Volkswagen Golf / Golf Plus. Manual - part 328

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  326  327  328  329   ..

 

 

Volkswagen Golf / Golf Plus. Manual - part 328

 

 

-2-.

– Operate hand vacuum pump -V.A.G 1390- until fuel comes out

of return hose. Be careful that no fuel is sucked into hand vac‐

uum pump.

– Connect return hose (blue marking) to fuel filter.

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

150

     Rep. Gr.20 - Fuel supply system

 

Charge air system with turbocharger

Safety precautions 

⇒ page 151

Rules for cleanliness 

⇒ page 151

 .

Installing hose connections with connector couplings

⇒ page 161

Assembly overview - turbocharger 

⇒ page 152

Removing and installing turbocharger 

⇒ page 156

Assembly overview - parts of charge air cooling 

⇒ page 158

Checking charge air system for leaks 

⇒ page 162

1.1

Safety precautions

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.

Observe following if test and measuring instruments are required

during a road test:
♦ Test and measuring instruments must be secured to rear seat

and operated by a second person from this location.

If test and measuring instruments are operated from front pas‐

senger seat and the vehicle is involved in an accident, there is a

possibility that the person sitting in this seat may receive serious

injuries when the airbag is triggered.

1.2

Rules for cleanliness

When working on the turbocharger, pay careful attention to the

following rules for cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐

connecting.

♦ Place removed parts on a clean surface and cover. Do not use

fluffy cloths!

♦ Carefully cover opened components or seal if repairs cannot

be carried out immediately.

♦ Install clean components only. Do not remove replacement

parts from packing until immediately before installing. Do not

use parts that have not been stored in their packing (e.g. in

tool boxes etc.).

♦ Existing transport and protective packaging and sealing caps

must only be removed immediately prior to installation.

♦ When making repairs, remove oil from connection and hose

ends.

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

1. Charge air system with turbocharger    

151

 

essary.

1.3

Assembly overview - turbocharger

Note

All hose connections are secured.

Charge air system must be free of leaks.

Renew self-locking nuts.

Before screwing on oil supply line, fill turbocharger at connec‐

tion with engine oil.

After installing turbocharger, run engine for about 1 minute at

idling speed to ensure that oil is supplied to turbocharger.

Observe rules for cleanliness 

⇒ page 151

 .

Observe safety precautions 

⇒ page 151

 .

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

152

     Rep. Gr.21 - Turbocharging/supercharging

 

Engine codes BLS and BXJ 

⇒ page 155

1.3.1

Engine codes BJB, BKC, BRU, BXE and BXF

1 - 10 Nm
2 - Union nut, 22 Nm
3 - Oil supply line

❑ Before installing oil sup‐

ply line, ensure that it is

not blocked.

❑ Before installing, fill tur‐

bocharger with engine

oil through oil supply line

connection

❑ Removing and installing

⇒ page 95

 .

4 - Union nut, 22 Nm
5 - Gasket

❑ Renew.
❑ Note installation posi‐

tion.

6 - Washer
7 - 25 Nm

❑ Renew.

8 - Support

❑ Between turbocharger

and cylinder block.

9 - 40 Nm

❑ First hand tighten all

bolts

10 - Connecting pipe

❑ Air filter/turbocharger

11 - Connecting piece
12 - Gasket

❑ Renew.

13 - Seal

❑ Renew.

14 - Connection, 40 Nm
15 - Oil return line

❑ To cylinder block.
❑ Tighten union nut to 30 Nm.

16 - 17 Nm
17 - Vacuum hose

❑ To solenoid valve block

18 - Turbocharger

❑ Can only be renewed with exhaust manifold.
❑ To remove turbocharger, remove right drive shaft ⇒  Running gear, axles, steering; Rep. Gr.  40 ; Re‐

moving and installing drive shafts .

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

1. Charge air system with turbocharger    

153

 

 

 

 

 

 

 

 

Content   ..  326  327  328  329   ..