Volkswagen Golf / Golf Plus. Manual - part 307

 

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Volkswagen Golf / Golf Plus. Manual - part 307

 

 

hole in the sealing flange -arrow-.

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

shaft stop pin engages in sealing flange whilst turning.

– 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 -T10100- .
– Turn crankshaft two rotations in engine direction of rotation

until crankshaft is just before TDC No. 1 cylinder.

– Repeat check and adjustment if necessary.
– 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 connecting pipe between charge air cooler and intake

connecting pipe.

– 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

66

     Rep. Gr.15 - Cylinder head, valve gear

 

Special tools and workshop

equipment required
♦ Drip tray -V.A.G 1306- or

drip tray -VAS 6208-

♦ Torque wrench -

V.A.G 1331-

♦ Torque wrench -

V.A.G 1332-

♦ Hand vacuum pump with

accessories -V.A.G 1390-

♦ Water drainage container -

V.A.G 1390/1-

♦ Retainer -T10014- (only ve‐

hicles ▸ 05.05)

Special tools and workshop equipment required
♦ Support bracket -10-222A- with adapters -10-222A/13- (only

vehicles ▸ 05.05)

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

1. Cylinder head    

67

 

is removed must be replaced in the same position when cylinder

head is installed.

WARNING

When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐

tions:

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

vated charcoal filter system, coolant, refrigerant, brake

fluid and vacuum) and electrical wiring in their original po‐

sitions.

♦ Ensure that there is sufficient clearance to all moving or

hot components.

1.4.1

Removing

Note

Before removing cylinder head, extract fuel using hand-operated

vacuum pump with accessories -V.A.G 1390- and water drainage

container -V.A.G 1390/1- 

⇒ page 147

 .

– Remove engine cover panel 

⇒ page 4

 . To do this, pull engine

cover upwards abruptly at front -arrows A- and then pull for‐

wards out of rear fastening -arrow B-.

– Remove two-piece engine cover 

⇒ page 4

– Remove plenum chamber bulkhead. ⇒  General body repairs,

exterior; Rep. Gr.  50 ; Body - front, plenum chamber bulk‐

head .

– Remove air filter housing with air mass meter and connecting

pipe.

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

68

     Rep. Gr.15 - Cylinder head, valve gear

 

– Remove insulation tray. ⇒  General body repairs, exterior;

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

– Drain coolant. 

⇒ page 102

– Disconnect fuel supply and return lines as well as coolant line

on cylinder head.

– Before removing cylinder head, extract fuel from tandem pump

using hand-operated vacuum pump with accessories -V.A.G

1390- and water drainage container -V.A.G 1390/1-

⇒ page 147

 .

– Pull fuel filter module upwards out of bracket and lay it with

hoses to side.

– Remove front exhaust pipe 

⇒ page 186

 .

– Remove turbocharger support and oil return from turbocharg‐

er.

– Remove oil supply line and lay it to side 

⇒ page 95

 .

Note

From 05.05 a modified engine support has been introduced, it is

no longer necessary to remove the engine support and supporting

the engine for the procedure “removing, installing and tensioning

toothed belt” 

⇒ page 50

– Remove toothed belt. 

⇒ page 50

– Remove toothed belt tensioning roller.
– Install hub for camshaft pulley 

⇒ page 80

 , Removing and

installing camshaft.

– Remove rear toothed belt guard securing bolts -2- and -4-.
– Unscrew Hall sender -G40- -3-.
– Remove exhaust gas recirculation connecting pipe.
– Pull off or disconnect all other electrical connections as nec‐

essary from cylinder head and lay to one side.

– Separate all connection, coolant, vacuum and intake hoses

from cylinder head.

Only vehicles ▸ 05.05)

Note

Both lifting eyes for the support are located on the cylinder head,

so an additional bracket for supporting the engine must be se‐

cured on the cylinder block.

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

1. Cylinder head    

69

 

 

 

 

 

 

 

 

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