Volkswagen Golf / Golf Plus. Manual - part 293

 

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Volkswagen Golf / Golf Plus. Manual - part 293

 

 

 

Specified torque

Bolts, nuts

M6

10 Nm

 

M8

20 Nm

 

M10

45 Nm

 

M12

60 Nm

1.4

Assembly mountings

Engine assembly mounting
A = 20 Nm + 90° (1/4 turn) further 

1)

B = 40 Nm + 90° (1/4 turn) further 

1)

C = 60 Nm + 90° (1/4 turn) further 

1)

1)

 Renew

Gearbox assembly mounting
A = 40 Nm + 90° (1/4 turn) further 

1)

B = 60 Nm + 90° (1/4 turn) further 

1)

1)

 Renew

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

10

     Rep. Gr.10 - Removing and installing engine

 

Caution

From model year 08, in manual gearboxes 02Q Heli Coil in‐

serts are installed in the threaded connections to pendulum

support. Difference ⇒  Rep. Gr.  34
For these and all other gearboxes bolts with strength class 10.9

must be used.
If Heli Coil inserts are not fitted in manual gearboxes 02Q, use

bolts with strength class 8.8 and the specified torques.

Bolt -A-
M10 x 35 strength class 8.8: turn 40 Nm + 90° further
M10 x 35 strength class 10.9: turn 50 Nm + 90° further
Always renew after removing
Bolt -B-
M10 x 75 strength class 8.8: turn 40 Nm + 90° further
M10 x 75 strength class 10.9: turn 50 Nm + 90° further
Always renew after removing
Bolt -C-
M14 x 1.5 x 70
100 Nm + turn 90° further
Tighten only if pendulum support is bolted to gearbox
Always renew after removing

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Removing and installing engine    

11

 

Dismantling and assembling engine

Assembly overview - poly V-belt drive 

⇒ page 12

Removing and installing poly V-belt 

⇒ page 13

Assembly overview - toothed belt drive 

⇒ page 15

Assembly overview - crankcase 

⇒ page 19

Note

If large quantities of metal particles or other deposits (caused, for

example, by partial seizure of the crankshaft or conrod bearings)

are found in the engine oil when making repairs, clean the oil

passages thoroughly and renew the engine oil cooler in order to

prevent further damage from occurring later.

1.1

Assembly overview - poly V-belt drive

1 - Belt pulley and vibration

damper

❑ Can only be installed in

one position, holes are

offset.

2 - 25 Nm
3 - Alternator
4 - Bracket

❑ For alternator and air

conditioner compressor.

5 - Poly V-belt tensioning ele‐

ment

❑ 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 13

 .

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

12

     Rep. Gr.13 - Crankshaft group

 

Special tools and workshop equipment required
♦ Locking pin -T10060 A-

♦ 16 mm open-end spanner -T 10241-

1.2.1

Removing poly V-belt

– Remove insulation tray. ⇒  General body repairs, exterior;

Rep. Gr.  50 ; Body - front; Assembly overview .

– Pull fuel filter out of bracket and lay it with hoses to side.
– Mark direction of rotation of poly V-belt.
– Swing tensioning element in direction of arrow to remove ten‐

sion from poly V-belt.

The open-end spanner 16 mm -T 10241- is particularly well suited

to relieve tension.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Dismantling and assembling engine    

13

 

 

 

 

 

 

 

 

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