Volkswagen Golf / Golf Plus. Manual - part 302

 

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Volkswagen Golf / Golf Plus. Manual - part 302

 

 

18 - To turbocharger.
19 - Sealing cap

❑ Renew seal if damaged

20 - Seal

❑ Renew if damaged.

21 - 10 Nm

❑ Observe tightening sequence 

⇒ page 48

 .

22 - Gasket for cylinder head cover

❑ Renew together with cylinder head cover only.
❑ Before fitting, seal transitions with “AMV 174 004 01” 

⇒ page 48

23 - 20 Nm
24 - Lifting eye
25 - Unit injector

❑ Removing and installing 

⇒ page 169

 .

26 - 10 Nm
27 - Central connector

❑ For unit injector

28 - From brake servo
29 - Tandem pump

❑ For fuel and vacuum supply
❑ Checking 

⇒ page 147

 .

❑ Removing and installing 

⇒ page 147

 .

❑ Must not be dismantled.

30 - Supply hose

❑ From fuel filter.
❑ White or with white marking.
❑ Check for secure seating.
❑ Secure with spring-type clips.

31 - Return hose

❑ To fuel filter
❑ Blue or with blue marking.
❑ Check for secure seating.
❑ Secure with spring-type clips.

32 - Gasket

❑ Renew

33 - Bracket
34 - 20 Nm
35 - Cylinder head

❑ Removing and installing 

⇒ page 67

 .

❑ After renewing, renew entire coolant

36 - Cylinder head gasket

❑ Renew
❑ Note marking 

⇒ page 47

❑ After renewing, renew entire coolant

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

46

     Rep. Gr.15 - Cylinder head, valve gear

 

⇒ page 198

 .

38 - Tensioning roller

❑ Remove engine support in order to remove and install 

⇒ page 16

 .

39 - 20 Nm + 

1

/8 turn (45°) further

Checking cylinder head for distortion

Special tools and workshop equipment required
♦ Straight edge
♦ Feeler gauges
Max. permissible distortion: 0.1 mm.

Note

Reworking diesel cylinder heads is not permissible.

Cylinder head gasket identification
♦ Part number = arrow 1
♦ Production control code = arrow 2 (can be disregarded)
♦ Holes = arrow 3

Note

Different thicknesses of cylinder head gasket are fitted de‐

pending on the piston projection. When renewing gasket,

install new gasket with same identification.

Piston projection at TDC must be determined when installing

new pistons or a short engine. 

⇒ page 41

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

1. Cylinder head    

47

 

cover

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-
♦ Sealant -AMV 174 004 01-

⇒ page 4

 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-.

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-.
– Remove upper toothed belt guard.
– Disconnect crankcase breather hose at union of rear of charge

air pipe.

– Unbolt bracket from exhaust gas recirculation valve.

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

48

     Rep. Gr.15 - Cylinder head, valve gear

 

Cylinder head cover, engine codes: BJB, BKC, BRU, BXE, BXF

Cylinder head cover, engine codes: BLS, BXJ
Installing for all engine codes
Installation is carried out in the reverse sequence of removal. In

the process, note the following:

Note

Renew cylinder head cover gasket and seal for bolts if dam‐

aged.

Renew seal for intake manifold flap. Engine codes BLS, BXJ

– Place a drop of sealant -AMV 174 004 01- (∅ approx. 5 mm)

-arrows- on edges of both sealing surfaces of bearing cap and

cylinder head at front of engine.

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

1. Cylinder head    

49

 

 

 

 

 

 

 

 

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