Volkswagen Golf / Golf Plus. Manual - part 294

 

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Volkswagen Golf / Golf Plus. Manual - part 294

 

 

– Remove poly V-belt.

1.2.2

Installing poly V-belt

– Installation is carried out in the reverse sequence of removal.

Note

Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.

When fitting poly V-belt, check direction of belt rotation and

ensure proper seating of belt in pulleys.

Lastly, place poly V-belt over alternator.

After completing repairs always:
– Start engine and check belt running.
Belt drive without air conditioner compressor

Belt drive with air conditioner compressor

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

14

     Rep. Gr.13 - Crankshaft group

 

1 - Toothed belt guard upper

part
2 - 100 Nm
3 - 25 Nm
4 - Camshaft pulley
5 - Hub

❑ With sender wheel
❑ Use counterhold tool -

T10051- to loosen and

tighten.

❑ To remove, use puller -

T10052-

❑ Removing and installing

⇒ page 80

 , removing

and installing camshaft.

6 - 10 Nm

❑ Renew

7 - Stud

❑ 15 Nm

8 - Rear toothed belt guard
9 - 25 Nm
10 - Sealing grommet

❑ Renew if damaged.

11 - 20 Nm + 

1

/8 turn (45°) fur‐

ther
12 - Tensioning roller

❑ Remove engine support

in order to remove and

install 

⇒ page 16

 .

13 - 20 Nm
14 - Idler roller
15 - Coolant pump

❑ Removing and installing 

⇒ page 106

 .

16 - Crankshaft toothed belt pulley
17 - 120 Nm + 

1

/4 turn (90°) further

❑ Renew
❑ Use counterhold tool -3099- to loosen and tighten.
❑ Do not additionally oil or grease thread and shoulder.
❑ Turning further can be done in several stages.

18 - 15 Nm
19 - Toothed belt guard lower part
20 - Belt pulley and vibration damper

❑ Can only be installed in one position, holes are offset.

21 - 10 Nm + 

1

/4 turn (90°) further

❑ Renew

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

1. Dismantling and assembling engine    

15

 

⇒ page 50

 .

24 - 40 Nm + 

1

/2 turn (180°) further

❑ Renew

25 - Toothed belt guard centre part
26 - Engine bracket

1.3.1

Removing and installing engine support

Special tools and workshop equipment required
♦ Support bracket -10 - 222 A-
♦ Torque wrench -V.A.G 1331-
– Remove engine cover.
– To do this, pull engine cover upwards abruptly at front and right

-arrows A- and then pull forwards out of rear fastening

-arrow B-.

Two-piece engine cover
For two-piece engine cover, first pull outer engine cover abruptly

upwards at -arrows-, then pull inner engine cover abruptly up‐

wards at -arrows-.

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

16

     Rep. Gr.13 - Crankshaft group

 

Do this by pressing in catch of push-on connectors.

Ensure that no fuel escapes (use a cloth).

– Lay fuel filter with hoses to side.
– Disconnect coolant hose from top of expansion tank.
– Remove expansion tank and lay it to side.
– Remove charge air pipe between charge air cooler and turbo‐

charger.

– Carefully cover or seal open ends.
Golf, Golf Plus and Touran:

– Fit engine support bracket -10-222A- with adapters -10-222A/

13- and take up weight of engine in installation position.

– Remove securing bolts from assembly mounting/engine sup‐

port -arrows- and remove complete assembly mounting.

Note

The assembly mounting may only be removed if the engine is

supported with support bracket 10-222A!

The engine support must only be loosened when the assembly

mounting has been removed.

WARNING

When  raising  and  lowering  engine  using  support  bracket

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

or torn off.

– Remove noise insulation tray ⇒  General body repairs, exteri‐

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

insulation .

– Remove front right wheel housing liner.

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

1. Dismantling and assembling engine    

17

 

 

 

 

 

 

 

 

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