Volkswagen Golf / Golf Plus. Manual - part 305

 

  Index      Volkswagen     Volkswagen Golf (2004) / Golf Plus (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  303  304  305  306   ..

 

 

Volkswagen Golf / Golf Plus. Manual - part 305

 

 

– Check whether the crankshaft can be locked with crankshaft

stop -T10100- .

If crankshaft cannot be locked:

– Loosen securing bolts -1- for camshaft toothed belt pulley.

– Turn crankshaft against engine direction of rotation slightly

until pin of crankshaft stop is located just before hole in sealing

flange -arrow-.

– Now turn crankshaft in engine direction of rotation until crank‐

shaft stop pin engages in sealing flange from rotational move‐

ment.

Continuation for all vehicles

– Fit counterhold tool -T10172- with pins -T10172/4- as shown.

Press counterhold tool -T10172- in direction of arrow, keeping

camshaft toothed belt pulley under tension.

– In this position, tighten camshaft toothed belt pulley securing

bolts -1- to 25 Nm.

– Remove locking pin -3359- and crankshaft stop -T10050- .
– Turn crankshaft two rotations in engine direction of rotation

until crankshaft is just before TDC No. 1 cylinder.

– Repeat check.

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

58

     Rep. Gr.15 - Cylinder head, valve gear

 

1

/2 turn (180 °) further.

Note

Before installing assembly mounting, tighten all engine bracket

bolts to prescribed torque.

– Install assembly mounting between engine and body (renew

securing bolts).

Specified torque, M8 bolts: 20 Nm + 90° (1/4 turn)
Specified torque, M10 bolts: 40 Nm + 90° (1/4 turn)
– Bolt engine assembly mounting to engine bracket by bringing

contact surfaces together using support bracket -10-222A- .

Specified torque: 60 Nm + 90° (1/4 turn)
– Install centre and lower parts of toothed belt guard.
– Install belt pulley vibration damper (renew securing bolts).
Specified torque: 10 Nm + 90° (1/4 turn)
– Install poly V-belt 

⇒ page 13

 .

– Install toothed belt guard upper part.
– Install front right wheel housing liner.
– Install coolant expansion tank.

– Bolt fuel filter bracket to engine mounting to 8 Nm torque

-arrows-.

– Engage fuel filter in bracket.
– Bolt on filler neck for window wash system.
– Fit engine cover.

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

1. Cylinder head    

59

 

further away from engine)

Note

A revised engine support has been introduced gradually and it is no longer necessary to remove the engine

support and to support the engine for the procedure “removing, installing and tensioning toothed belt”.

To change the tensioning roller, for both versions the engine support must be removed.

Special tools and workshop

equipment required
♦ Diesel injection pump lock‐

ing pin -3359-

♦ Locking pin -T10060 A-
♦ Crankshaft stop -T10100-
♦ Counterhold tool -T10172-
♦ Special wrench, long reach

-T10264-

♦ Locking tool -T10265-

Removing
– Remove engine cover. 

⇒ page 4

 To do this, pull engine cover

upwards abruptly at front -arrows A- and then pull forwards out

of rear fastening -arrow B-.

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

60

     Rep. Gr.15 - Cylinder head, valve gear

 

WARNING

♦ In extreme cases the fuel lines and the fuel can reach a

temperature of 100 °C on vehicles with unit injector en‐

gine. Allow the fuel to cool down before disconnecting the

lines - danger of scalding.

♦ Wear protective gloves.
♦ Wear eye protection.

– Pull fuel supply hose -1- and fuel return hose -2- off fuel lines.
– Pull off coolant line -3-.
– Remove bolt -1-.

– Remove connecting pipe between charge air cooler and intake

connecting pipe, to do this, lightly lift retaining clips -arrows-.

– Disconnect fuel supply line -3- and return line -2- by pulling

release tabs.

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

1. Cylinder head    

61

 

 

 

 

 

 

 

 

Content   ..  303  304  305  306   ..