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 

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 .

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 

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 .

❑ 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