Volkswagen Golf / Golf Plus. Manual - part 295

 

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Volkswagen Golf / Golf Plus. Manual - part 295

 

 

– Lower engine with support bracket -10-222A- until lower bolt

can be loosened and removed.

– Remove engine support upwards.
Installing
– Position engine support from above on cylinder block.
– Insert new bolts and tighten hand-tight.

Caution

The tightening sequence and specified torques for the engine

support securing bolts must always be followed. Otherwise the

engine support can be stressed and it can break.

– Tighten bolts for engine support in the sequence shown

-1…3- to 40 Nm + 

1

/2 turn (180 °) further. To do this, raise or

lower engine using support bracket -10 - 222 A- .
I : Engine support with less clearance to engine
II: Engine support with greater clearance to engine

Note

Before installing assembly mounting, tighten all engine support

bolts to prescribed torque.

– Install assembly mounting between engine and body, renew

securing bolts 

⇒ page 10

 .

– Bolt engine assembly mounting to engine support -arrows- by

bringing contact surfaces together using support bracket

-10-222A- . Specified torque: 60 Nm + 90° (1/4 turn) further.

Further assembly is basically the reverse of the dismantling se‐

quence. In the process, note the following:
♦ Ensure that fuel hose connections are tight.
♦ Do not interchange supply line and return line (return line blue

or with blue marking, supply line black).

♦ When installing charge air pipes, ensure that locking lugs en‐

gage correctly.

– Install wheel housing liner.
– Install noise insulation tray ⇒  General body repairs, exterior;

Rep. Gr.  50 ; Body - front; Assembly overview - noise insula‐

tion

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

18

     Rep. Gr.13 - Crankshaft group

 

1 - Cylinder block

❑ Removing and installing

sealing flange and fly‐

wheel 

⇒ page 20

 .

❑ Removing and installing

crankshaft 

⇒ page 33

❑ Dismantling and assem‐

bling pistons and con‐

rods 

⇒ page 33

2 - Gasket

❑ Renew

3 - Oil filter bracket

❑ Dismantling and assem‐

bling 

⇒ page 92

 .

4 - 15 Nm + 

1

/4 turn (90°) fur‐

ther

❑ Renew
❑ First fit upper left and

lower right bolts and

then tighten all four bolts

diagonally.

5 - Bracket
6 - 20 Nm
7 - Connection

❑ For thermostat.

8 - 15 Nm
9 - O-ring

❑ Renew

10 - Thermostat

❑ Removing and installing

⇒ page 108

 .

❑ Observe installation position 

⇒ page 108

 , removing and installing thermostat.

❑ Check: Heat thermostat in water
❑ Opening begins at approx. 85 °C
❑ Ends at approx. 105 °C
❑ Opening lift at least 7 mm.

11 - Hexagon bolt

❑ Tightening sequence and torque specifications ⇒  Heating, air conditioning; Rep. Gr.  87 ; Removing and

installing compressor bracket .

12 - Bracket

❑ For alternator, if air conditioner compressor is fitted

13 - Poly V-belt tensioning element
14 - 25 Nm
15 - Sump

❑ Clean sealing surface before fitting.
❑ Install with silicone sealant -D 176 404 A2- .

16 - 15 Nm

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

1. Dismantling and assembling engine    

19

 

flange and flywheel

Assembly overview - sealing flange and flywheel 

⇒ page 20

Removing and installing engine speed sender 

⇒ page 31

Renewing crankshaft oil seal - pulley end 

⇒ page 21

 .

Removing and installing sealing flange - pulley end

⇒ page 21

 .

Renewing crankshaft sealing flange - flywheel end 

⇒ page 25

 .

2.1

Assembly overview - sealing flanges and flywheel

Note

Repairing clutch ⇒  6-speed manual gearbox 02S; Rep. Gr.  30 ; Repairing clutch.

1 - Seal

❑ Do not additionally oil or

grease the oil seal seal‐

ing lip.

❑ Before installing, re‐

move oil residue from

crankshaft journal using

a clean cloth.

❑ Renewing crankshaft oil

seal - pulley end

⇒ page 21

 .

2 - Sealing flange

❑ Must be positioned on

dowel sleeves.

❑ Removing and installing

⇒ page 23

 .

❑ Install with silicone seal‐

ant -D 176 404 A2-

⇒ page 23

 .

3 - Cylinder block

❑ Removing and installing

crankshaft 

⇒ page 33

❑ Dismantling and assem‐

bling pistons and con‐

rods 

⇒ page 33

4 - 60 Nm + 

1

/4 turn (90°) fur‐

ther

❑ Renew

5 - Flywheel

❑ To remove and install

flywheel, counterhold

with 3067.

6 - Intermediate plate

❑ Must be positioned on dowel sleeves.
❑ Do not damage or bend when assembling.

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

20

     Rep. Gr.13 - Crankshaft group

 

8 - Sealing flange with oil seal

❑ Renew complete with oil seal and sender wheel only.
❑ Removing and installing 

⇒ page 25

 .

9 - Removing and installing engine speed sender -G28- 

⇒ page 31

 .,

❑ Loosen and tighten using commercially available ball-ended hexagon key socket
❑ Specified torque: 5 Nm.

2.2

Renewing crankshaft oil seal - pulley end

Special tools and workshop

equipment required
♦ Counterhold tool -3099-
♦ Oil seal extractor -3203-
♦ Assembly tool -T10053-
♦ Torque wrench -

V.A.G 1331-

♦ Torque wrench -

V.A.G 1332-

2.2.1

Removing

– Remove toothed belt. 

⇒ page 50

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

2. Removing and installing sealing flange and flywheel    

21

 

 

 

 

 

 

 

 

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