VW Golf Mk5 2004 & Golf Plus Mk5 2005 4-cylinder diesel engine (1.9l engine) - Workshop Manual

1.2 Engine data......Page 7
1.1 Removing engine......Page 8
1.3 Notes on installing......Page 13
1.4 Assembly mountings......Page 16
1.1 Assembly overview - poly V-belt drive......Page 18
1.2.1 Removing poly V-belt......Page 19
1.2.2 Installing poly V-belt......Page 20
1.3 Assembly overview - toothed belt drive......Page 21
1.3.1 Removing and installing engine support......Page 22
1.4 Assembly overview - crankcase......Page 25
2.1 Assembly overview - sealing flanges and flywheel......Page 26
2.2.1 Removing......Page 27
2.2.2 Installing......Page 28
2.3.1 Removing......Page 29
2.3.2 Installing......Page 30
2.4.1 Pressing out sealing flange with sender wheel......Page 31
2.4.2 Pressing in sealing flange with sender wheel......Page 32
2.4.3 A - Assembling seal with sender wheel on assembly tool -T10134-......Page 33
2.4.4 B - Attaching assembling tool -T10134- with sealing flange on crankshaft flange......Page 34
2.4.5 C - Bolting assembly tool -T10134- onto crankshaft flange......Page 35
2.4.7 E - Checking sender wheel installation position on crankshaft......Page 36
2.5 Removing and installing engine speed sender -G28-......Page 37
3.1 Assembly overview - crankshaft......Page 39
3.1.1 Renewing needle bearing in crankshaft - vehicles with dual clutch gearbox......Page 40
3.2 Crankshaft dimensions......Page 44
4.1 Assembly overview - pistons and conrods......Page 45
4.2 Separating new conrod......Page 46
4.3 Checking piston projection at TDC......Page 47
4.5 Piston rings, cylinder bore and piston installation position......Page 48
1 Cylinder head......Page 50
1.1 Assembly overview - cylinder head......Page 51
1.2 Removing and installing cylinder head cover......Page 54
1.3 Removing, installing and tensioning toothed belts......Page 56
1.3.1 Removing and installing toothed belt (vehicles with engine support bolted close to engine)......Page 57
1.3.2 Removing and installing toothed belt (vehicles with engine support bolted further away from engine)......Page 66
1.4 Removing and installing cylinder head......Page 73
1.4.1 Removing......Page 74
1.4.2 Installing......Page 76
1.5 Checking compression......Page 77
2.1 Assembly overview - valve gear......Page 80
2.2 Checking valve guides......Page 82
2.3.1 Removing......Page 84
2.3.2 Installing......Page 85
2.4.1 Removing......Page 86
2.4.2 Installing......Page 88
2.5.1 Removing......Page 90
2.5.2 Installing......Page 91
1.2 Checking engine oil level......Page 92
2.1 Assembly overview - oil pump, sump......Page 93
2.2 Removing and installing sump......Page 94
2.2.1 Removing......Page 95
2.2.2 Installing......Page 96
3.1 Assembly overview - oil filter bracket and engine oil cooler......Page 98
3.2.1 Test procedure......Page 99
3.3 Assembly overview - oil supply line to turbocharger......Page 100
3.4.2 Installing......Page 101
1 Parts of cooling system......Page 103
1.1 Parts of cooling system, body side......Page 104
1.2 Parts of cooling system, engine side......Page 105
1.3 Coolant hose schematic diagram......Page 107
1.4.1 Draining......Page 108
1.4.2 Filling......Page 110
1.5.2 Installing......Page 111
1.6.1 Removing......Page 112
1.6.2 Installing......Page 113
1.7.1 Removing......Page 114
1.7.2 Installing......Page 115
1.8 Checking cooling system for leaks......Page 116
1.9 Checking engine oil cooler for leaks......Page 118
1 Safety precautions when working on fuel supply system......Page 120
2 Rules for cleanliness......Page 121
3.1 Assembly overview - fuel tank......Page 122
3.2 Emptying fuel tank......Page 123
3.2.1 Emptying fuel tank, bleeding fuel system when fuel pump is intact......Page 124
3.2.3 Emptying fuel tank if it is less than 3/4 full......Page 126
3.3 Removing and installing fuel tank......Page 127
3.3.2 Installing......Page 128
3.4.1 Removing......Page 129
3.5 Removing and installing fuel gauge sender......Page 130
3.6.1 Checking function and voltage supply......Page 131
3.6.2 Checking current draw of fuel pump......Page 132
4.1 Assembly overview - fuel tank......Page 133
4.2 Emptying fuel tank......Page 134
4.2.1 Emptying fuel tank, bleeding fuel system when fuel pump is intact......Page 135
4.2.2 Emptying fuel tank if it is more than 3/4 full......Page 136
4.2.3 Emptying fuel tank if it is less than 3/4 full......Page 137
4.3.1 Removing fuel tank......Page 138
4.4 Removing and installing fuel gauge sender 2 -G169-......Page 141
4.5 Removing and installing suction-jet pump......Page 143
4.6.2 Checking function and voltage supply......Page 144
4.6.3 Checking current draw of fuel pump......Page 145
5.1 Assembly overview - fuel filter......Page 146
5.2 Removing and installing fuel cooler......Page 147
5.3.1 Removing......Page 148
5.4.1 Checking delivery pressure......Page 149
5.4.2 Checking for internal leaks......Page 152
5.5 Removing and installing tandem pump......Page 153
5.5.1 Removing......Page 154
5.5.2 Installing......Page 155
1.2 Rules for cleanliness......Page 157
1.3 Assembly overview - turbocharger......Page 158
1.3.1 Engine codes BJB, BKC, BRU, BXE and BXF......Page 159
1.3.2 Engine codes BLS and BXJ......Page 161
1.4 Removing and installing turbocharger......Page 162
1.5 Assembly overview - parts of charge air cooling......Page 164
1.5.1 Engine codes BJB, BKC, BRU, BXE and BXF......Page 165
1.5.2 Engine codes BLS and BXJ......Page 166
1.6.1 Installing hose connections with connector couplings......Page 167
1.7 Checking charge air system for leaks......Page 168
1.8.1 Vehicles with particulate filter......Page 170
1.8.2 Vehicles without particulate filter......Page 171
1.1 Safety precautions......Page 172
1.3 Assembly overview - unit injector......Page 173
1.4.1 Removing......Page 175
1.4.2 Installing......Page 176
1.5 Adjusting non-contact gap of unit injectors......Page 177
1.6.2 Installing......Page 178
1.7.1 Engine codes BKC, BRU, BXE and BXF......Page 180
1.7.2 Engine code BJB......Page 181
1.8 Cleaning the intake manifold flap support, Engine code BLS and BXJ......Page 182
1.9 Assembly overview - air filter......Page 183
2.1 Reading and erasing engine control unit fault memory......Page 184
2.2 Adapting functions and components......Page 185
2.4 Removing and installing anti-theft engine control unit, Golf......Page 186
2.6 Removing and installing anti-theft engine control unit, Golf Plus......Page 189
1.1 Assembly overview - front exhaust pipe with catalytic converter......Page 192
1.2 Assembly overview - front exhaust pipe with particulate filter......Page 193
1.3 Assembly overview - silencer with mountings (vehicles with front wheel drive)......Page 195
1.3.1 Separating front and rear silencers......Page 196
1.4 Assembly overview - silencer with mountings (vehicles with four-wheel drive)......Page 197
1.5 Aligning exhaust system free of stress......Page 198
2.1.1 Engine codes BKC, BRU, BXE and BXF......Page 199
2.1.2 Engine code BJB......Page 201
2.1.3 Engine codes BLS and BXJ......Page 202
1.1 Removing, installing and checking glow plugs......Page 204
1.2 Characteristics of ceramic glow plugs......Page 205
1.3 Removing, installing and checking ceramic glow plugs......Page 206