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30 - Turbocharger guide vane position sender -G500- cop Vo
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Applies only to engine: BRM Prote AG.
3. Charge air system with turbocharger, engine codes BLS, BRM 187
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
3.2 Removing and installing turbocharger, engine codes BLS (without diesel
particulate filter), BRM
AG. Volkswagen AG d
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orm
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Caution
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du
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If foreign bodies are found in the charge air system, the charge
ab
ility
air duct must be cleaned and the charge air cooler renewed if
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necessary.
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hole
spec
es, in part or in w
t to the co
Installing page 193
rrectness of i
3.2.1 Removing
l purpos
nform
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at
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ion
c
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or
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for
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t.
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Prote AG.
Disconnect connector -2- on air mass meter -G70- .
Pull breather hose -1- off and unhook from bracket -arrow-.
Release spring-type clip -3- with spring-type clip pliers -VAS
5024A- and pull intake hose off air mass meter -G70- .
Pull intake manifold -5- off the air duct.
Unscrew bolt -4- and take off air filter housing.
3. Charge air system with turbocharger, engine codes BLS, BRM 189
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
Remove both bolts -arrows- from upper charge air pipe -A-.
Remove noise insulation General body repairs, exterior;
Rep. Gr. 50 ; Noise insulation .
Remove the bolt -arrows- of the charge air pipe -A- from the
oil sump.
Remove charge air pipe on turbocharger and pull it forwards
as far as possible.
AG. Volkswagen AG d
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at
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io
in t
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to 25 mm -3094- .
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Release connectors e-1- d byand -2- and pull off. ua
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Remove hose -3-.
auth or
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Detach vacuum hose -4-.
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pt
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Remove bracket. To do this remove nuts -1-.
c by lksw
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Prote AG.
Remove right-hand drive shaft on gearbox Running gear,
axles, steering; Rep. Gr. 40 ; Servicing drive shafts; Removing
and installing drive shafts .
3. Charge air system with turbocharger, engine codes BLS, BRM 191
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
AG. Volkswagen AG d
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t to the co
Unscrew bolts -2- and -3- and take exhaust gas recirculation
cooler off.
rrectness o
cial p
f inform
mer
atio
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n
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Cop py
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rig ht
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Remove bolts -1-, -2- and -4- and take oil return line -3- off
complete from cylinder block and turbocharger.
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Note
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Do not take the turbocharger -2- off after having removed the
y li
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ab
nuts -1- as the oil supply pipe is still connected to the turbo
ility
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charger.
wit
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Let the two loosened nuts -1- onto the threaded studs to pre
hole
spec
vent the turbocharger from falling.
es, in part or in w
t to the co
Remove nuts -1- from turbocharger.
rrectness of i
l purpos
Unscrew union nut -arrow- and pull oil supply pipe off turbo
charger.
nf
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t
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Press the engine forwards and take turbocharger out down
t. rig
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wards.
p by
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Prote AG.
3.2.2 Installing
Fit the turbocharger -2- on the threaded studs.
To prevent turbocharger from falling screw on two new nuts
-1- by hand.
3. Charge air system with turbocharger, engine codes BLS, BRM 193
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
Fit oil supply line to the turbocharger and fit union nut
-arrow-.
AG. Volkswagen AG d
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Install oil return line -3- complete. by Vol not
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Renew bolts -4-. thor eo
au ra
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nl
pt
du
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ab
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hole
spec
es, in part or in w
t to the co
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mercia
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First screw all bolts -2- and -3- from exhaust gas recirculation
n
c
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Cop py
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Note
1 - 10 Nm
2 - Retainer
3 - Heat shield
4 - 10 Nm
5 - Oil supply line
With union nut, 22 Nm
From turbocharger to oil n AG. Volkswagen AG do
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filter bracket byV
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Before installing oil sup ir se tee
tho
ply line, ensure that it is au or
ac
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pt
Before installing, fill tur
du
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oil through oil supply line
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connection.
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page 114 .
spec
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or
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8 - Vacuum hose
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9 - Seal
t
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Renew.
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3. Charge air system with turbocharger, engine codes BLS, BRM 195
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
ce
le
un
pt
Can only be renewed together with turbocharger
an
d
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ab
14 - 25 Nm
pe
ility
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Renew.
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15 - 25 Nm
hole
spec
es, in part or in w
16 - Seal
t to the co
Renew.
17 - Connecting pipe
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For exhaust gas recirculation.
l purpos
nform
ercia
Renew.
m
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19 - 15 Nm
on in
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20 - O-ring
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21 - Banjo bolt, 60 Nm
n
t.
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Cop py
22 - Support
t. rig
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With oil return line
AG.
Caution
Removing
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no-G450-
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securing bolts.
tho eo
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Disconnect
s connector for bank 1 exhaust gas temperature
ce
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Separate electrical connectors to particulate filter.
erm
ab
ility
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Gr. 50 . h re
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f in
lation cooler.
atio
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t.
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Unscrew securing bolts for exhaust manifold. t. Cop py
rig
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Tilt the engine forwards in lower mounting and remove turbo yri
p by
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charger with exhaust manifold downwards.
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Prote AG.
Installing
Install in reverse order.
Note
3. Charge air system with turbocharger, engine codes BLS, BRM 197
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Jetta 2005 , Bora 2006 , Golf Variant 2007 olk
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4-cylinder diesel engine with unit injectoris-e Edition 05.2007
d b ara
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3.5 Parts of charge air cooling - Assembly
a c
ss
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overview, engine codes BLS, BRM
nl
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ab
ility
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Note
wit
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hole
Charge air system must be free of leaks.
spec
es, in part or in w
For assembly use lubricant (water without additive) if neces
t to the co
sary. Do not use lubricants containing oil.
When making repairs, remove oil from connection and hose
rrectness of i
ends.
l purpos
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at
om
ion
c
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or
1 - 8 Nm
his
ate
do
riv
cum
for
2 - Retainer
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t.
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op
Note installation posi C py
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tion.
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by c lksw
3 - Charge air cooler cted agen
Prote AG.
4 - Seal
5 - 3 Nm
6 - Charge air pressure sender
-G31- with intake air tempera
ture sender -G42-
7 - Oil seal
Renew if damaged.
8 - O-ring
Renew if damaged.
9 - Connecting hose
10 - Hose clip
11 - Connecting pipe
12 - Connecting hose
13 - To intake manifold
14 - 8 Nm
15 - Sleeve
16 - Grommet
17 - Connector
18 - Turbocharger
19 - To charge air cooler
20 - Silencer
21 - Connecting hose
22 - Connecting pipe
AG. Volkswagen AG d
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23 - Connecting hose Volksw not
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24 - Bonded rubber horis mounting nte
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25 - From airss filter c
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bumper .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.
3. Charge air system with turbocharger, engine codes BLS, BRM 199
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
4 Hose connections
ce
e
nl
pt
du
an
WARNING
itte
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erm
ab
ility
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, is n
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occur. Observe installation instructions.
hole
spec
es, in part or in w
t to the co
Note
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All hoses of the charge air system are secured with hose clips or
l purpos
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Removing
m
at
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ion
Unlock quick release coupling by pulling on the securing clip
c
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or
-arrow-.
his
ate
do
riv
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en
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Installing
t.
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Cop py
. rig
When installing, ensure that locking lugs -A- engage securely.
t
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If renewed, place seal in groove of charge air hose. Ensure
by
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the seal is correctly seated in the groove.
AG.
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nl
pt
du
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Note
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ab
ility
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After charge air lines with spring-type clips have been removed
wit
, is n
and installed there is a danger of the hose slipping when driving.
h re
hole
For this reason spring washers are installed that may only be
spec
opened if there is a defect in the charge air line. During repairs
es, in part or in w
t to the co
the spring washer must be destroyed using the appropriate tool
and renewed with a part from ETKA (Electronic Parts Cata
logue) .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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by
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Prote AG.
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nl
pt
du
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Remove front bumper General body repairs; Rep. Gr. 63 ;
erm
ab
Front bumper
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Unscrew air guides on left and right side of charge air cooler.
h re
hole
spec
es, in part or in w
WARNING
t to the co
The air conditioning system refrigerant circuit must not be
opened.
rrectness of i
l purpos
Note
nf
ercia
orm
m
atio
To prevent damage to condenser or to refrigerant lines and ho
om
n in
ses, ensure that lines and hoses are not stretched, kinked or bent.
or c
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sd
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Remove securing bolts -2- from the condenser and fit to lock
o
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cu
carrier.
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t.
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Remove bolts -1- on charge air cooler. t. Cop py
rig
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Swivel the charge air cooler slightly back. p by
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Unhook charge air cooler upwards and take off downwards. Prote AG.
5.1.2 Installing
Install in reverse order. During this step, observe the following:
Install front bumper General body repairs; Rep. Gr. 63 ;
Front bumper .
Note
Renew seal.
ce
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nl
pt
du
an
Install cooler page 132 .
itte
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ab
Torque settings
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Component Nm
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spec
Charge air cooler to lock carrier 8
es, in part or in w
t to the co
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nf
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t.
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Cop py
t. rig
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Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards. gen AG
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204
Prote AG.
Rep. Gr.21 - Turbocharging/supercharging
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
Note
If there is water in the sight glass, drain at water drain screw -6-.
Caution
The pressure must not exceed 0.5 bar! If the pressure is too
high this can cause damage to the engine.
n AG. Volkswagen A
Open valve -4- and wait until
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the
wagetest circuit is filled.
G do
Ifesneces
not
sary readjust pressuredto
by 0.5 bar.
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Check the chargeuthair
o system for leaks by hearing, touching,
or
with commercially
ss available leak detector spray or using ultra
a ac
sonic tester -V.A.G 1842- .
ce
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nl
pt
du
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itte
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erm
ab
Note
ility
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instructions
spec
es, in part or in w
If leaks occur, when doing any repair work observe notes for
charge air system page 183 . t to the co
nf
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valve -N18-
ility
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12 - Turbocharger
h re
hole
spec
13 - Non-return valve
es, in part or in w
t to the co
nf
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orm
m
atio
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n in
or c
thi
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sd
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
1 - Turbocharger
2 - Connecting pipe air filter/
turbocharger
3 - Non-return valve
Note installation posi
tion.
4 - To brake servo
5 - Charge pressure control
solenoid valve -N75 -
6 - Air filter
7 - Cylinder head/cylinder
block
8 - Intake manifold
9 - Bypass flap
For exhaust gas recircu
lation cooler.
10 - Radiator
For exhaust gas recircu
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11 - Exhaust gas recirculation ised ara
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valve -N18- ut
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12 - Exhaust gas recirculation s
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pt
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13 - Non-return valve
ility
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tion.
ole,
spec
urposes, in part or in wh
14 - Non-return valve
t to the co
Note installation posi
tion.
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f inform
mer
atio
om
n
c
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or
n thi
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sd
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pr
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t.
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Cop py
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AG. Volkswagen AG d
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urposes, in part or in wh
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mer
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c
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Cop py
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pt
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the driver's door contact switch. For safety reasons, the connector
ab
ility
-arrow- must be removed from the fuel delivery unit before open
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spec
Caution
es, in part or in w
t to the co
tions:
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or
atio
hot components.
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n in
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t.
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Cop py
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by c lksw
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Prote AG.
WARNING
WARNING
aged. pt
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ility
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fluffy cloths!
Carefully cover opened components or seal if repairs cannot
nf
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atio
n in
use parts that have not been stored in their packing (e.g. in
thi
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sd
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can be avoided. Do not move vehicle unless absolutely nec
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Also ensure that no diesel fuel comes into contact with the
co Vo
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coolant hoses. Should this occur, the hoses must be cleaned
agen
Prote AG.
immediately. Damaged hoses must be renewed.
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Note
erm
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Some components are mounted under the engine cover.
, is n
h re
hole
spec
es, in part or in w
t to the co
1 - Intake manifold flap motor -
V157-
Removing and installing
rrectness of i
page 235
l purpos
nf
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o
N18-
rm
m
atio
Removing and installing
om
n in
page 233
or c
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Removing and installing
o
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f
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page 245
t.
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4 - Unit injectors
. C rig
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rig by
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Unit injector solenoid co Vo
by lksw
valve, No. 1 cyl. - N240-
cted agen
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ab
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20 - Multi-pin connector
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
Location page 214
22 - 3-pin connector rrectness of i
For Hall sender -G40- .
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t.
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24 - Hall sender -G40-
C py
t. rig
gh ht
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For camshaft position p by
o Vo
by c lksw
cted
Location page 215
agen
Prote AG.
25 - Charge air pressure sender -G31- with intake air temperature sender -G42-
Location page 213
Fitting location: charge air pressure sender - G31- intake air tem
perature sender -G42-
In air duct pipe behind the radiator -arrow-.
n AG. Volkswagen AG age does
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ility
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, is n
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hole
spec
Fitting location: exhaust gas recirculation cooler change-over
es, in part or in w
valve -N345-
t to the co
On rear left cylinder head.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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ng
ce
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un
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an
d
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rm
ab
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
Fitting location: Fuel temperature sender -G81-
rrectness of i
The sender -arrow- is fitted on engine front left.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
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t.
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Cop py
Fitting location: Engine speed sender -G28-
t. rig
gh ht
pyri by
Vo
o
On flywheel side of engine.
c by lksw
cted agen
Prote AG.
1- Engine speed sender -G28-
2- Sender wheel
n AG. Volkswagen AG do
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Fitting location of multi-pin connector for unit injectors
erm
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ility
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knurled nut -arrow 2-.
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
atio
-G83- , engine codes BKC, BXE
om
n in
or c
sd
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f
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.
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du
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Fitting location: brake light switch -F- and brake pedal switch -
F47-
l purpos
nf
move, install and mount brake pedal - assembly overview;
ercia
o
brake light switch -F- and brake pedal switch -F47- .
rm
m
atio
om
n in
or c
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Fitting location: Clutch position sender -G476- Prote
cted AG.
agen
AG. Volkswagen AG d
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pt
du
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erm
Plug position -2.1- in 5-pin relay carrier via the onboard supply
wit
, is n
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
ion
c
in t
or
do
riv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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un
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an
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7 - O-ring
itte
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ab
Renewing page 222 .
ility
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8 - O-ring
is n
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ole,
spec
urposes, in part or in wh
9 - O-ring
t to the co
Renewing page 222 .
10 - Heat shield seal
rrectne
Renew.
s
11 - Circlip
s o
cial p
f i
12 - Cylinder head
nform
mer
13 - Clamping block
atio
om
n
c
n thi
e
ther
t
sd
iva
o
pr
Renew.
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
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ce
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un
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an
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erm
ab
ility
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wit
is n
h re
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spec
urposes, in part or in wh
t to the co
rrectne
f inform
1.5.1 Removing
mer
atio
om
i
or
n thi
e
sd
iva
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pr
cum
Turn crankshaft until the cam pair for the unit injector which is
r
fo
en
ng
ce
le
ment screws.
un
pt
an
d
itte
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Remove rocker arm securing bolts -2- (from outwards to in
rm
ab
wards) with socket -3410- and take rocker arm shaft off.
pe
ility
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wit
, is n
Loosen tensioning block securing bolt -3- using special
h re
wrench, long reach -T10054- and remove tensioning block.
hole
spec
es, in part or in w
Lever connector off unit injector with a screwdriver. To avoid
t to the co
canting, support opposite side of connector with light finger
pressure.
Observe unit injector cylinder allocation.
rrectness of i
l purpos
nform
ercia
a
com
head seat.
tion in
r
te o
thi
s
iva
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.5.2 Installing
Note
Note
Oil seals and insert the injector unit with greatest care in the
cylinder head seat.
Push the injector unit evenly into the cylinder head onto its
stop.
Insert the clamping block in the slot on the side of the unit
injector.
Note
AG. Volkswagen A
If the unit injector is not at right angles to the
olks
tensioning
wagen block theG does no
securing bolt may loosen and this canddamage by
V the unit injector or t gu
ara
the cylinder head. or
ise nte
e th or
au ac
ss
Therefore align the unit injector as follows.
ce
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pt
du
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Screw the new securing bolt into the tensioning block only so
itte
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far that the unit injector can still be turned easily.
erm
ab
ility
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, is n
brackets.
h re
hole
spec
Check dimension -a- from outer edge of cylinder head to roun
es, in part or in w
t to the co
range of at least 400 mm).
Cylinder Dimension a
rrectness of i
1 333.0 0.8 mm
l purpos
2 245.0 0.8 mm
3 153.6 0.8 mm
nf
ercia
or
4 65.6 0.8 mm
m
m
atio
om
n in
or c
and 270 (3/4 turn) further. Turning further can be done in sev
thi
te
sd
a
eral stages.
iv
o
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rp
cu
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m
f
Fit rocker arm shaft and tighten new securing bolts as follows:
en
ng
t.
yi Co
Cop py
t. rig
First evenly tighten inner bolts -2- and then outer bolts -1- gh ht
yri by
hand-tight. Then tighten to 20 Nm and turn 90 (1/4 turn) further
cop Vo
by lksw
cted agen
evenly in the same sequence.
Prote AG.
Fit the dial gauge onto the adjustment screw of the 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 on dial gauge
-arrow B- positioned at lowest point.
Remove dial gauge.
Now turn the adjuster screw into rocker arm until significant
resistance can be felt (unit injector is at limit stop).
Turn adjuster screw 180 back from stop.
Hold adjuster screw in this position and tighten lock nut to 30
Nm.
Connect unit injector connector.
Install cylinder head cover page 61 .
Install toothed belt guard.
1.6.1 Removing
Remove unit injector page 219 . AG. Volkswagen AG d
agen oes
ksw
Lever old O-rings very carefully out ofbunit
y V injector.
ol not
gu
ara
ed
is nte
Above all ensure that burrs are nothor caused on O-ring seating. eo
aut ra
s c
1.6.2 Installing s
ce
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nl
pt
du
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erm
ab
Note
ility
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Avoid rolling when sliding onto the O-rings. The O-rings must
not be twisted in their seats in unit injector.
l purpos
at
fully.
om
ion
c
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do
priv
cum
or
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t.
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Remove the assembly sleeve. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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rm
ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
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un
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an
d
itte
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ab
pe
1 - Intake manifold
ility
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wit
Tighten securing bolts
, is n
h re
to 22 Nm.
hole
spec
2 - O-ring
es, in part or in w
t to the co
Renew.
3 - Intake connecting pipe
rrectness of i
With exhaust gas recir
culation valve.
l purpos
4 - 10 Nm
nform
ercia
V157-
a
com
t.
yi
ing this the stop stroke is
Co
Cop py
reduced.
t. rig
gh ht
pyri by
Vo
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6 - 10 Nm
c by lksw
cted agen
Prote AG.
7 - Connecting pipe
To exhaust gas recircu
lation cooler.
8 - 22 Nm
9 - Seal
Renew.
1 - Seal
replace
2 - Intake manifold
Tighten securing bolts
to 22 Nm
3 - Oil seal
Renew.
4 - Intake connecting pipe
5 - Intake manifold flap motor -
V157-
The intake manifold flap
is closed for approx.
3 seconds when the en
gine stands and then
opens again. When do
ing this the stop stroke is
reduced.
6 - From charge air cooler
7 - 10 Nm
8 - Exhaust gas recirculation
valve -N18- with exhaust gas
recirculation potentiometer -
G212-
Assembly overview - ex
haust gas recirculation
page 263
9 - Seal
n AG. Volkswagen AG do
Renew. lkswage es n
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yV ua
10 - Connecting pipe ir se
d b ran
tee
o
To exhaust gas recircu auth or
ac
lation cooler. ss
ce
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nl
Assembly overview -
pt
du
an
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erm
ab
11 - 22 Nm
ility
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wit
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12 - Retainer
h re
hole
For connector
spec
es, in part or in w
13 - 22 Nm
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.8.1 Removing and installing intake manifold, engine codes BKC, BXE
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
Removing page 227
gh ht
pyri by
Vo
co lksw
by
Installing page 230 cted agen
Prote AG.
Removing
Remove engine cover. To do this, pull engine cover upwards
abruptly at front -arrows A- and then pull forwards out of rear
fastening -arrow B-.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
The hoses -2- remain connected.
es, in part or in w
t to the co
Place lines -2- on air duct pipe to side.
Remove air pipe. To do this lift retaining clips -1- lightly.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Disconnect connector -2- on air mass meter -G70- . cop Vo
by lksw
cted agen
Prote
Pull breather hose -1- and air duct hose -3- off.
AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Pull off or disconnect coolant hoses -1- and -2- using hose
clamps to 25 mm -3094- .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Pull vacuum hoses -arrow 2- off.
o Vo
by c lksw
cted agen
Prote AG.
Pull vacuum hose -arrow 3- off non-return valve for brake ser
vo.
ce
le
Remove engine lifting eye on rear of cylinder head -arrow-.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f
Remove lower connecting pipe on change-over flap for ex
inform
haust gas recirculation -arrows-.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.8.2 Removing and installing intake manifold, engine codes BLS, BRM
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Remove air pipe. To do this lift retaining clips -1- slightly and
remove the bolt -3- from the transport bracket.
pt
Installing
du
an
itte
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ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
logue ETKA .
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nf
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orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
Remove intake manifold flap motor - V157- page 235 .
an
d
itte
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erm
ab
Remove noise insulation General body repairs, exterior;
ility
ot p
h re
Loosen connecting pipe -6- from intake pipe -4-. Remove bolts
ole,
Release connector -3- from intake pipe -4- and pull off.
t to the co
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.9.2 Installing
Install in reverse order. In the process, note the following:
ce
e
page 233 .
nl
pt
du
an
itte
y li
erm
ab
potentiometer -G212- with exhaust gas recirculation valve -
ility
ot p
wit
, is n
h re
Clean exhaust gas recirculation valve sooted surfaces with a
hole
spec
plastic brush . Afterwards remove loose soot with a cloth.
es, in part or in w
t to the co
For protection against soot particles cover intake manifold in
ner part with a lint-free cloth.
Clean exhaust gas recirculation valve seat in intake manifold
rrectness of i
Take the cloth out of the intake manifold and clean the intake
nf
ercia
Assembling
atio
om
n in
c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
1.11.1 Removing
orm
m
atio
m
n in
or c
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Remove air pipe. To do this lift retaining clips -1- slightly and
remove the bolt -3- from the transport bracket.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
Disconnect connector -arrow- on intake manifold flap motor -
ce
le
un
pt
V157- .
an
d
itte
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erm
ab
Remove bolts -13- and take intake manifold flap motor -
ility
ot p
V157- off.
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f
1.11.2 Installing
inform
mer
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
t.
yi Co
op
Hoses must be locked with clamps Electronic parts cata
C py
t. rig
logue ETKA .
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
When installing air pipes with plug-in connectors, ensure that
AG.
1 - O-ring
Renew if damaged.
2 - Connector
3 - Hose clip
4 - Intake hose
To turbocharger
5 - Connector
For heater element for
crankcase breather -
N79- .
Only fitted in vehicles
with cold country equip
ment
. Volkswagen AG
a gen AG does
6 - Air mass meter
Vol -G70-
ksw not
gu
y
db ara
7 - O-ring orise nte
eo
h
ut
sRenew.
sa
ra
c
ce
le
8 - 8 Nm
un
pt
an
d
itte
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ab
ility
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10 - 8 Nm
wit
is n
h re
11 - Vacuum hose
ole,
spec
t to the co
12 - 6 Nm
13 - Filter element
rrectne
14 - Air duct
To lock carrier.
ss o
cial p
n
c
i
or
sd
va
o
pr
cum
r
fo
t.
yi Co
op
18 - 10 Nm
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.13 Connection diagram for charge pressure control, engine codes BKC, BXE
ce
le
un
pt
an
d
block
itte
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rm
ab
pe
7 - Tandem pump
ility
ot
wit
, is n
8 - Breather hose
h re
hole
To air filter
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tio
thi
do
r
rp
cum
en
ng
t.
yi Co
P3 - To vacuum unit for exhaust gas recirculation cooler change- . Cop py
over
t rig
gh ht
pyri by
Vo
co
P4 - Breather hose to air filter
by lksw
cted agen
Prote AG.
P5 - To vacuum reservoir
P6 - To vacuum unit for charge pressure control
Note
Puller -T10118-
pt
du
an
itte
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erm
ab
ility
Note
ot p
wit
, is n
h re
spec
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
239
cted agen
Prote AG.
1. Diesel direct injection system
Jetta 2005 , Bora 2006 , Golf Variant 2007
4-cylinder diesel engine with unit injector - Edition 05.2007
AG. Volkswagen AG d
agen oes
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tho eo
au ra
ss c
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un
pt
an
d
itte
1.15.2 Installing
y li
rm
ab
pe
ility
Install in reverse order. In the process, note the following:
ot
wit
, is n
h re
Tighten securing bolt -2- of the engine speed sender -G28-
hole
spec
-1- to 5 Nm.
es, in part or in w
t to the co
Install oil filter bracket page 107 .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
cum
sender - G28-
fo
en
ng
t.
yi Co
op
The sender wheel for engine speed sender -G28- is removed and
C py
t. rig
gh
installed together with the crankshaft sealing flange -flywheel
ht
pyri by
Vo
o
end- page 38 .
c by lksw
cted agen
Prote AG.
1.17.1 Removing
Remove engine cover. To do this, pull engine cover upwards
abruptly at front -arrows A- and then pull forwards out of rear
fastening -arrow B-.
Vehicles with engine codes BKC, BXE
Remove air filter housing with air mass meter and connecting
pipe.
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
Disconnect connector -2- on air mass meter -G70- .
ole,
spec
urposes, in part or in wh
Pull breather hose -1- off and unhook from bracket -arrow-.
t to the co
Release spring-type clip -3- with spring-type clip pliers -VAS
5024A- and pull intake hose off air mass meter -G70- .
rrectne
Pull intake manifold -5- off the air duct.
Unscrew bolt -4- and take off air filter housing.
ss o
Continuation for all models
cial p
f inform
Removing battery Electrical system; Rep. Gr. 27 ; Remov
mer
atio
ing and installing battery; Vehicles with diesel engine .
om
n
c
i
or
n thi
e
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Pull 6-pin relay carrier under electronics box off, engine com
partment in -direction of arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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ho eo
Take 6-pin relay carrier -arrow-
s aut
out of cover. ra
c
s ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.17.2 Installing
Install in reverse order. In the process, note the following:
Installing battery Electrical system; Rep. Gr. 27 ; Removing
and installing battery; Vehicles with diesel engine .
ce
e
nl
pt
du
an
Special tools and workshop equipment required
itte
y li
erm
ab
Vehicle diagnosis, testing and information system -VAS
ility
ot p
5051B-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
Connect vehicle diagnosis, testing and information system -VAS
n
c
in t
or
5051B- as follows:
his
ate
do
riv
cum
or
en
ng
t.
yi Co
op
Start engine and run at idling speed. C py
t. rig
gh ht
yri
Only if engine does not start:
p by
co Vo
by lksw
cted agen
Switch on ignition.
Prote AG.
The display shows the control unit identification and coding -2- as
well as the chassis number and the identification number of the
immobilizer (centre part).
AG. Volkswagen AG d
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Note ised b ara
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h
ut ra
A print-out can be made if required. Press the Print sbutton.
s a c
ce
le
un
pt
an
d
Select diagnostic function:
itte
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rm
ab
Press key 02 - Read fault memory on display.
pe
ility
ot
wit
, is n
If no fault is stored in engine control unit 0 fault detected is
h re
displayed. hole
spec
es, in part or in w
If faults are stored in the engine control unit, these are shown
t to the co
one below the other on the display.
Press the button.
rrectness of i
Press key 05 - Erase fault memory on display.
l purpos
nform
ercia
a
com
tio
Special tools and workshop equipment required
n in
r
te o
thi
Vehicle diagnosis, testing and information system -VAS
s
iva
do
5051B-
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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nl
pt
du
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2.3 Removing and installing engine control
itte
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erm
ab
unit
ility
ot p
wit
, is n
h re
tion page 245
hole
spec
es, in part or in w
t to the co
page 245
rrectness of i
unit without theft protection
l purpos
Note
nf
ercia
orm
m
atio
If you wish to replace the engine control unit, connect the Vehicle
om
n in
diagnosis, testing and information system -VAS 5051B- and carry
or c
thi
te
sd
iva
o
r
rp
cu
Removing
o
m
f
en
ng
t.
yi Co
Switch off ignition. t. Cop py
rig
gh ht
yri
Remove wiper arms and the plenum chamber cover Elec
p by
o Vo
by c
trical system; Rep. Gr. 92 ; Windscreen wiper system; Re
lksw
cted agen
Prote
moving and installing the windscreen wiper system .
AG.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Saw set -V.A.G 1561/14-
Pliers
rrectness of i
l purpos
Note
nf
ercia
If you wish to replace the engine control unit, connect the Vehicle
orm
diagnosis, testing and information system -VAS 5051B- and carry
m
atio
m
n in
or c
thi
te
sd
a
Removing
iv
o
r
rp
cu
o
en
ng
t.
yi Co
op
Remove wiper arms and the plenum chamber cover Elec C py
t. rig
trical system; Rep. Gr. 92 ; Windscreen wiper system; Re
gh ht
yri by
moving and installing the windscreen wiper system . cop Vo
by lksw
cted agen
Prote AG.
Remove bulkhead in plenum chamber General body re
pairs, exterior; Rep. Gr. 50 ; Plenum chamber bulkhead;
Plenum chamber bulkhead - Assembly overview .
Saw shear head bolts so that two parallel surfaces are created
-arrows-.
Remove bolts with pliers .
ce
e
nl
pt
Lever the protective housing out upwards using the screw
du
an
itte
driver -A- and pull it off sideways from the retaining plate
y li
erm
ab
-arrow-.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Release front connector -1- from engine control unit and pull
orm
it off.
m
atio
om
n in
or c
thi
e
sd
iva
o
r
rp
cu
Then release rear connector on engine control unit and pull it
o
m
f
en
ng
off.
t.
yi Co
Cop py
Installing
t. rig
gh ht
pyri by
Vo
o
Fit rear connector to engine control unit and lock it in position. by c lksw
cted agen
Prote AG.
Push engine control unit onto bracket.
Fit front connector to engine control unit and lock it in position.
Push protective housing onto bracket.
Tighten new shear bolts -1- evenly until heads shear off.
Install bulkhead in plenum chamber General body repairs,
exterior; Rep. Gr. 50 ; Plenum chamber bulkhead; Plenum
chamber bulkhead - Assembly overview .
Install wiper arms and the plenum chamber cover Electrical
system; Rep. Gr. 92 ; Windscreen wiper system; Removing
and installing the windscreen wiper system .
26 Exhaust system
1 Exhaust system
Caution
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
be damaged. spec
es, in part or in w
t to the co
Renew seals, gaskets and self-locking nuts.
After working on the exhaust system, ensure that the system
is not under stress and that there is sufficient clearance to the
rrectness of i
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
Parts of exhaust system - Assembly overview, engine codes BLS
an
d
itte
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(with catalytic converter), BRM page 251
erm
ab
ility
ot p
wit
diesel particulate filter) page 252
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
1.1.1 Parts of exhaust system - Assembly overview, engine codes BKC, BXE
rrectne
The exhaust manifold and the turbocharger are one component,
removing and installing page 177 .
ss o
cial p
f
1 - Front exhaust pipe with cat
inform
alytic converter
mer
atio
2 - Mounting
om
n
c
Renew if damaged.
or
n thi
te
sd
va
3 - 25 Nm
i
o
pr
cum
r
fo
4 - Clamp-type clip
en
ng
t.
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op
5 - 25 Nm
C py
t. rig
gh ht
yri by
6 - Bolt/screw cop Vo
by lksw
cted agen
Prote AG.
7 - Mounting
8 - Retaining ring for front si
lencer
Renew if damaged.
9 - Front and rear silencers
For repairs, renew indi
vidually.
10 - Mounting
With support loop
Renew if damaged.
11 - Connection point
For repairs
Marked by three inden
tations on circumfer
ence of exhaust pipe.
During production, front
and rear silencers are
installed as a single
component. For repairs,
front and rear silencers
are supplied separately.
The connection is made
with a clamp-type clip.
G. Volkswage
1.1.2 Parts of exhaust system
olksw
agen - Assembly
A n AG d
overview,
oes
not engine codes BLS (with cat
alytic converter),b BRM
y V gu
d ara
e nt
ris ee
tho or
The exhaust manifold and au the turbocharger are one component, ac
ss
removing and installing page 188 .
ce
le
un
pt
an
d
itte
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1 - Front exhaust pipe with cat
erm
ab
alytic converter
ility
ot p
wit
is n
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preparation for diesel
ole,
spec
particulate filter
urposes, in part or in wh
t to the co
2 - Lambda probe -G39-
3 - Clip
rrectne
4 - Seal
Renew.
ss o
f in
tion.
form
mer
5 - 7 Nm
atio
om
n
c
6 - Mounting
i
or
n thi
te
Renew if damaged.
sd
iva
o
pr
cum
r
7 - 25 Nm
fo
en
ng
t.
yi Co
8 - Clamp-type clip t. Cop py
rig
gh ht
yri
9 - 25 Nm p by
co Vo
by lksw
cted agen
10 - Retaining ring for front si Prote AG.
lencer
Renew if damaged.
11 - Front and rear silencers
For repairs, renew indi
vidually.
12 - Mounting
With support loop
Renew if damaged.
13 - Connection point
For repairs
ce
le
un
pt
Aligning exhaust system free of stress page 260
an
d
itte
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erm
ab
14 - Mounting
ility
ot p
wit
15 - 40 Nm
is n
h re
ole,
16 - Support
spec
urposes, in part or in wh
17 - 40 Nm
t to the co
rrectne
1.1.3 Front exhaust pipe - Assembly overview, engine code BLS (with diesel par
ticulate filter)
ss o
cial p
f inform
1 - 8 Nm
mer
atio
m
n
c
sor 1 -G450-
i
or
n thi
te
sd
a
3 - Retainer
iv
o
pr
cum
r
en
ng
t.
yi Co
4 - 10 Nm Cop py
t. rig
gh ht
yri
5 - Control line, 45 Nm p by
o Vo
by c lksw
cted agen
6 - Lambda probe -G39- , 50 Prote AG.
Nm
Grease threads only
with hot bolt paste - G
052 112 A3- , hot bolt
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 bank 2 -G448 - , 45 Nm
Lubricate thread of
sender using hot bolt
paste - G 052 112 A3-
8 - Particulate filter
Removing and installing
page 257 .
9 - Front exhaust pipe
10 - Marking
For clamp.
11 - To front silencer
12 - 25 Nm
13 - Mounting
Renew if damaged.
14 - Exhaust gas temperature sender 3 -G527-
Lubricate thread of sender using hot bolt paste - G 052 112 A3-
15 - From turbocharger
16 - Clamp, 7 Nm AG. Volkswagen AG d
agen oes
olksw not
17 - Seal d by V gu
ara
ise nte
Renew.
hor eo
aut ra
s Note installation position.
s c
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e
nl
18 - 25 Nm
pt
du
an
itte
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19 - Retainer
erm
ab
ility
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wit
, is n
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hole
spec
1.1.4 Silencer - Assembly overview, engine code BLS (with diesel particulate fil
es, in part or in w
t to the co
ter)
rrectness of i
2 - 25 Nm
Renew.
nf
ercia
orm
3 - Clamp-type clip
m
atio
om
n in
4 - 25 Nm
or c
thi
te
5 - Retainer
sd
iva
o
r
rp
cu
m
f
en
ng
t.
yi
6 - Retaining rings
Co
Cop py
. rig
Renew if damaged.
ht ht
rig by
copy Vo
lksw
7 - Rear silencer
by
cted agen
Prote AG.
8 - Mounting
Renew if damaged.
9 - Connection point
For repairs
Marked by three inden
tations on circumfer
ence of exhaust pipe.
During production, front
and rear silencers are
installed as a single
component. For repairs,
front and rear silencers
are supplied separately.
The connection is made
with a clamp-type clip.
Separating front and
rear silencers
page 259
Fitting location of rear
clamp-type clip (repair
double clamp)
page 260
Evenly tighten threaded connections of clamp (repair double clamp).
Torque settings for clamp (repair double clamp): M8 = 25 Nm gen AG. Volkswagen AG d
a oes
ksw
Aligning exhaust system free of stress page 260 by
Vol
not
gu
a
ed ran
10 - Front silencer oris tee
th or
au ac
ss
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e
nl
pt
du
1.2 Removing and installing front exhaust
an
itte
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erm
ab
pipe
ility
ot p
wit
, is n
Removing and installing front exhaust pipe with catalytic convert
h re
er, engine codes BKC, BXE page 254 hole
spec
es, in part or in w
t to the co
er, engine codes BLS, BRM page 255
Removing and installing front exhaust pipe with diesel particulate
rrectness of i
filter, engine code BLS page 257
l purpos
nform
ercia
at
om
i
Special tools and workshop equipment required
on
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
cum
for
en
Slide clamp-type clip backwards and take exhaust pipe off.
ng
t.
yi Co
op py
Installing t. C rig
gh ht
pyri by
Install in reverse order. In the process, note the following:
co Vo
by lksw
cted agen
Prote AG.
Renew seal.
Align exhaust system free of stress page 260 .
Torque settings
Component Nm
Front exhaust pipe to turbocharger 7
Mounting to subframe 25
Strut to gearbox and front exhaust pipe 40
Front cross member to body 25
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing page 256
l purpos
nform
ercia
Removing
m
at
om
ion
c
in t
or
his
ate
do
riv
cum
or
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Torque settings
un
pt
an
d
itte
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Component Nm
rm
ab
pe
ility
wit
, is n
h re
Mounting to subframe 25
hole
spec
t to the co
code BLS
l purpos
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
i
or
n thi
te
40 .
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
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erm
ab
separating point provided in the connecting pipe.
ility
ot p
h re
cumference of the exhaust pipe.
hole
spec
Special tools and workshop equipment required
es, in part or in w
t to the co
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
or chain pipe cutter -VAS 6254- C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Eye protection
Separate
WARNING
AG. Volkswagen AG d
agen oes
olksw not
To avoid injury from metal shavings, wear eye protection
d by V
and gu
ara
protective clothing. rise nte
tho eo
au ra
ss c
ce
e
nl
Cut through exhaust pipe -arrow 2- e.g. with body saw -
pt
du
an
V.A.G 1523 A- at right angles at the separating point.
itte
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erm
ab
Connect
ility
ot p
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
A second mechanic is required to tighten the repair clamp-type
clip.
rrectness of i
Secure front silencer in the retainers. The front clamping
l purpos
nf
ercia
o
Position the repair clamp-type clip at the side markings
rm
m
atio
om
n in
or c
thi
Fitting location of rear clamp-type clip (repair double clamp)
te
sd
iva
o
r
cu
o
m
f
en
ng
Install repair double clamp so that the bolt ends do not protrude
t.
yi Co
op
beyond bottom of clamp.
C py
t. rig
gh ht
yri by
Align exhaust system free of stress when cold page 260 . cop Vo
by lksw
cted agen
Prote
Tighten the repair double clamp.
AG.
Prerequisite
The exhaust system must be aligned when it is cold.
Procedure agen
AG. Volkswagen AG d
oes
olksw not
V gu
Loosen bolts on front retaining clip -1-. ed by ara
nte
ris
o eo
Position clamp-type clip -1- so thatauthe
th distance -a- to the ra
marking on the pipe -2- is 5 mm and
ss tighten front bolt by hand. c
ce
le
The -arrow- points in direction of travel.
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Move the exhaust system with silencer forwards until the di
mension -a- = 911 mm is reached on the outer hand hold
l purpos
nform
ercia
a
Aligning tailpipes
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
Align rear silencer so that dimension -a- between bumper cut- by c lksw
cted agen
out and end pipes on the left and right-hand sides are the Prote AG.
same.
At the same time the distance -b- from bumper cut-out to end
pipes must be parallel.
To align tail pipe, loosen rear silencer mountings if necessary.
ce
le
un
pt
an
d
y li
erm
page 266
ab
ility
ot p
wit
is n
h re
ole,
spec
2.1 Parts of exhaust gas recirculation - As
urposes, in part or in wh
t to the co
sembly overview
Engine codes BKC, BXE page 262
rrectne
Engine codes BLS, BRM page 263
ss
2.1.1 Parts of exhaust gas recirculation - As
o
cial p
f in
sembly overview, engine codes BKC,
form
mer
BXE
atio
om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng
1 - 22 Nm
2 - Intake manifold
With exhaust gas recir
culation valve and in
take manifold flap motor
-V157- .
Tighten securing bolts
to 22 Nm.
Removing and installing
page 224 .
3 - Seal
Renew.
4 - Connecting pipe
5 - Exhaust gas recirculation
cooler
Removing and installing
page 266 .
6 - 10 Nm
7 - Exhaust manifold/turbo
charger
AG. Volkswagen AG d
Removing and installing
lksw
agen oes
not
page 177d b.y Vo gu
a
e ran
ris tee
8 - Connecting
ut pipe
ho or
sa ac
9 - Bypasss flap
ce
le
un
pt
ab
activated
urposes, in part or in wh
t to the co
10 - Retainer
For bypass flap.
rrectne
11 - 5 Nm
ss o
cial p
f inform
atio
n
c
BRM
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
Note
en
ng
t.
yi Co
Cop py
The function/control of the exhaust gas recirculation system is
t. rig
gh ht
yri by
undertaken by diesel direct injection system control unit -J248
op Vo
by c lksw
- via exhaust gas recirculation potentiometer -G212- .
cted agen
Prote AG.
1 - Intake manifold
With intake manifold
flap motor -V157-
Exhaust gas recircula
tion potentiometer -
G212- and exhaust gas
recirculation valve -
N18-
Dismantling and assem
bling intake pipe with ex
haust gas recirculation
potentiometer -G212-
and exhaust gas recir
culation valve -N18-
page 234
Tighten securing bolts
to 22 Nm.
Removing and installing
page 231 .
2 - Seal
Renew.
3 - Exhaust gas recirculation
cooler
Removing and installing
page 271 .
4 - 22 Nm
5 - Adjustment unit for bypass
flap AG. Volkswagen AG d
agen oes
Component of exhaust olksw not
y V gu
gas recirculation coolerrised b ara
nt ee
tho or
6 - Connecting pipe s au ac
s
ce
le
7 - 22 Nm
un
pt
an
d
Renew.
itte
y li
erm
ab
8 - Exhaust manifold/turbocharger
ility
ot p
wit
h re
ole,
9 - 10 Nm
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
1 - 22 Nm
ility
ot p
wit
, is n
2 - Connecting pipe
h re
hole
spec
3 - 22 Nm
es, in part or in w
Renew.
t to the co
4 - Seal
Renew.
rrectness of i
5 - To exhaust gas recircula
l purpos
tion cooler.
6 - To intake manifold
nform
ercia
at
om
i
cooler
on
c
in t
or
his
te
page 271 .
a
do
priv
cum
or
8 - Pipe/hose line
f
en
ng
t.
yi Co
9 - Heat shield Cop py
t. rig
gh ht
yri
10 - Spring-type clip p by
co Vo
by lksw
cted agen
11 - Coolant hose Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
h re
lation system has a cooler through which coolant flows.
hole
spec
The engine control unit determines when the recirculated ex
es, in part or in w
t to the co
haust gas is routed via the cooler. The control unit actuates a
vacuum unit via the exhaust gas cooler change-over valve -
N345- , which in turn operates the exhaust gas recirculation
rrectness of i
change-over valve.
l purpos
nf
ercia
equipment required
orm
m
atio
Hose clamps to 25 mm
om
n in
-3094-
or c
thi
te
Torque wrench -
sd
iva
o
r
V.A.G 1331-
rp
cu
o
m
f
en
ng
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Place hoses -1- up to -3- on air duct pipe to side.
Remove air pipe. To do this lift retaining clips -1- lightly.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
Disconnect connector -2- on air mass meter -G70- .
ht
pyri by
Vo
co lksw
by
Pull breather hose -1- and air duct hoses -3- and -5- off.
cted agen
Prote AG.
Pull off or disconnect coolant hoses -1- and -2- on exhaust gas
recirculation cooler using hose clamps to 25 mm -3094- .
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Pull off or disconnect coolant hoses -1- and -2- using hose
ce
e
nl
clamps to 25 mm -3094- .
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Pull vacuum hose -arrow 3- off non-return valve for brake ser
rm
vo.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
haust gas recirculation -arrows-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
BLS, BRM
itte
y li
erm
ab
ility
ot p
wit
, is n
Special tools and workshop
h re
equipment required
hole
spec
Hose clamps to 25 mm es, in part or in w
t to the co
-3094-
Torque wrench -
V.A.G 1331-
rrectness of i
Torque wrench -
l purpos
V.A.G 1410-
Spring-type clip pliers -VAS
nform
ercia
5024A-
m
at
om
i
Drip tray for workshop hoist
on
c
in t
-VAS 6208 -
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Remove bolts -1-, -2- and -4- and take oil return line -3- off
complete from cylinder block and turbocharger.
n AG. Volkswagen AG do
lkswage es n
o ot g
Pull pipe/hose line -1- off. d byV ua
ran
ir se tee
Unscrew bolts -2- and -3- and uthtake exhaust gas recirculation
o
or
cooler off. ss
a ac
ce
e
nl
Installing
pt
du
an
itte
y li
Install in reverse order. In the process, note the following:
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
at
om
in t
or
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Test procedure
Final control diagnosis performed.
Lift engine cover sideways -arrows 1- and pull off forwards
-arrow 2-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
Detach vacuum hose at mechanical exhaust gas recirculation
du
an
itte
valve.
y li
erm
ab
ility
Connect diesel extractor -VAS 5226 - or hand-operated vac
ot p
wit
uum pump -V.A.G 1390- to the valve.
, is n
h re
hole
spec
hand-operated vacuum pump.
es, in part or in w
t to the co
Pull diesel extractor -VAS 5226- or hand-operated vacuum
pump hose off exhaust gas recirculation valve.
rrectness of i
The closing of the valve should be clearly audible. The mem
brane rod moves in direction of intake manifold
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
1 Checking glow plug system
itte
y li
rm
ab
pe
ility
Checking, removing and installing glow plugs page 274
ot
wit
, is n
h re
1.1 Checking, removing and installing glow plugs
hole
spec
es, in part or in w
t to the co
Special tools and workshop
equipment required
rrectness of i
U/J extension and socket,
10 mm -3220-
l purpos
nform
ercia
a
1526 C- or hand multimeter
com
tion in
-V.A.G 1526 A-
r
te o
thi
s
Auxiliary measuring set -
iva
do
r
V.A.G 1594 C-
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
WARNING
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
spec
es, in part or in w
plug one after the other. Diode lights up: glow plug OK., diode
does not light up: renew glow plug.
rrectness of i
Removing
Remove glow plugs with jointed spanner -3220- .
l purpos
Installing
nform
ercia
sequence.
at
om
ion
c
his
Nm.
ate
do
priv
cum
or
en
ng
t.
yi Co
plugs, checking Cop py
ht. rig
rig ht
py by
Test prerequisites
co Vo
by lksw
cted agen
Prote AG.
Engine is cold
Ignition switched off
Removing
WARNING
n AG. Volkswagen AG do
wage
Ceramic glow plugs page 275 are sensitive toybumps Volks es n
ot g
and bending. ir se
d b ua
ran
o tee
h
For this reason dropped down glow plugs au must never be
t or
ac
used, even if no damage can be seen obviously (and even
ss
ce
le
if the height was about 2 cm).
un
pt
an
d
itte
y li
It is absolutely necessary to follow the installation instruc
rm
ab
tions, otherwise there is risk of a pin crack which may
pe
ility
result in an engine damage.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
move components hindering the installation.
l purpos
nform
ercia
a
com
t
Detach glow plug connectors from glow plugs.
ion in
r
te o
thi
s
iva
do
r
Installing
rp
cum
fo
en
g
t.
yi Co
Cop py
.
Before installing, all deposits must be removed completely
t rig
gh ht
yri by
from cylinder head bore and thread. cop Vo
by lksw
cted agen
Prote AG.
Note
The thread of the hole in the cylinder head or the ceramic glow
plugs must never be greased or oiled.
Fit the ceramic glow plugs into the cylinder head by hand using
the jointed wrench -3220- .
Install glow plugs with jointed wrench -3220- and tighten to 15
Nm.
WARNING
After installing and before the first engine start on the cold
engine, always check resistance of all ceramic glow plugs.
If a defective ceramic glow plug is broken remove all frag
ments from the engine, otherwise these can cause dam
age to the engine.
Specification: max. 1
If the specification is exceeded, renew defective ceramic glow
plugs.