D3E8001E712-Engine Mechanical Fuel Injection and Ignition

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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
10 - Engine Assembly
13 - Crankshaft, Cylinder Block
15 - Cylinder Head, Valvetrain
17 - Lubrication
19 - Cooling System
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24 - Multiport Fuelrise Injection
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26 - Exhaust a System, Emission Controls
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28 - Ignition/Glow Plug System
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E8001E712

Golf 2004 ➤
Engine Mechanical, Fuel Injection and Ignition - Edition 07.2015
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Engine Data . . . . . . . . . . . . . . . . . . . . . g.e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . . . . . . . . . . . . . 2
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10 - Engine Assembly . . . . . . . . . .ise.d.b . . . . . . . . . . . . . . . . . . . . . .g.ua.ra.n . . . . . . .
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1 Description and Operationauth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e o.r a. . . . . . ....... 3
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1.1 Engine and Transmissions Mountings, Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 3
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2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.2 Engine, Securing to the Engine and Transmission Holder VAS6095 . . . . . . . . . . . . . . . . 9
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3.3 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1.1 Chain Drive and Cylinder Block Overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2 Sealing Flange and Dual-Mass Flywheel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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1.3 Crankshaft Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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1.4 Piston Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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2.1 Piston and Cylinder Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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3.1 Ribbed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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3.2 Seal, Flywheel Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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3.3 Crankshaft Seal, Vibration Damper Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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3.4 Sealing Flange, Vibration Damper Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.5 Crankshaft Sensor Wheel, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1.1 Cylinder Head Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.2 Cover Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3 Valvetrain Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.4 Valve Seat, Refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.2 Compression, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.3 Valve Guide, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1 Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.2 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3 Timing Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.4 Camshaft Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.5 Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.6 Valve Stem Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.1 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.1 Lubrication System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.2 Oil Filter Housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.3 Oil Pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.1 Oil Pressure and Switch, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.1 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2 Oil Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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2.1 Coolant Hose Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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2.2 Cooling System Components Overview, Body Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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2.3 Cooling System Components Overview, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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2.4 Coolant Thermostat Housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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3.1 After-Run Coolant Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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3.2 Coolant Fan, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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4.1 Coolant Thermostat Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

4.2 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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4.3 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

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1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

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1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

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2.1 Emergency Fuel Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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2.2 Electronic Power Control System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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2.3 EVAP System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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2.4 Accelerator Pedal Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.5 Fuel Tank and Attachments Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.6 EVAP System Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.7 Leak Detection Pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.1 Fuel Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.1 Suction Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.2 Fuel Delivery Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.3 Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.4 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4.5 Leak Detection Pump and EVAP Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.3 Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.1 Functions and Components, Adapting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.2 Engine Control Module DTC Memory, Checking and Erasing . . . . . . . . . . . . . . . . . . . . . . 145
2.3 Component Location Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.4 Fuel Injection System Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.5 Intake Manifold Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2.6 Fuel Rail Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.7 Air Filter Housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3.1 Technical Data . . . .ag. e.n.A.G.. V. o. lk. s.w.a.ge. n. A.G. d.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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5.1 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

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5.2 Motronic Engine Control Module J220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

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Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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2.1 Secondary Air Injection System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

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2.2 Secondary Air Injection System Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 170

2.3 Exhaust Manifold, Front Exhaust Pipe, Catalytic Converter and Attachments Overview . . 172
2.4 Muffler and Mounts Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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3.1 Combination Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

s
iva
do
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rp
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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1.2 Ignition, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
co Vo
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AG.
2.1 Ignition System Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.1 Test Data and Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4.1 Ignition Coils with Power Output Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
6 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Contents iii
Golf 2004 ➤
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iv Contents
Golf 2004 ➤
00 – General, Technical Data

1 General Information n AG. Volkswagen AG do
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(Edition 07.2015) byV
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⇒ “1.1 Engine Number”, page 1 tho tee
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1.1 Engine Number
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The engine number “engine code” and “serial number” is located
itte
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next to the vibration damper on the cylinder block under the cool‐
erm
ab
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ant pump.
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In addition, a sticker with the “engine code” and “serial number”
h re
ole,
is affixed to the intake manifold.
spec
The engine code is also included on the vehicle data label.
t to the co
rrectness o
cial p
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mer
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1. General Information 1
Golf 2004 ➤
2 Specifications
⇒ “2.1 Engine Data”, page 2
2.1 Engine Data

Engine Code BJS
Manufactured from 10.03
Emission values in accordance with AG. Volkswagen AG d
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Cylinder arrangement sed by ara
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ri
Cylinder angle ho eo
15.0°
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Displacement Liter 3.2
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Output kW at RPM 177 at 6200
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Torque Nm at RPM 320 at 3200
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Bore diameter mm 84.0
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Stroke mm 95.9
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Compression ratio 11.25
spec
es, in part or in w
Research Octane Num‐ minimum 98 unleaded 3
t to the co
ber (RON)
♦ 1 LEV = Low Emission Vehicles
rrectness of i
♦ 2 VR = V-Arrangement in compact in-line design
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♦ 3 In exceptional circumstances min. 95 RON, however with nf

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reduced performance
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Engine Code BJS

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Fuel injection, ignition Motronic ME7.1.1

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Ignition sequence 1-5-3-6-2-4

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Knock control 2 knock sensors
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Oxygen Sensor (O2S) regulation 4 sensors
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On Board Diagnostic (OBD) Prote
cted AG.
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OBD ll
Catalytic converter yes
Exhaust Gas Recirculation (EGR) no
Turbocharger, Supercharger no
Secondary Air Injection (AIR) System yes
Electronic Power Control (EPC) yes
Variable intake manifold yes
Variable valve timing Yes 1
Leak diagnostic system yes
♦ 1 Two independently variable camshafts.
2 Rep. Gr.00 - General, Technical Data

Golf 2004 ➤
10 – Engine Assembly
1 Description and Operation
⇒ “1.1 Engine and Transmission Mountings, Aligning”,
page 3 wage
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1.1 Engine and Transmission Mountings, ris
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Alignings ho
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Special tools and workshop equipment required
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♦ Engine Support Bridge - 10-222A-
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♦ Bracket for Engine - 10-222A/1-
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♦ Engine Support Adapter - 10-222A/3-
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spec
WARNING
t to the co
Before loosening the bolts, secure the engine/transmission as‐
sembly using the engine support bridge - 10-222A- .
rrectness
Engine Mount
o
cial p
f inform
Dimension -a- = 14.0 mm
mer
atio
Dimension -b- = a minimum of 10.0 mm
om
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Both bolt heads -1- must be flush with the edge -c-.
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Transmission Mount
The edges -a and b- must be parallel to each other.
Note
Tightening specifications for the engine and transmission mounts.

Refer to ⇒ “2.1 Fastener Tightening Specifications”, page 4 .
1. Description and Operation 3

AG. Volkswagen AG d
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Golf 2004 ➤ orise nte
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Engine Mechanical, Fuel Injection and Ignition - Edition
aut 07.2015 ra
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2 Specifications
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⇒ “2.1 Fastener Tightening Specifications”, page 4
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2.1 Fastener Tightening Specifications
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spec
Engine Mount
t to the co
1- Engine mount to body 1 40 Nm + 90° (1/4) ad‐
ditional turn
rrectne
2- Support to engine mount and body 20 Nm + 90° (1/4) ad‐
1 ditional turn
ss
3- Engine mount to engine mount 100 Nm
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bracket
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1- Transmission mount to body 1 40 Nm + 90° (1/4) ad‐ C py
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2- Transmission mount to body 1 20 Nm + 90° (1/4) ad‐
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ditional turn
AG.
3- Transmission mount to transmis‐ 100 Nm

sion mount bracket
Pendulum Support
1- Pendulum support to transmission 50 Nm
2- Pendulum support to transmission 50 Nm
3- Pendulum support to subframe 25 Nm
♦ 1 Always replace
4 Rep. Gr.10 - Engine Assembly

Golf 2004 ➤
3 Removal and Installation

⇒ “3.1 Engine, Removing”, page 5
⇒ “3.2 Engine, Securing to the Engine and Transmission
gen AG
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⇒ “3.3 Engine, Installing”, page 10
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3.1 Engine, Removing ss
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♦ Engine Support - T10102-
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♦ Engine/Gearbox Jack - VAG1383A-
h re
ole,
♦ Step Ladder - VAS5085-
spec
t to the co
♦ Spring Type Clip Pliers - VAS5024A-
– The engine is removed downward together with the transmis‐
sion.
rrectne
– All cable ties which are opened or cut off when removing the
engine, must be replaced in the same position when installing
ss o
the engine.
cial p
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mer
atio
Note
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To perform this procedure, the ground cable must be disconnec‐
te
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ted from the battery. Check whether a coded radio is installed. If

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so, obtain the anti-theft code beforehand.
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– Turn off the ignition and disconnect the ground cable from the
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– Remove the engine cover.
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– Disconnect the ignition coil connectors and unclip ignition coil

wires.
– Remove the battery and battery holder.
– Remove the air filter housing and connecting pipe. Refer to
⇒ “2.7 Air Filter Housing Overview”, page 154 .
WARNING
The fuel supply lines are under pressure! Wear protective gog‐
gles and protective gloves to avoid damage and contact with
skin. Wrap a cloth around the connection before removing a
fuel hose. Then release pressure by carefully disconnecting
the hose connection.
3. Removal and Installation 5

Golf 2004 ➤
– Disconnect the supply line -1- (with a white mark) and return
line -2- (with a blue mark) and catch any leaking fuel with a
shop cloth.
Note
Press the buttons together on the connections to do so.
– Seal the lines so that the fuel system is not contaminated by

dirt, etc. wage
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– Remove the noise insulation, along with ed the left and right
by ara
sides. Refer to “Body, Front” in ⇒ Body
horis Exterior; Rep. Gr. 50 ; nte
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Description and Operation . ut ra
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– Remove the ribbed belt. Refer to
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⇒ “3.1 Ribbed Belt”, page 32 .
an
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– Unbolt the power steering pump from the accessory bracket
ility
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and place it to the side; the hoses remain connected. Refer to
wit
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⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Removal and
h re
Installation .
hole
spec
es, in part or in w
– Remove the securing clamps for the power steering pressure
t to the co
line.
Vehicles with Air Conditioning (A/C)
rrectness of i
WARNING
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Do not open the A/C refrigerant circuit.
nform
mercia
at
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Note his
ate
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♦ The refrigerant circuit must only be opened in shops with

for
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trained personnel and the necessary range of tools and shop

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♦ To prevent damage to the A/C condenser and also to the re‐
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frigerant lines/hoses, ensure that the lines/hoses are not Prote
cted AG.
agen
stretched, kinked or bent.
To facilitate removal and installation of the engine without having

to open the refrigerant circuit:
– Remove the retaining clamp(s) from the refrigerant lines.
– Remove the A/C compressor. Refer to ⇒ Heating, Ventilation
and Air Conditioning; Rep. Gr. 87 ; Description and Operation .
– Secure the A/C compressor to the body so that the refrigerant
lines/hoses are not burdened.
Continuation for All Vehicles
– Disconnect the shift mechanism from the transmission. Refer
to ⇒ Manual Transmission; Rep. Gr. 34 ; Removal and In‐
stallation .
– Separate the clutch hydraulic line from the slave cylinder. Re‐
fer to ⇒ Manual Transmission; Rep. Gr. 30 ; Description and
Operation .
– Remove the front bumper cover. Refer to “Front Bumper” in ⇒
Body Exterior; Rep. Gr. 63 ; Removal and Installation .

Golf 2004 ➤
– Bring the lock carrier into the service position. Refer to “Body,
Front” in ⇒ Body Exterior; Rep. Gr. 50 ; Description and Op‐
eration .
– Remove the intake manifold. Refer to
⇒ “5.1 Intake Manifold”, page 162 .
– Disconnect the vacuum and vent hoses from the engine.
– Disconnect the electrical connectors for the following compo‐
nents:
Note
Before disconnecting the connectors, mark the allocation to the

component.
♦ Engine Coolant Temperature Sensor - G62- with Engine Cool‐

ant Temperature Gauge Sensor - G2-
♦ After-Run Coolant Pump - V51-
♦ Camshaft Adjustment Valve 1 - N205-
♦ Exhaust Camshaft Adjustment Valve 1 - N318-
♦ Camshaft Position Sensor - G40-
♦ Camshaft Position Sensor 2 - G163-
n AG. Volkswagen A
♦ Cylinder 1 Fuel Injector - N30- to Cylinder
olks
w6
agFuel
e
Injector - N84-
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♦ Engine Speed Sensor - G28- rised nte
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♦ Knock Sensor 1 - G61- ss au ra
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♦ Knock Sensor 2 - G66-

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♦ Oil Level Thermal Sensor - G266-
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Installed locations. Refer to
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⇒ “2.3 Component Location Overview”, page 146 .

, is n
h re
hole
– Disconnect all electrical connections as necessary from the

spec
engine and free them up.

es, in part or in w
t to the co
– Disconnect and free up all electrical connections from the

transmission, generator, and starter.
rrectness of i
– Drain the coolant. Refer to

⇒ “1.1 Draining and Filling”, page 100 .
l purpos
– Disconnect the coolant hose quick release couplings from the

radiator.
nform
ercia
– Disconnect the coolant hoses from the engine using the Spring
m
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com
ti
Type Clip Pliers - VAS5024A- .

on in
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– Remove the drive axles. Refer to : ⇒ Suspension, Wheels,

s
iva
Steering; Rep. Gr. 40 ; Removal and Installation

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Prote AG.

Golf 2004 ➤
– Remove the pendulum support bolts -arrows-.

– Remove the catalytic converter. Refer to
⇒ “2.3 Exhaust Manifold, Front Exhaust Pipe, Catalytic Con‐
verter and Attachments Overview”, page 172 .
– Remove the front driveshaft. Refer to “Driveshaft and Com‐
ponents” in ⇒ Manual Transmission; Rep. Gr. 39 ; Removal
and Installation .
– Remove the front exhaust pipe. Refer to
– Remove the generator and accessory bracket. Refer to ⇒
Electrical Equipment; Rep. Gr. 27 ; Description and Opera‐
tion .
– Remove the bracket for the Secondary Air Injection Pump Mo‐
tor - V101- from the oil pan.
– Install the Engine Support - T10102- to the Engine/Gearbox
AG. Volkswagen AG d
Jack - VAG1383A- . agen oes
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– Position the Engine Support - uT10102-
tho to the cylinder block eo
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and secure it with the bolts s-1-.
s a c
ce
le
– Gently lift the engine and transmission using the Engine/Gear‐

un
pt
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box Jack - VAG1383A- .

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spec
t to the co
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– Remove the engine mount to engine mount bracket bolts
-arrows- from above.
ss o
cial p
f inform
mer
Note
atio
om
n
c
Use the Step Ladder - VAS5085- to remove the bolts.

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– Remove the transmission mount to transmission mount brack‐
AG.
et bolts -arrows- from above.

– Carefully lower the engine with transmission.
Note
Carefully guide the engine with transmission, when lowering, to

prevent damage to the body.

Golf 2004 ➤
3.2 Engine, Securing to the Engine and

Transmission Holder - VAS6095-
♦ Engine and Transmission Holder - VAS6095-
♦ Holding Fixture - VW540-
♦ Spacers - VW540/1B-
♦ Lifting Tackle - 3033-
♦ Shop Crane - Load Cap = 700-1200 KG - VAS6100-
Secure the engine to the engine and transmission holder -
VAS6095- when working on it, otherwise use the Holding Fixture
- VW540- with the Spacers - VW540/1B- . n AG. Volkswagen A G do
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Procedure olks ot g
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– Remove the transmission. thori tee
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– Install the Lifting Tackle -ss3033- as follows and
lift the engine
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using the Shop Crane - Load Cap = 700-1200 Kg - VAS6100-

nl
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off of the Engine/Gearbox Jack - VAG1383A- .
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Vibration damper side: -Position 3-
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Flywheel side: -Position 11-
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If using the Engine and Transmission Holder - VAS6095- :
spec
es, in part or in w
t to the co
rrectness of i
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ate
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– Secure the engine to the Engine and Transmission Holder - Prote AG.
VAS6095- as shown.
If using the Holding Fixture - VW540- :

Golf 2004 ➤
– Bolt the Holding Fixture - VW540- to the cylinder block using

three Spacers - VW540/1B- . To secure the lower right
-arrow-, use a commercially available grade 8.8, M12 x 160
bolt.
3.3 Engine, Installing

♦ Torque Wrench (5-50 Nm) - VAG1331-
♦ Grease for Clutch Plate Splines - G 000 100-
♦ Cable Ties
Installation is carried out in the reverse order while noting the fol‐
lowing:
– Check the clutch release bearing, if necessary replace the
slave cylinder with release bearing. Refer
n AG. Voto
lks⇒
waManual
gen AG Trans‐
wage does
mission; Rep. Gr. 30 ; Removal
Volks and Installation . not
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– Clean the driveshaft hsplines
ris
e
and lightly lubricate using Grease tee
ut o - G 000 100- .
for Clutch Plate Splines or
a ac
ss
– Check whether the alignment sleeves for aligning the engine
ce
le
un
pt
to the transmission are in the cylinder block, install them if

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necessary.
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– When installing the engine and transmission assembly, check

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wit
for clearance to the subframe as well as to the radiator.

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hole
– Align the engine and transmission mounts. Refer to

spec

es, in part or in w
t to the co
page 3 .
rrectness of i
Note
l purpos

nform
ercia
– Install the bracket and generator. Refer to ⇒ Electrical Equip‐

m
a
com
ti
ment; Rep. Gr. 27 ; Description and Operation .

on in
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– Install the front exhaust pipe. Refer to

s
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fo
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t.
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– Install the front driveshaft. Refer to “Driveshaft and Compo‐
Co
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nents” in ⇒ Manual Transmission; Rep. Gr. 39 ; Removal and t. C rig
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Installation . p by
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– Install the catalytic converter. Refer to Prote AG.

Golf 2004 ➤
– Install the drive axles. Refer to ⇒ Suspension, Wheels, Steer‐

ing; Rep. Gr. 40 ; Removal and Installation .
– Install the hydraulic line to the clutch slave cylinder. Refer to
⇒ Manual Transmission; Rep. Gr. 30 ; Description and Op‐
eration .
– Bleed the clutch system. Refer to ⇒ Manual Transmission;
Rep. Gr. 30 ; General Information .
– Install the shift mechanism. Refer to ⇒ Manual Transmission;
Rep. Gr. 34 ; Removal and Installation .
– If necessary, adjust the shift cable. Refer to ⇒ Manual Trans‐
mission; Rep. Gr. 34 ; Description and Operation . AG. Volkswagen AG do
agen w es n
olks ot g
– Install the power steering pump. Refer eto
d b⇒ Suspension,
yV ua
ran
Wheels, Steering; Rep. Gr. 48 ; Removal
ho
ris and Installation . tee
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au ac
– Install the ribbed belt. Refer to ss
ce
e
nl
pt
du
an
itte
– Electrical connections and routing. Refer to ⇒ Wiring dia‐
y li
erm
ab
grams, Troubleshooting & Component locations.
ility
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– Install the center noise insulation, along with the left and right
wit
, is n
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sides. Refer to ⇒ Body Exterior; Rep. Gr. 50 ; Description and
hole
Operation .
spec
es, in part or in w
– Install the intake manifold. Refer to
t to the co
– Install the air filter housing with connecting pipe. Refer to
rrectness of i
⇒ “2.7 Air Filter Housing Overview”, page 154 .
l purpos
– Fill with coolant. Refer to

nf
ercia
– Connect the battery.
orm
m
atio
– Connect the Vehicle Diagnosis & Service System. -
om
n in
VAS5052- .
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– Perform a vehicle system test in “Guided Fault Finding”. sd

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– End the vehicle system test, this will automatically erase any
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Diagnostic Trouble Code (DTC) entries which occurred during

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the assembly.
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– Generate a readiness code in conjunction with a road test. cop Vo
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– Then, perform a vehicle system test again and repair any oc‐
AG.
curring malfunctions if necessary.

– Check the headlamp adjustment and adjust as necessary.
Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Diagnosis and
Testing .
Tightening Specifications
Bolted Connections Specification
Bolts and Nuts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M12 60 Nm
Deviation from
Engine to transmission bolts M10 60 Nm
Engine to transmission bolts M12 80 Nm
Starter to transmission 65 Nm

Golf 2004 ➤
Note

AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
rrectness of i
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at
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ion
c
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or
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ate
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ng
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Cop py
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Prote AG.

Golf 2004 ➤
4 Special Tools
♦ Engine Support Adapter - 10-222A/3-
♦ Holding Fixture - VW540-
♦ Spacers - VW540/1B-
AG. Volkswagen AG d
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♦ Lifting Tackle - 3033- aut ra
ss c
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♦ Engine Support - T10102-

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♦ Torque Wrench (5-50 Nm) -
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VAG1331-
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♦ Torque Wrench (40-200
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h re
Nm) - VAG1332-
hole
spec
♦ Engine/Gearbox Jack -
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VAG1383A-
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Holder - VAS6095-
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♦ Shop Crane - Load Cap =
700-1200 KG - VAS6100-
rrectness of i
♦ Drip Tray for VAS6100 -
VAS6208-
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Golf 2004 ➤
13 – Crankshaft, Cylinder Block

⇒ “1.1 Chain Drive and Cylinder Block Overviews”, page 15
⇒ “1.2 Sealing Flange and Dual-Mass Flywheel Overview”, page
22
⇒ “1.3 Crankshaft Overview”, page 24
⇒ “1.4 Piston Overview”, page 26
1.1 Chain Drive and Cylinder Block Over‐

views
Note
When performing any repair work, secure the engine to the En‐
gine and Transmission Holder - VAS6095- or Holding Fixture -
VW540- with Spacers - VW540/1B- .
Note
♦ If large quantities of metal particles or abraded material are

detected during engine repairs, it may mean the crankshaft or
rod bearings are damaged. To preventnfurther . Volkdamage,
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Golf 2004 ➤
I - Refer to
⇒ “1.1.1 Chain Drive”,
page 17
II - Refer to
⇒ “1.1.2 Cylinder Block”,
page 20
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16 Rep. Gr.13 - Crankshaft, Cylinder Block

Golf 2004 ➤
1.1.1 Chain Drive
1 - Control Housing
❑ Lightly lubricate the con‐
tact surfaces of the
seals before installing.
❑ Removing and instal‐
ling. Refer to
⇒ “3.5 Camshafts”,
page 77 .
❑ Disassembly and as‐
sembly. Refer to
⇒ Fig. ““Disassembling
and Assembling the
Control Housing”“ ,
page 48 .
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page 48 .
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❑ Always replace.
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3 - Timing Chain, Camshafts

t to the co
❑ Mark the rotation direc‐

tion before removing (in‐
stalled position). Refer
rrectness of i
to
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⇒ Fig. ““Timing Chain,

Marking”“ , page 19 .
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ling. Refer to
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page 60 .
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❑ Removing and installing. Refer to ⇒ “3.4 Camshaft Adjuster”, page 70 .
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6 - Guide Ring
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7 - Screw
❑ 8 Nm
❑ Install using liquid locking fluid - D 000 600 A2- .
8 - Tensioning Rail
❑ For the camshaft timing chain -item 3-.
9 - Pin
❑ 18 Nm
10 - Chain Tensioner
❑ 40 Nm

Golf 2004 ➤
❑ Only rotate the engine with the chain tensioner installed.
11 - Seal
❑ Replace if damaged or leaking.
12 - Sprocket
❑ For the oil pump timing chain -item 17-.
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❑ 60 Nm + 90° (1/4) additional turn.
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❑ Use the counter-holder tool - T10069- to tighten and loosen.
hole
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15 - Chain Tensioner with Tensioning Rail
t to the co
❑ For the oil pump timing chain -item 17-.
❑ Before installation, release the locking device in the chain tensioner using a small screwdriver and press
rrectness of i
the tensioning rail against the chain tensioner.
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16 - Drive Gear
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❑ Integral part of the crankshaft.
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❑ The ground down tooth aligned with the main bearing cap joint = Top Dead Center (TDC) for cylinder 1.
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17 - Timing Chain, Oil Pump
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19 - Pin without Collar
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❑ 10 Nm
❑ For the guide rail -item 18-.
20 - Pin
❑ 18 Nm
21 - Bolt
❑ 23 Nm
22 - Intake Camshaft Adjuster
❑ Identification: 24E
23 - Bolt
❑ Always replace.
❑ The contact surface of the sensor wheel must be dry around the bolt head when assembling.
❑ To remove and install, counter hold the camshaft using a 32 mm wrench. Refer to
⇒ “3.5 Camshafts”, page 77 .
24 - Guide Rail
25 - Exhaust Camshaft Adjustment Valve 1 - N318-
❑ For the exhaust camshaft.

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❑ Before disconnecting,
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mark the allocation of the connector or to the component.
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26 - Camshaft Adjustment Valve 1 - N205-
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❑ For the intake camshaft.
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❑ For the camshaft timing chain.
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❑ Clipped into the control housing.
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Timing Chain, Marking
rrectne
– Mark the timing chains before removing (for example, with a
paint arrow pointing in rotation direction).
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Note
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Do not mark the chain using a center punch or similar means!
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Golf 2004 ➤
1.1.2 Cylinder Block
1 - Bolt
❑ 45 Nm
2 - Engine Mount Bracket
3 - Bolt
❑ 5 Nm
❑ Fastened to the intake
manifold.
4 - Dipstick
❑ The oil level must not be
above the Max. mark!
❑ Marks. Refer to
⇒ Fig. ““Oil Dipstick
Marks”“ , page 90 .
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hole
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wheel Overview”,
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page 22 .
❑ Crankshaft overview.
rrectness of i
Refer to
⇒ “1.3 Crankshaft Over‐
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view”, page 24 .
❑ Piston and connecting
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rod overview. Refer to

⇒ “1.4 Piston Overview”,
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❑ Installed location: Between cylinders 1 and 3.

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❑ 10 Nm
10 - Oil Pump Drive Cover
11 - O-Ring
❑ Always replace.
❑ Coat with oil before installing.
12 - Oil Pump Drive
13 - Oil Check Valve
❑ 5 Nm
❑ Pay attention to the installed position.
❑ Clean if badly contaminated.

Golf 2004 ➤
❑ See the note in ⇒ “1.1 Chain Drive and Cylinder Block Overviews”, page 15 .
14 - Intermediate Shaft
15 - Guide Ring
16 - Bolt/Screw
❑ 8 Nm
❑ Install using liquid locking fluid - D 000 600 A2- .
❑ Installed location:
wage Between cylinders
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20 - Bolt
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❑ 25 Nm
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21 - Oil Drain Plug
❑ 30 Nm
❑ Always replace the seal.
rrectne
22 - Oil Pan
ss
❑ Removing and installing. Refer to ⇒ “4.1 Oil Pan”, page 97 .

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23 - Oil Level Thermal Sensor - G266-

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24 - Bolt
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❑ 12 Nm
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❑ Overview. Refer to ⇒ “2.2 Oil Filter Housing Overview”, page 90 .

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❑ Coolant hose connection diagram. Refer to ⇒ “2.1 Coolant Hose Connection Diagram”, page 103 .
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❑ Used to align the accessory bracket.
27 - Accessory Bracket
❑ For the generator, Air Conditioning (A/c) compressor, and power steering pump.
28 - Vibration Damper
❑ Remove and install the ribbed belt. Refer to ⇒ “3.1 Ribbed Belt”, page 32 .
29 - Bolt
❑ Always replace.
❑ Use the Counter-Holder Tool - T10069- for loosening and tightening. Refer to
⇒ Fig. ““To Loosen and Tighten the Bolt, Secure the Vibration Damper Using the Counter-Holder Tool -
T10069- ”“ , page 22 .
❑ Tighten using the Torque Wrench - VAG1601-
30 - Engine Speed Sensor - G28-

Golf 2004 ➤
To Loosen and Tighten the Bolt, Secure the Vibration Damper

Using the Counter-Holder Tool - T10069-
Note
♦ The vibration damper bolt must be replaced.

♦ Tighten the bolt using the torque wrench - VAG1601-
1.2 Sealing Flange and Dual-Mass Fly‐

wheel Overview
Note
When performing any repair work, secure the engine to the En‐
gine and Transmission Holder - VAS6095- or the Holding Fixture
- VW540- with Spacers - VW540/1B- .
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Servicing the clutch. Refer to ⇒ Manual Transmission; Rep. Gr.
wagen A oes
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Golf 2004 ➤
1 - Bolt
❑ 100 Nm + 180° (1/2) ad‐
ditional turn.
❑ Always replace.
❑ Use the counter-holder
tool - T10069- for loos‐
ening and tightening.
Refer to
⇒ Fig. ““To Loosen and
Tighten the Bolt, Secure
the Vibration Damper
Using the Counter-
Holder Tool -T10069-
”“ , page 22 .
❑ Tighten using the torque
wrench - V.A.G 1601- .
2 - Vibration Damper
❑ Remove and install the
ribbed belt. Refer to
⇒ “3.1 Ribbed Belt”,
page 32 .
3 - Bolt
❑ 10 Nm
4 - Seal
❑ Only replace the metal
sealing flange separate‐
ly. Refer to
⇒ “3.3 Crankshaft Seal,
Vibration Damper Side”,
page 33 .
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⇒ “3.4 Sealing Flange, Vibration Damper Side”, page 35 .
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❑ Coat the sealing surface with silicone adhesive sealant - D 176 501 A1- .
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6 - Cylinder Block
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hole
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7 - Sealing Flange
t to the co
❑ Coat the sealing surface with silicone adhesive sealant - D176 501 A1- .
8 - Seal
rrectness of i
❑ Remove using the pulling hook - T20143- .

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❑ Polytetrafluoroethylene (PTFE) version of the seal.

❑ Identification: no inner coil spring.
nform
ercia
❑ Do not coat the lip on the seal with oil or grease.

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❑ Wipe off any oil on the crankshaft journal with a clean cloth before installing.
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❑ Removing and installing. Refer to ⇒ “3.2 Seal, Flywheel Side”, page 32 .

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9 - Dual-Mass Flywheel
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Golf 2004 ➤
❑ To loosen and tighten, use the counter-hold tool - T10044- (with 5 mm spacers) or the counter-holder
tool - T10069- .
11 - Bolt
❑ 25 Nm
1.3 Crankshaft Overview
Note
♦ Before removing the crankshaft, prepare a suitable place to

store it to make sure that the sensor wheel -item 6- does not
make contact or become damaged.
♦ When performing any repair work, secure the engine to the
Engine and Transmission Holder - VAS6095- swa
or
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AG.Holding
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♦ When changing bearing shells ensure
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❑ Bearing cap 1: Vibration
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❑ Bearing cap 5 with
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❑ The retaining tabs on
the bearing shells and
rrectness of i
cylinder block/bearing
caps must align above
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one another.
2 - Bolt
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❑ 30 Nm + 180° (1/2) ad‐

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❑ Always replace.
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❑ Do not interchange
used bearing shells
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4 - Thrust Washer
❑ For bearing cap 5
❑ Observe the locating
point
5 - Crankshaft
❑ Before removing, ob‐
serve the note in
⇒ “1.3 Crankshaft Over‐
view”, page 24 .
❑ Axial clearance:
New: 0.07 to 0.23 mm

Golf 2004 ➤
Wear limit: 0.30 mm

❑ Measure radial clearance using Plastigage®:
New: 0.02 to 0.06 mm
Wear limit: 0.10 mm

❑ Do not rotate the crankshaft when measuring the radial play.
❑ Crankshaft dimensions:
Main bearing: 59.958 to 59.978 mm
Connecting rod bearing: 53.958 to 53.978 mm

❑ Reworking is not permissible.
6 - Sensor Wheel
❑ For the Engine Speed Sensor - G28- .
❑ Always replace.
❑ Installing. Refer to ⇒ “3.5 Crankshaft Sensor Wheel, Installing”, page 36 .
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❑ Opening pressure - 2.0 bar.
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❑ Removing and installing. Refer to ⇒ Fig. ““Oil Spray Nozzle, Removing and Installing”“ , page 89 .
❑ See the note in ⇒ “1.1 Chain Drive and Cylinder Block Overviews”, page 15 . rrectness of i
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Golf 2004 ➤
1.4 Piston Overview
1 - Piston Rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers for
removal and installa‐
tion.
❑ Identification “TOP”
faces towards the piston
crown.
❑ Checking ring gap. Re‐
fer to agen
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Groove Clearance,
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Checking”“ , page 28 .
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2 - Piston
hole
spec
❑ Checking. Refer to
es, in part or in w
⇒ Fig. ““Piston, Check‐
t to the co
ing”“ , page 28 .
❑ Mark the installed loca‐ rrectness of i
tion to the connecting
rod and to which cylin‐
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❑ Flatter side of the piston
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crown faces toward the

center of the cylinder
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❑ Piston installing. Refer

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❑ Mark to which cylinder it belongs -B-.

❑ Installed position: Marks -A- must align.
5 - Bearing Shell
❑ Do not interchange used bearing shells (mark them).
❑ Bearing shell retaining tabs must be firmly seated in the notches.
❑ Axial clearance:
New: 0.05 to 0.31 mm
Wear limit: 0.40 mm

❑ Measure radial clearance using Plastigage®:
New: 0.02 to 0.07 mm
Wear limit: 0.10 mm

❑ Do not rotate the crankshaft when checking the radial clearance.

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au ac
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6 - Connecting Rod Bearing Cap
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❑ Mark to which cylinder it belongs -B-.
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❑ Installed position: Marks -A- must align.
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7 - Bolt
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❑ Always replace.
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❑ Lubricate the threads and contact surface.
❑ Tighten to 30 Nm to measure the radial play, do not tighten the additional turn.
rrectness of i
8 - Cylinder Block
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❑ Checking the cylinder bore. Refer to ⇒ Fig. ““Cylinder Bore, Checking”“ , page 29 .
❑ Crankshaft overview. Refer to ⇒ “1.3 Crankshaft Overview”, page 24 .
nform
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❑ For the correct piston and cylinder dimensions. Refer to

⇒ “2.1 Piston and Cylinder Dimensions”, page 31 .
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9 - Piston Pin
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❑ If difficult to move, heat the piston to 60 °C (140 °F).
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❑ Remove and install using a pilot drift - VW222 A- .
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♦ Feeler Gauge
Test Sequence
– Push the ring squarely from above, down to approximately 15
mm from the bottom of the cylinder. To do this use a piston
without rings.
Piston Ring Gap
New Wear limit
Compression ring mm 0.20 to 0.40 1.0
Tapered ring mm 0.20 to 0.40 1.0
Oil scraping ring mm 0.25 to 0.50 1.0

Golf 2004 ➤
Piston Ring Groove Clearance, Checking

♦ Feeler Gauge
– Clean the ring groove before checking.
Piston Ring Ring to Groove Clearance
New Wear limit
Compression ring mm 0.04 to 0.09 0.15
Tapered ring mm 0.03 to 0.06 0.15 . Volkswagen AG
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Oil scraping ring mm 0.02 to 0.06 0.15Volkswa not
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♦ External Micrometer (75-100 mm)

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Take the measurement approximately 6 mm from the lower edge

of the piston skirt and offset 90° to the piston axis.
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Golf 2004 ➤
Deviation from nominal dimension: Max. 0.04 mm

Cylinder Bore, Checking
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♦ Internal Dial Gauge (50-100 mm_
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Test Sequence
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Measure diagonally at 3 positions transversely -A- and longitudi‐
nally -B-.
rrectne
Deviation from nominal size: Max. 0.08 mm.
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Note
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Measurement of the cylinder bore may not be performed when
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the cylinder block is mounted on the Engine and Transmission
om
Holder - VAS6095- or the Holding Fixture - VW540- , false meas‐
n
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♦ Piston Insertion Funnel - T10147-
Note
♦ Install using the Piston Insertion Funnel - T10147-

♦ If a new piston insertion funnel is used to install the pistons,
first pass the piston with oiled piston rings through the funnel
twice and remove the resulting metal shavings if necessary.
Only then can you install the piston with piston rings.
Procedure
– Push the piston by hand into the oiled piston insertion funnel.
The flat side of the piston crown must face toward the tab on
the piston insertion funnel -arrow-.
– Hold the piston insertion funnel (with the piston inserted) on
the upper edge and press the piston in with both thumbs.

Golf 2004 ➤
– Push the piston in until it protrudes approximately 15 mm from

the lower edge of the piston insertion funnel.
– Insert the piston into the appropriate cylinder bore. The tab on
the piston insertion funnel -arrow- must face the center of the
cylinder block.
– Press the piston insertion funnel tightly against the cylinder
block and push the piston in.
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Golf 2004 ➤
2 Specifications
⇒ “2.1 Piston and Cylinder Dimensions”, page 31
2.1 Piston and Cylinder Dimensions

Honing Dimen‐ Piston Diameter Cylinder Bore
sion Diameter
Basic dimension mm 83.965 84.010
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2. Specifications 31
Golf 2004 ➤

⇒ “3.1 Ribbed Belt”, page 32
⇒ “3.2 Seal, Flywheel Side”, page 32
⇒ “3.3 Crankshaft Seal, Vibration Damper Side”, page 33
⇒ “3.5 Crankshaft Sensor Wheel, Installing”, page 36
3.1 Ribbed Belt

♦ M8 x 50 Bolt
Removing
– Remove the right noise insulation. ⇒ Body Exterior; Rep. Gr.
50 ; Body Front; Noise insulation (gasoline engine), assembly
overview
– Mark the rotation direction on the ribbed belt.
– To relieve tension on the ribbed belt, screw a M8 x 50 bolt into
the hole -A- on the ribbed belt tensioner.
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Only screw the bolt in so is far until the ribbed belt can be removed,ante
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otherwise the tensioner
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– Remove the ribbed belt.

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Installing
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– Install the ribbed belt as illustrated.

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– Remove the bolt from the tensioner housing.

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Note
rrectness of i
♦ Ensure, before installing the ribbed belt, that all ancillaries

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(generator, Air Conditioning (A/C) compressor, power steering

pump) are secured tightly.
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♦ Note the previously marked rotation direction if reinstalling the

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old belt and be sure that it is seated correctly on the pulleys.

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After completing repairs always:

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– Start the engine and check the belt running.

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3.2 Seal, Flywheel Side

♦ Assembly Tool - T10122-
♦ Pulling Hook - T20143-

Golf 2004 ➤
Removing
– Remove the transmission.
– Place the Pulling Hook - T20143/2- behind the sealing lip of
the seal as shown in the illustration.
– Support the Pulling Hook - T20143/2- on the sealing flange
and pry out the seal in the direction of -arrow-.
Installing
– Pull the seal -A- with the outer side over the sleeve - T10122/1-
onto the Assembly Tool - T10122/2- .
– Separate both assembly sleeves.
– Then place the Assembly Tool - T10122/2- with a dry seal onto
the crankshaft journal.
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– Now, drive the sealbinto y V the sealing flange until it is seated
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using the Assembly orise Tool - T10122/3- .
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– Install the transmission.
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3.3 Crankshaft Seal, Vibration Damper Side

rrectness of i
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♦ Pulling Hook - T20143/1-
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♦ Counter-Holder Tool - T10069-

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♦ Torque Wrench - VAG1601-

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agen 3. Removal and Installation
Golf 2004 ➤
Removing
– Remove vibration damper. To do so, secure the vibration
damper using the Counter-Holder Tool - T10069- .
– Place the Pulling Hook - T20143/1- behind the sealing lip of

the seal as shown in the illustration.
– Support the Pulling Hook - T20143/1- on the sealing flange
and pry out the seal in the direction of -arrow-.
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A Polytetrafluoroethylene (PTFE) seal (Teflon) -2- is gradually

being introduced instead of the inner coil spring type seal -1-. This
has a wider sealing lip. PTFE seals are installed free of oil and
rrectness of i
grease. If a PTFE seal was installed, only this type of seal may
be used as a replacement part!
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– Before installing, remove any remaining oil from the end of the
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crankshaft with a clean cloth.

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– Install the Guide Sleeve - T10215/1- -1- onto the front of the
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crankshaft journal.
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– Carefully slide the seal -2- onto the guide sleeve as far as
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– Press in the seal until seated using the Thrust Sleeve -
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T10215/2- -3-. To do this use the old vibration damper bolt by c lksw
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Note

♦ Tighten the bolt using the Torque Wrench - VAG1601-

Golf 2004 ➤
– Install the vibration damper and secure it using the Counter-

Holder Tool - T10069- .
– Tighten the new bolt to 100 Nm + an additional 180° (1/2) turn.
– Install the ribbed belt. Refer to ⇒ “3.1 Ribbed Belt”, page 32 .
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3.4 Sealing Flange, VVibration
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♦ Counter-Holder Toolss-a T10069- ac
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♦ Torque Wrench - VAG1601-
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Removing
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Note
To remove the sealing flange, the engine must be removed. Refer
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to ⇒ “3.1 Engine, Removing”, page 5 .
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⇒ “3.1 Ribbed Belt”, page 32 . nform
mer
– For assembly work, the engine should be secured on the En‐

atio
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gine and Transmission Holder - VAS6095- . Refer to

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c
⇒ “3.2 Engine, Securing to the Engine and Transmission Hold‐

or
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er VAS6095 ”, page 9 .
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– Remove the vibration damper. To do so, secure the vibration

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damper using the Counter-Holder Tool - T10069- .

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– Remove the oil pan. Refer to ⇒ “4.1 Oil Pan”, page 97 .
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– Remove the sealing flange bolts and flange.
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– Remove any sealant residue from the sealing surfaces.
Installing
– Before installing, remove any remaining oil from the end of the
crankshaft with a clean cloth.

Golf 2004 ➤
– Cut the sealant tube nozzle at the front mark (nozzle diameter:
approximately 3 mm).
– Apply a bead of sealant approximately 2 to 3 mm wide as
shown -arrows- onto the clean sealing surface of the sealing
flange.
Note
♦ Cover the seal with a clean cloth before applying the sealant
bead.
♦ The sealant bead must not be thicker than 2 to 3 mm, other‐
wise the excess sealant could get into the oil pan and clog the
oil pump strainer.
♦ Note the expiration date of the sealant.
♦ The sealing flange must be installed within 5 minutes after ap‐
plication of the sealant.
– Insert the Guide Sleeve - T10215/1- -1- at the front onto the
crankshaft -3-.
– Now, slide the sealing flange with the seal -2- carefully over
the guide sleeve.
– Secure the sealing flange to the cylinder block.

– Install the oil pan. Refer to ⇒ “4.1 Oil Pan”, page 97 .
Note

♦ Tighten the bolt using the Torque Wrench - VAG1601-
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– Install the vibration damper and secure
auth it using the Counter- eo
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Holder Tool - T10069- . ss c
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– Tighten the new bolt to 100 Nm + an additional 180° (1/2) turn.

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– Install the engine.

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3.5 Crankshaft Sensor Wheel, Installing

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♦ Liquid Locking Fluid - D 000 600 A2-

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Procedure
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Make sure crankshaft/sensor wheel contact surfaces are free of

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oil and grease.

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Rep. Gr.13 - Crankshaft, Cylinder Block Prote AG.
Golf 2004 ➤
Note
The sensor wheel may only be installed once, since the waattach‐
gen AG
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ment points -arrows- for the countersunk screws -1- y Vin the sensor
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wheel -2- are so severely deformed after installing,ris
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that the sec‐ ara
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ond time that the screw heads make contact uth on the crankshaft
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-3- the sensor wheel will lie loosely underss athe screw heads. c
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– For additional securing, apply a thin coat of Liquid Locking
an
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Fluid - D 000 600 A2- on the surface of the crankshaft/sensor
erm
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wheel.
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– Check that when installing "VR6" -arrow- is aligned with the
h re
individual threaded hole.
hole
spec
es, in part or in w
– Tighten all new bolts lightly by hand.
t to the co
– First, tighten the bolt -1- to 10 Nm + an additional 90° (1/4)
turn.
rrectness of i
– Then, tighten the bolts -2- to 10 Nm + an additional 90° (1/4).
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Prote AG.

Golf 2004 ➤
4 Special Tools
Special tools and workshop

equipment required
♦ Pulling Hook - T20143-
♦ Counter-Holder Tool -
T10069-
♦ Torque Wrench -
VAG1601-
Nm) - VAG1332-
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Golf 2004 ➤
AG. Volkswagen AG d
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4. Special Tools 39
Golf 2004 ➤
15 – Cylinder Head, Valvetrain

1 Description and Operation lksw
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⇒ “1.1 Cylinder Head Overview”, page 40 rised b ara
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⇒ “1.2 Cover Overview”, page 44 aut ra
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⇒ “1.3 Valvetrain Overview”, page 46
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⇒ “1.4 Valve Seat, Refacing”, page 48
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1.1 Cylinder Head Overview
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Note
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♦ If an exchange cylinder head is installed, all contact surfaces
between the hydraulic lash adjusters, roller rocker arms and
rrectne
cam running surfaces of the camshaft must be oiled before
installing the cylinder head cover.
ss
♦ The plastic protectors installed to protect the open valves must
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cial p
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only be removed immediately before installing the cylinder
inform
head.
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atio
♦ When replacing the cylinder head the entire amount of coolant
om
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must be replaced.
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♦ Intake manifold removing and installing. Refer to
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♦ Intake manifold overview. Refer to

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⇒ “2.5 Intake Manifold Overview”, page 152 .
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40 Rep. Gr.15 - Cylinder Head, Valvetrain

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Golf 2004 ➤
d
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nte Injection
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and Ignition - Edition 07.2015
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1 - Bolt s
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❑ 10 Nm du
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2 - Bracket
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❑ For the fuel lines.
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3 - Mounting Frame
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spec
4 - Bolt/Nut
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❑ 10 Nm
❑ The bolt has a spacer
sleeve and seal.
rrectness of i
❑ Replace the seal if dam‐
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5 - O-Ring
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❑ Replace if damaged.
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❑ Coat with oil before in‐

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stalling.
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❑ For the ignition coil with

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6 - Cap
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7 - Cylinder Head Cover
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ling. Refer to
⇒ “3.1 Cylinder Head
Cover”, page 55 .
8 - Lifting Eye
9 - Bolt
❑ 23 Nm
11 - Combination Valve
❑ Removing and installing. Refer to
⇒ “2.2 Secondary Air Injection System Components Overview”, page 170 .
❑ Checking. Refer to ⇒ “3.1 Combination Valve, Checking”, page 176 .
12 - Camshaft Adjustment Valve 1 - N205-
13 - Exhaust Camshaft Adjustment Valve 1 - N318-
14 - Bracket
❑ For the wiring harness.
15 - O-Ring
❑ For the oil passage seal.
❑ Always replace.

AG. Volkswagen AG d
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Golf 2004 ➤ oris nte
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16 - Camshaft Position Sensor 2 - G163-
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17 - Chain Tensioner
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spec
❑ 40 Nm
es, in part or in w
t to the co
18 - Seal
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19 - Bracket
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❑ For the wiring harness and ground connection.

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20 - Bolt
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com
tion in
❑ 8 Nm
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21 - Seal
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❑ For the camshaft adjustment valve 1 -item 12- and exhaust camshaft adjustment valve 1 -item 13-.
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❑ Installing. Refer to ⇒ Fig. ““Cover Seal, Installing”“ , page 45 . ht. rig
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22 - Coolant Thermostat Housing by c lksw
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❑ Removing and installing. Refer to ⇒ “4.1 Coolant Thermostat Housing”, page 111 .
❑ Overview. Refer to ⇒ “2.4 Coolant Thermostat Housing Overview”, page 108 .
23 - Seal
❑ Always replace.
24 - Camshaft Position Sensor - G40-
25 - Cover
❑ Can be removed and installed with the engine installed.
❑ Removing and installing. Refer to ⇒ “1.2 Cover Overview”, page 44 .
❑ If only the cover has been removed, prepare the cylinder head gasket for installation. Refer to
⇒ Fig. ““Cylinder Head Seal, Preparing for Assembly”“ , page 43 .
❑ With a O-ring for the oil passage seal -item 15-.
26 - Bolt
❑ Always replace.
❑ The contact surface of the sensor wheel must be dry around bolt head when assembling.
❑ Identification: 32A
28 - Guide Rail
❑ Clipped into the control housing.

Golf 2004 ➤
30 - Cylinder Head Gasket
❑ Made of metal.
❑ Always replace.
❑ After replacing, replace the entire amount of coolant.
31 - Cylinder Head
❑ Checking for distortion. Refer to ⇒ Fig. ““Checking the Cylinder Head for Distortion”“ , page 43 .
❑ Removing and installing. Refer to ⇒ “3.2 Cylinder Head”, page 56 .
32 - Belt Tensioner
❑ For the ribbed belt.
❑ Removing and installing the ribbed belt. Refer to ⇒ “3.1 Ribbed Belt”, page 32 .
33 - Bolt
❑ Always replace.
❑ Observe the installation instructions and sequence when loosening and tightening. Refer to
⇒ “3.2 Cylinder Head”, page 56 .
34 - Cylinder Head Cover Gasket
❑ Pay attention to the installed position. agen
AG. Volkswagen AG d
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Checking the Cylinder Head for Distortion
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♦ Straight Edge
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♦ Feeler Gauge
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♦ Maximum permissible distortion: 0.05 mm.

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Cylinder Head Seal, Preparing for Assembly

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♦ Sealant D176 501

Golf 2004 ➤
– Clean old sealing compound from the 3 mm holes in the cyl‐

inder head gasket -arrows-.
– Fill the 3 mm holes in the cylinder head gasket with sealant
D176 501 and coat the sealing surface on the cover and the
sealing flange with sealant D176 501. Install the cover imme‐
diately.
Note
With the cylinder head installed only half of the holes in the cyl‐
inder head gasket are visible.
1.2 Cover Overview
1 - Wiring Router
❑ For the coolant hoses
and wiring harness.
❑ Coolant hose connec‐
tion diagram. Refer to
⇒ “2.1 Coolant Hose
Connection Diagram”, agen
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2 - Bolt rise tee
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❑ 8 Nm ss au ac
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3 - Camshaft Position Sensor

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❑ For the exhaust cam‐

pe
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shaft.
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❑ Before disconnecting,
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mark the allocation of

spec
the connector to the

es, in part or in w
component.
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4 - Chain Tensioner
❑ 40 Nm
rrectness of i
❑ For the camshaft timing

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chain -item 10- in the

⇒ “1.1 Cylinder Head
Overview”, page 40 .
nform
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❑ Only rotate the engine

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with the chain tensioner

ion in
installed.
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5 - Seal
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❑ Replace if damaged or
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6 - Bracket
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❑ For the wiring harness
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and ground connection.
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7 - Bracket
❑ For the after-run coolant pump.
8 - After-Run Coolant Pump - V51-
❑ Checking. Refer to ⇒ “3.1 After-Run Coolant Pump, Checking”, page 109 .

Golf 2004 ➤
9 - Seal
❑ For the camshaft adjustment valve 1 - N205- and exhaust camshaft adjustment valve 1 - N318-
-items 12 and 13- in the ⇒ “1.1 Cylinder Head Overview”, page 40 .
❑ Installing. Refer to ⇒ Fig. ““Cover Seal, Installing”“ , page 45 .
10 - Bolt
❑ 23 Nm
11 - Bracket
❑ For the wiring harness.
12 - Coolant Thermostat Housing
13 - Seal
❑ Always replace.
14 - Cover
❑ Coat the sealing surfaces with Silicone adhesive sealant - D 176 501 A1- .
❑ Cylinder head gasket, preparing for installation. Refer to
⇒ Fig. ““Cylinder Head Seal, Preparing for Assembly”“ , page 43 .
16 - O-Ring
❑ For the oil passage seal.
❑ Always replace.
Cover Seal, Installing AG. Volkswagen AG d

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♦ Fitting Sleeve - 3378-

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♦ Thrust Pad - 3253/6-

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– Do not lubricate the seal.

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45
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agen
Golf 2004 ➤
– Install the seal into the cover -1- using the Fitting Sleeve -
3378- and pull it in flush using the Thrust Pad - 3253/6- .
1.3 Valvetrain Overview
1 - Nut
❑ 5 Nm + 45° (1/8) addi‐
tional turn.
2 - Exhaust Camshaft Bearing
Cap
❑ Installation order. Refer
to
⇒ “3.5 Camshafts”,
page 77 .
3 - Seal
❑ If one seal is leaking, re‐
place all 3 seals.
❑ Lightly oil the contact
surface of the seals
when installing the con‐
trol housing.
❑ Do not spread the seals
excessively when instal‐
ling.
4 - Exhaust Camshaft
❑ Check the radial clear‐
ance using Plasti‐
gage®:
Wear limit: 0.1 mm AG. Volkswagen AG d
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❑ Run out: d by V gu
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Maximum 0.01 mm utho eo
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❑ Checking axial play. Re‐
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fer to
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⇒ Fig. ““Checking the

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Camshaft Axial Play”“ ,

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page 82 .
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❑ Identification and tim‐

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ing. Refer to
spec
⇒ Fig. ““Camshaft Iden‐

tification, Valve Timing”“ , page 82 .

t to the co
❑ Removing and installing. Refer to ⇒ “3.5 Camshafts”, page 77 .

5 - Control Housing
rrectne
❑ Lightly lubricate the contact surfaces of the seals before installing.

s
❑ Disassembly and assembly. Refer to

s o
⇒ Fig. ““Disassembling and Assembling the Control Housing”“ , page 48 .

cial p
f inform
❑ Check the control housing strainer for contamination before installation. Refer to
mer
⇒ Fig. ““Checking the Control Housing Strainer for Contaminants”“ , page 48 .

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❑ Removing and installing. Refer to ⇒ “3.3 Timing Chains”, page 60 . C py
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7 - Exhaust Camshaft Adjuster cop Vo
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❑ Identification: 32A Prote AG.
❑ Rotate the engine only with the camshaft adjuster and timing chain installed.

Golf 2004 ➤
8 - Bolt
❑ Always replace.
❑ The contact surface of the sensor wheel must be dry around the bolt head when assembling.
❑ Rotate the engine only with the camshaft adjuster and timing chain installed.
10 - Cylinder Head Height
❑ Minimum height: -a- = 139.9 mm. AG. Volkswagen AG d
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11 - Valves by
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❑ Do not grind, only hand lapping is permitted.horis nte
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12 - Cylinder Head ss c
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❑ Checking for distortion. Refer to ⇒ Fig. ““Checking the Cylinder Head for Distortion”“ , page 43 .
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❑ Removing and installing. Refer to ⇒ “3.2 Cylinder Head”, page 56 .
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❑ Refacing the valve seats. Refer to ⇒ “1.4 Valve Seat, Refacing”, page 48 .
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13 - Hydraulic Lash Adjuster
spec
❑ Before installing, check the axial play in the camshafts. Refer to
t to the co
⇒ Fig. ““Checking the Camshaft Axial Play”“ , page 82 .
❑ Do not interchange.
rrectne
❑ With hydraulic valve clearance compensation.
14 - Valve Stem Seal
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❑ Removing and installing. Refer to ⇒ “3.6 Valve Stem Seals”, page 80 .
cial p
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15 - Clip
mer
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❑ Make sure it is secure.
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16 - Roller Rocker Arm
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❑ Before installing, check the axial play in the camshafts. Refer to

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⇒ Fig. ““Checking the Camshaft Axial Play”“ , page 82 .

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❑ Do not interchange.
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❑ Check the roller for easy movement.
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❑ Lubricate the contact surface.
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❑ Use the clip to secure the arm to the hydraulic lash adjuster when installing.
Prote AG.
17 - Valve Spring
❑ Removing and installing. Refer to ⇒ “3.6 Valve Stem Seals”, page 80 .
18 - Spring Plate
19 - Valve Retainers
20 - Intake Camshaft Bearing Cap
❑ Installation order. Refer to ⇒ “3.5 Camshafts”, page 77 .
21 - Intake Camshaft
❑ Check the radial clearance using Plastigage®:
Wear limit: 0.1 mm
❑ Run out:
Maximum 0.01 mm

Golf 2004 ➤
❑ Checking axial play. Refer to ⇒ Fig. ““Checking the Camshaft Axial Play”“ , page 82
Disassembling and Assembling the Control Housing

1 - Guide rail: clipped into the control housing
2 - Control housing
3 - Camshaft adjustment valve 1
4 - Exhaust camshaft adjustment valve 1
5 - Bolt, 8 Nm
Checking the Control Housing Strainer for Contaminants

– Unclip the strainer -2- from the rear side of the control housing
-1- and remove any possible contamination.
1.4 Valve Seat, Refacing

Special tools and workshop equipment required n AG. Volkswagen AG do
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♦ Depth Gauge d byV ua
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♦ Valve Seat Refacing Tool utho
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Procedure
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Note
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♦ When repairing engines with leaking valves, it is not sufficient

h re
to reface or replace the valve seats and valves. It is also nec‐

hole
spec
essary to check the valve guides for wear. This is particularly

es, in part or in w
important on high mileage engines. Refer to

t to the co
⇒ “2.3 Valve Guide, Checking”, page 53 .

♦ The valve seats should only be refaced just enough to produce
rrectness of i
a perfect seating pattern. The maximum permissible refacing

dimension must be calculated before the work is carried out.
l purpos
If the refacing dimension is exceeded, the function of the hy‐

draulic lash adjusters can no longer be guaranteed and there‐
nform
ercia
fore the cylinder head should be replaced.

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– Remove the camshafts. Refer to

on in

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Maximum Permitted Refacing Dimension Is Calculated as Fol‐

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lows:
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– Insert the valve and press it firmly against the seat.
Co
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Prote AG.

Golf 2004 ➤
Note
If the valve is to be replaced as part of a repair, use a new valve

for the calculation.
– Measure the distance -a- between the valve stem tip and up‐
per edge of the cylinder head.
– Calculate the Max. permissible refacing dimension from the
measured distance -a- and minimum dimension.
Minimum Dimensions:
Short intake valve mm 31.8
Long intake valve mm 10.2
Short exhaust valve mm 31.8
Long exhaust valve mm
agen
A 10.2
G. Volkswagen AG
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The measured distance -a- minus the eminimum
db
y
dimension = the ua
ran
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Max. permissible refacing dimension.
thor tee
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Example: ss
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nl
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Measured distance 10.6 mm
an
itte
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— Minimum dimension 10.2 mm
erm
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= Maximum permissible refacing dimen‐ 0.4 mm
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sion
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Intake Valve Seat, Refacing
t to the co
a - = 32.8 mm diameter
b - = Max. permissible refacing dimension. Refer to ⇒ page 48 .
rrectness of i
c - = 0.9 to 1.5 mm
l purpos
d - = Maximum diameter: 38.0 mm

nform
ercia
r2 - = Radius 2.0 mm
m
at
Z - = Cylinder head lower edge

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α - 45° valve seat angle

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β - 30° upper correction angle

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γ - 60° lower correction angle

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Exhaust Valve Seat, Refacing
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a - = 29.8 mm diameter cted agen
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b - = Max. permissible refacing dimension. Refer to ⇒ page 48 .

c - = 1.2 to 1.7 mm
d - = Maximum diameter: 35.0 mm
r2 - = Radius 2.0 mm
Z - = Cylinder head lower edge
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle

Golf 2004 ➤
Valve Dimensions
AG. Volkswagen AG d
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Valves must notssbe ground. Only hand lapping is permitted.
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Intake Valves
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Dimension Short Long
ility
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Intake Valve Intake Valve
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Diameter a mm 33.20 33.20
hole
spec
Diameter b mm 5.98 5.98
es, in part or in w
t to the co
c mm 102.46 136.36
α ∠° 44°40´ 44°40´
rrectness of i
Exhaust Valves
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Dimension Short Long

Exhaust Valve Exhaust Valve
nform
ercia
Diameter a mm 30.20 30.20

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Diameter b mm 5.97 5.97
ion
c
in t
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c mm 102.20 136.20
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ate
α ∠° 44°40´ 44°40´ do
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Golf 2004 ➤
2 Diagnosis and Testing

⇒ “2.1 Valve Timing, Checking”, page 51
⇒ “2.2 Compression, Checking”, page 52
⇒ “2.3 Valve Guide, Checking”, page 53
2.1 Valve Timing, Checking

♦ Camshaft Bar - T10068A-
Test Sequence
– Remove the intake manifold and the cylinder head cover. Re‐
fer to ⇒ “5.1 Intake Manifold”, page 162 .
– Rotate the crankshaft using the vibration damper bolt, in en‐
gine rotation direction to the Top Dead Cylinder (TDC) cylinder
1 mark -arrow-.
– It must be possible to install the Camshaft Bar - T10068A- into

both camshaft grooves.
G. Volkswagen
If the Camshaft Barlk-sw
T10068A-
agen
A
cannot be installed:
AG do
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– Rotate the secrankshaft
db again in engine rotation direction
ara
nt one
ri
more time.
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or
a ac
ss
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un
pt
Note
an
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itte
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ab
If the camshaft bar cannot be installed, rotate the crankshaft in

ility
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engine rotation direction until approximately 5 mm past the TDC

wit
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mark for cylinder 1 (dependent on drive chain tolerances).

h re
ole,
spec
Verify the installed marks on the camshaft adjuster with the marks
t to the co
on the control housing:
– The marks -A and B- on the camshaft adjusters must align with

rrectne
the notches -arrows- on the control housing -C-.

– The distance between the tooth -1- and the tooth -2- of the
ss o
camshaft adjusters must be exactly 16 rollers of the camshaft

cial p
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timing chain.
form
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Note
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The illustration shows a engine with the cover removed.

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t.
If the marks do not match: Replace or reinstall the timing chain.
yi Co
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Refer to ⇒ “3.3 Timing Chains”, page 60 . t. C rig
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– If the marks match: Install the cylinder head cover and intake
co Vo
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manifold. Refer to ⇒ “5.1 Intake Manifold”, page 162 .
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Prote AG.
2. Diagnosis and Testing 51

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Golf 2004 ➤ olks
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2.2 Compression, Checking
a ac
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♦ Puller for Ignition Coil - T10095A-
pe
ility
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♦ Compression Tester - VAG1763-
spec
es, in part or in w
♦ Spark Plug Removal Tool - 3122B-
t to the co
rrectness of i
Test Conditions
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• The engine oil temperature must be at least 30 ℃ (86 °F)

• Battery voltage must be at least 11.5 volts
nform
ercia
Test Sequence
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ion in
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– Place the assembly tool - T10118- on the release button
thi
s
iva
-arrow-, release the connector retainers, and carefully pull up
do
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c
the connectors from the ignition coils.
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t.
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Cop py
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Prote AG.
– Slide the puller for ignition coil - T10095A- onto the straight
side of the connector in the direction of -arrow- and pull out the
ignition coil with power output stage.

AG. Volkswagen AG d
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Golf 2004 ➤
s
s Engine Mechanical, Fuel Injection and Ignition - Edition 07.2015
ce
le
un
pt
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– Remove the No. 29 fuse from the fuse holder.itte
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ab
Removing the No. 29 fuse interrupts the voltage supply to the
ility
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injectors.
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is n
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ole,
– Remove the spark plugs using the Spark Plug Removal Tool
spec
- 3122B- .
t to the co
– Check the compression pressure using the Compression
Tester - VAG1763- .
rrectne
Note
ss o
cial p
f
Using the tester. Refer to the operating instructions.
inform
mer
atio
– Operate the starter until the tester shows no further pressure
om
increase.
n
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or
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Compression Pressure:
t
sd
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New: 10 to 13 bar (145.03 to 188.54 psi)
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ng
t.
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Wear limit: 7.5 bar (108.77 psi)
Co
Cop py
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gh
Permissible difference between all cylinders: 3 bar (43.51 psi)
ht
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– Thereafter, reinstall the spark plugs and the ignition coils with
agen
Prote AG.
power output stages. Refer to
⇒ “4.1 Ignition Coils with Power Output Stages”, page 182 .
After the test is completed:
– Connect the Vehicle Diagnosis and Service System. -
VAS5052- .
– Perform a vehicle system test using “Guided Fault Finding”.
– End the vehicle system test, this will automatically erase any
Diagnostic Trouble Code (DTC) entries which occurred during
the assembly.
– Generate a readiness code in conjunction with a road test.
Observe the safety precautions that apply to road tests.
– Perform a test drive.
– Then, perform a vehicle system test again and repair any oc‐
curring malfunctions if necessary.
2.3 Valve Guide, Checking

♦ Dial Gauge Holder - VW387-
♦ Dial Gauge

Golf 2004 ➤
Test Sequence
– Insert a new valve into the guide. The valve stem tip must be
flush with the guide. Due to the slight difference in stem diam‐
eters, ensure that only an wintake
agen valve is used
AG. Volkswagen AGin
dothe
e
intake
guide and an exhausty Vvalve
olks in the exhaust guide. s not g
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ed
– Determine the tilt
ho clearance. Wear limit: 0.8 mm
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t or
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If the tilt clearance
ss is exceeded:
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un
pt
– Replace the cylinder head.
an
d
itte
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pe
ility
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wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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tion in
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thi
s
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Prote AG.

Golf 2004 ➤

⇒ “3.1 Cylinder Head Cover”, page 55
AG. Volkswagen AG d
agen oes
⇒ “3.2 Cylinder Head”, page 56 Volksw not
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d by ara
e
⇒ “3.3 Timing Chains”, page 60 horis nte
eo
aut ra
⇒ “3.4 Camshaft Adjuster”, page 70ss c
ce
e
nl
⇒ “3.5 Camshafts”, page 77
pt
du
an
itte
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⇒ “3.6 Valve Stem Seals”, page 80
erm
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ility
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3.1 Cylinder Head Cover
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
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Note
nform
ercia

m
at
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ion
c
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or
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ate
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or
battery.
f
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t.
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– All cable ties which are opened or cut off when removing, must t. Cop py
be replaced in the same position when installing.
rig
gh ht
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by c
lksw
cted agen
Prote AG.
– Remove the ignition coils with power output stages for cylin‐
ders 1 through 6 using the Puller for Ignition Coil - T10095A- .
Refer to

Golf 2004 ➤
– Loosen the cylinder head cover bolts/nuts in sequence

-11 through 1-.
Installing
lowing:
Note
♦ Replace the cylinder head cover and/or seal if damaged or

leaking.
♦ First bolt the intake manifold to the cylinder head. Then, fasten
the bolts for the shield and intake manifold support. AG. Volkswagen AG d
agen oes
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♦ Make sure the fuel hoses are secure. by
Vol not
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Tightening Specifications aut ra
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ss
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Bolted Connections Specification

un
pt
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d
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Cylinder head cover to cylinder head 10 Nm
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rm
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pe
Intake manifold to cylinder head 15 Nm
ility
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Intake manifold to support 20 Nm
h re
hole
Shield to exhaust manifold 25 Nm
spec
es, in part or in w
Oil dipstick guide tube to intake manifold 5 Nm
t to the co
3.2 Cylinder Head
rrectness of i
l purpos
nform
ercia
♦ Drip Tray - VAG1306-

m
a
com
tion in
r

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thi
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♦ Spring Type Clip Pliers - VAS5024A- do

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cum
fo
♦ Lifting Tackle - 3033-

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ng
t.
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op py
♦ Puller for Ignition Coil - T10095A- t. C rig
gh ht
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by c lksw
cted agen
Prote AG.
♦ Silicone Adhesive Sealant - D 176 501 A1-
Requirements
The engine must be no more than warm to the touch.
Removing
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to clearance issues:
♦ Route lines of all types (for example, fuel, hydraulic, Evap‐
orative Emission (EVAP), coolant, refrigerant, brake fluid
and vacuum) and electrical wiring so that the original path
is followed.
♦ To prevent damage to the lines, make sure there is suffi‐
cient clearance to all moving or hot components.

Golf 2004 ➤
– First, check whether a coded radio is installed. If so, obtain the

anti-theft code.
– Disconnect the battery ground cable with the ignition turned
off.
– Remove the camshaft adjuster. Refer to
⇒ “3.4 Camshaft Adjuster”, page 70 .
AG. Volkswagen
n AG do
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– Unbolt the front Voexhaust pipe from the exhaust
not manifold. Refer
gu
by
to rised ara
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⇒ “2.3utExhaust Manifold, Front Exhaust Pipe, Catalytic
ho e o Con‐
ra
verter
ss a and Attachments Overview”, page 172 . c
ce
le
– Free up and remove all necessary wires from the cylinder

un
pt
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head.
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– Remove the bolt and pin -arrows- for the guide rail -1- and
pe
ility
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remove the guide rail.
wit
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– Place the timing chain aside.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
– Loosen and unscrew the cylinder head bolts in the sequence

ion in
specified -1 through 20- starting from the outside working to‐

r
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ward the inside.

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Prote AG.

Golf 2004 ➤
– Install the Lifting Tackle - 3033- as follows and carefully lift the
cylinder head using the Shop Crane - Load Cap = 700-1200 wage
es n
kg - VAS6100- . Vibration damper side: -Position 3- and fly‐ y Volks ot g
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wheel side: -Position 11- rised b ran
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♦ The lifting tackle side marked 1 through 12 faces toward the
rm
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flywheel side.
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♦ The threaded spindles are set in length according to necessity.
h re
hole
spec
– Carefully lift the cylinder head off.
es, in part or in w
t to the co
– Insert clean cloths into the cylinder bores so that no dirt or
abrasive powder can get between the cylinder wall and piston.
rrectness of i
– Also, prevent dirt and emery cloth particles from getting into
the coolant.
l purpos
– Carefully clean the cylinder head and cylinder block sealing

surfaces. This ensures that no scoring or scratches are formed
nform
ercia
(when using abrasive paper the grade must not be less than
m
100).
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– Carefully remove any metal particles, emery remains and the
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cloths.
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If the piston for cylinder 1 is not at TDC:
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– Rotate the crankshaft using the vibration damper bolt in engine cop Vo
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rotation direction to the cylinder 1 TDC mark -arrow-, have a cted agen
Prote AG.
second mechanic guide the timing chain by hand when doing
this.
Note
♦ Only remove the new cylinder head gasket from its packaging
immediately before installing.
♦ Handle the new gasket with extreme care. Damaging will lead
to leaks.
– Install the new cylinder head gasket. Inscription (part number)

must be legible.
– Ensure that the alignment sleeves are inserted into the cylin‐
der block holes 12 and 20 and that the cylinder head gasket
is seated.
– Position the camshafts in the cylinder head to TDC for cylinder
1.

AG. Volkswagen AG d
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Engine
d by Mechanical, Fuel Injection and gIgnition
V ua
ran - Edition 07.2015
e
oris tee
h
– ut
It must be possible to install thes aCamshaft Bar - T10068A- into
or
ac
both camshaft grooves. s
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nl
pt
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ility
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es, in part or in w
t to the co
rrectness of i
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– Apply a 2 mm bead of Silicone Adhesive Sealant - D 176 501

A1- -arrows- on the cylinder block/sealing flange.
nf
ercia
– Immediately place the new cylinder head gasket on. The text
orm
(part number) must be visible.
m
atio
om
n in
– Fill both 3 mm holes in the cylinder head gasket with some
or c
Silicone Adhesive Sealant - D 176 501 A1- .
thi
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o
– Install the cylinder head, insert the new cylinder head bolts and
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tighten them hand tight.
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Prote AG.
The longer cylinder head bolts must be inserted in the middle
holes of the cylinder head.

Golf 2004 ➤
– Tighten the cylinder head bolts in the sequence specified

-1 through 20-, starting from the inside and working toward the
outside, as follows:
– Tighten all the bolts to 30 Nm.
– Then, tighten all the bolts to 50 Nm.
– Then, tighten all the bolts an additional (90° (1/4) turn using a
ratchet.
– Afterwards, tighten all the bolts again an additional (90° (1/4)
turn.
Further installation is in the reverse order of removal.
Note
Make sure that the O-ring for sealing the oil passage and the seal
in the cover are installed.
– Install the camshaft adjuster and the cover. Refer to

– Install the cylinder head cover and intake manifold. Refer to
⇒ “5.1 Intake Manifold”, page 162 . agen
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Fill with new coolant. Refer to d by ara
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⇒ “1.1 Draining and Filling”, page 100 . thor eo
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Note
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ab
There is no requirement to retighten the cylinder head bolts after
ility
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repairs.
wit
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3.3 Timing Chains
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
at
om
ion
c
in t
r
Removing the Camshaft Timing Chain:

o
his
ate
do
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– Remove the transmission. Refer to ⇒ Manual Transmission;

p
cum
or
Rep. Gr. 34 ; Removal and Installation .

f
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– Remove the dual-mass flywheel. t. Cop py
rig
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– Remove the oil pan. Refer to ⇒ “4.1 Oil Pan”, page 97 . pyri by
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Prote AG.
– Remove the cylinder head cover. Refer to
⇒ “3.1 Cylinder Head Cover”, page 55 .
– Remove the coolant thermostat housing. Refer to
⇒ “4.1 Coolant Thermostat Housing”, page 111 .

Golf 2004 ➤
– Disconnect the connecting hose -3- and the vacuum hose

-2- from the Secondary Air Injection (AIR) combination valve.
– Reposition the clamp -1- and remove the coolant hose.
AG. Volkswagen AG d
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– Mark and disconnect d b the electrical connectors.
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1- Camshaft aPosition
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2- Camshaft Position Sensor 2 - G163-
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3- Camshaft Adjustment Valve 1 - N205-

itte
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4- Exhaust Camshaft Adjustment Valve 1 - N318-
pe
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– Remove the wiring guide from the camshaft timing chain cov‐
h re
er.
hole
spec
es, in part or in w
t to the co
rrectness of i
gine rotation direction to the Top Dead Center (TDC) cylinder
l purpos
1 mark -arrow-. nform

mercia
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Cop py
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– The camshaft lobes -A- for cylinder 1 must face each other. cop Vo
by lksw
cted agen
Prote AG.

Golf 2004 ➤
– Install the camshaft bar - T10068A- into both camshaft

grooves. If necessary, slightly rotate the camshaft back and
forth using an open end wrench.
– Remove the chain tensioner -arrow-.
AG. Volkswagen AG d
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ab
pe
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– Remove the bolts -1 through 3- and remove the cover hori‐
h re
zontally from the cylinder head. Take care not to damage the
hole
spec
cylinder head gasket in the process.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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– Remove the bolts and remove the sealing flange -arrow- hor‐ thi
s
iva
izontally from the cylinder block. Take care not to damage the
do
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cylinder head gasket in the process.

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– Remove the seal from the sealing flange.
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– Remove the Camshaft Bar - T10068A- .
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pyri by
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cted agen
Prote AG.

Golf 2004 ➤
– Loosen and remove the sprocket bolt -arrow-.
– Secure the vibration damper using the Counter-Hold Tool -

T10069- when doing so.
– Remove the small sprocket and the camshaft timing chain.
– Carefully remove the camshaft timing chain from behind the
cylinder head gasket rib.
AG. Volkswagen AG d
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Removing the Oil Pump Timing Chain from the Intermediate

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– Remove the chain tensioner with tensioning rail bolts
wit
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-arrows-.
h re
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spec
– Remove the large sprocket and the oil pump timing chain.
t to the co
Note
rrectne
If the camshaft adjuster and the guide rail must also be replaced,
perform the replacements before the timing chain is reinstalled.
ss o
cial p
Installing the Oil Pump Timing Chain and the Chain Tensioner f inform
mer
with Tensioning Rail:

atio
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n
c
– First, rotate the crankshaft to TDC for cylinder 1. When doing

i
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this, the ground tooth on the crankshaft drive gear -arrow-

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must align with the main bearing cap joint.

i
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– Turn the intermediate shaft so that the flattened side faces up.
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– Install the timing chain into the guide rail and mount it onto the t. C rig
gh ht
crankshaft. yri
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Prote AG.

Golf 2004 ➤
– Install the large sprocket into the timing chain so that the tab
on the sprocket aligns with the tab on the cylinder block -B-.
– Mount the large sprocket and the chain onto the intermediate
shaft.
During installation make sure that the chain runs completely
straight in the guide rail from the crankshaft to the intermediate
shaft.
• The ground tooth on the crankshaft drive gear must align with
the main bearing cap joint -arrow A-.
• The tab on the large sprocket must align with the tab
-arrow B- behind it.
– If the large sprocket cannot be installed, rotate the intermedi‐
ate shaft slightly.
– Mount the small sprocket on thegintermediate

AG. Volkswagshaft.
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tion is possible in one position
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– Install and tighten the risbolt -arrow- hand tight because the small ntee
e a
tho
sprocket must beauremoved one more time. or
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spec
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t to the co
– Install the chain tensioner with tensioning rail. To do this, re‐

lease the locking splines on the chain tensioner with a small
rrectness of i
screwdriver and press the tensioning rail against the tension‐

er.
l purpos
Note
nform
mercia
at
If equipped with a transportation safeguard, remove this immedi‐

om
io
ately after installation.

n
c
in t
or
his
ate
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for
en
ng
t.
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op
– Install the chain tensioner with tensioning rail in this position C py
t. rig
and tighten the bolts -arrow- to 8 Nm.
gh ht
pyri by
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co lksw
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cted agen
Prote AG.

Golf 2004 ➤
Installing the Camshaft Timing Chain:

Conditions
• The camshaft adjusters are installed
• The camshaft lobesg-A-
en Afor
G. Vcylinder
olkswagen1
AGmust
d
face each other.
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pt
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erm
ab
ility
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– Install the Camshaft Bar - T10068A- into both camshaft
wit
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grooves.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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or c
– Remove the sprocket bolt -arrow- and small sprocket. The

thi
e
large sprocket may not be removed.

t
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– Guide the camshaft timing chain from above, between the

o
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f
en
ng
tensioning rail and the guide rail in the direction of the inter‐
t.
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op
mediate shaft. C py
t. rig
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pyri by
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cted
Note
agen
Prote AG.
♦ The 3 adjacent copper colored chain links are placed on the

small sprocket.
♦ It is possible that an additional copper colored chain link is
equipped on a new camshaft timing chain. Ignore this chain
link.

Golf 2004 ➤
– Rotate the camshaft adjuster all the way to the left until it stops.
Lay the camshaft timing chain onto the guide rail and onto the
camshaft adjuster. Align the 2 separate copper colored chain
links -C- to the marks on the camshaft adjusters.
– Install the small sprocket into the camshaft timing chain. The
mark -B- must align with the center copper color chain link
-A-.
– Install the small sprocket together with the camshaft timing

chain onto the intermediate shaft. Installation is possible in one
position only. Tighten the new sprocket bolt -arrow- by hand.
lkswage es n
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pt
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ab
ility
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– Secure the vibration damper using the Counter-Holder Tool -

wit
T10069- .
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
– Tighten the sprocket bolt -arrow- to 60 Nm + an additional 90°

n in
or c
(1/4) turn. The additional turn can occur in several stages.

thi
te
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Cop py
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pyri by
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Prote AG.

Golf 2004 ➤
Note
When turning the crankshaft, the tensioning rail must be pressed

strongly by hand (instead of the chain tensioner) against the cam‐
. Volkswagen AG
shaft timing chain -arrow- to
swprevent
agen AG the chain from
doesjumping off.
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ility
Check the Position of the Crankshaft Relative to the Intermediate
ot
wit
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Shaft.
h re
hole
spec
• The ground tooth on the crankshaft drive gear must align with
es, in part or in w
the main bearing cap joint -arrow A-.
t to the co
• The tab on the large sprocket -arrow B- must align with the tab
behind it.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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cum
fo
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
Check the Position of the Copper Colored Chain Links with Re‐
Prote
cted AG.
agen
spect to the Adjustment Marks:
• Align the copper colored chain links to the adjustment marks.

Golf 2004 ➤
Check the adjustment marks on the camshaft adjuster with the

marks on the control housing:
– Forcefully press the camshaft tensioning rail by hand (instead

of with the chain tensioner) against the camshaft timing chain
and rotate the crankshaft 4 turns in engine rotation direction.
Note
After rotating the crankshaft, the copper colored chain links are
no longer aligned with the adjustment marks.
The Assembly May Continue If All of the Adjustment Marks Fit.
– Clean the old sealant from the 3 mm holes in the cylinder head
gasket -arrows-.
Note
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gen AG
With the cylinder head installed only half of the holes in the cyl‐ Volkswa does
not
inder head gasket are visible. ed
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– Clean the sealing surfaces on the engine and both scovers;
s a c
they must be free of oil and grease.
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le
un
pt
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itte
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erm
ab
ility
ot p
– Check whether the sealing flange pins are inserted in the cyl‐
wit
is n
inder block. h re
ole,
spec
– Thinly coat the sealing surfaces -shown cross hatched- of the
sealing flange with the Silicone Adhesive Sealant - D 176 501

t to the co
A1- .
rrectne
Note
s
The lower sealing flange must be installed within 5 minutes of

s o
cial p
applying the sealant.

f inform
mer
atio
om
n
c
i
or
n thi
te
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pr
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

Golf 2004 ➤
– Install the sealing flange underneath -arrow- and tighten the

bolts diagonally and in stages.
– Fill the 3 mm holes in the cylinder head gasket -arrows- with

the Silicone Adhesive Sealant - D 176 501 A1- .
– Replace the seal in the sealing flange if there are any leaks.
Refer to ⇒ Fig. ““Cover Seal, Installing”“en, Apage
G. Volk45
swa. gen AG
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olks not
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ab
pe
ility
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– Check whether the alignment sleeves -2 and 3- are inserted

hole
spec
in the cover.
es, in part or in w
t to the co
– Insert the new seal -1- and new seal -4-.

– Coat the sealing surfaces on the cover with Silicone Adhesive
Sealant - D 176 501 A1- and install the cover immediately.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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fo
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.

Golf 2004 ➤
– Install the cover and lightly tighten all of the bolts. Then tighten
the bolts as follows:
♦ Tight the bolts -1 and 3- to 5 Nm. n AG. Volkswagen AG do
swage es n
♦ Tighten the bolts -3- to 23 Nm. byV
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♦ Tight the bolts -1 and 2- to 10 Nm. tho tee
or
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– Install the chain tensioner and tighten it to 40 Nm.
ss
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un
pt
– Install the thermostat housing. Refer to
an
d
itte
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erm
ab
ility
– Install the cylinder head cover and intake manifold. Refer to ot p
wit
is n
h re
ole,
spec
t to the co
Component Nm
Guide rail pin (without a collar) to cylinder block 10
rrectne
Chain tensioner with tensioning rail to cylinder 8
block
s
Sprocket to intermediate shaft 60 + 90°
s o
cial p
f
Camshaft adjuster to camshafts 60 + 90°
inform
mer
Sealing flange to cylinder block 10
atio
m
Cover M6 10
o
n
c
i
or
n
M8 23
thi
te
sd
va
Chain tensioner to cylinder block 40

i
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t.
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3.4 Camshaft Adjuster Cop py
t. rig
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cop Vo
by lksw
cted agen
Prote AG.
♦ Camshaft Bar - T10068-
♦ Sealant, Black - AMV 174 04 01-
♦ Sealing Paste - AMV 188 001 02-
Removing
– Remove the connecting hose -4- and vacuum hose -1- from
Secondary Air Injection (AIR) system combination valve.
– Unscrew bolt -2- and remove the ground wire.
– Reposition the clamps -3 and 5- and remove the coolant ho‐
ses.

Golf 2004 ➤
– Identify and disconnect the electrical connectors:

1- Camshaft Position Sensor - G40-
2- Camshaft Position Sensor 2 - G163-
3- Camshaft Adjustment Valve 1 - N205-
4- Exhaust Camshaft Adjustment Valve 1 - N318-
– Loosen the cylinder head cover bolts/nuts in sequence

-11 through 1-. AG. Volkswagen
agen AG do
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pt
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w

t to the co
gine rotation direction to the Top Dead Center (TDC) cylinder

1 mark -arrow-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
– At the same time, the Camshaft Bar - T10068- must able to be

en
ng
t.
yi Co
installed in both camshaft grooves. Rotate the crankshaft 1Cop py
additional turn, if necessary.
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2004 ➤
– Remove the camshaft timing chain tensioner -arrow-.
– Remove the bolts -1 through 3- and cover horizontally from the

cylinder head. When doing so, ensure the cylinder head gas‐
ket is not damaged.
– Remove the Camshaft Bar - T10068- .
Note
The Camshaft Bar - T10068- must not be installed when loosen‐

ing or tightening the camshaft adjuster bolts.
– Remove the intake camshaft adjuster bolt while counter-hold‐

ing the camshaft hex with a 32 mm open end wrench.
– Remove the intake camshaft adjuster.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
h
aut ra
ss c ce
e
nl
pt
du
– Remove the exhaust camshaft adjuster bolt while counter-

an
itte
y li
holding the camshaft hex with a 32 mm open end wrench.

erm
ab
ility
ot p
– Remove the exhaust camshaft adjuster.

wit
, is n
h re
– Lay the camshaft timing chain over the camshaft adjuster

hole
valves.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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f
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ng
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pyri by
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Prote
72
AG.
Rep. Gr.15 - Cylinder Head, Valvetrain
Golf 2004 ➤
Installing, (Adjusting the Valve Timing)

– Check the TDC mark -arrow- on the crankshaft again.
– Verify the camshaft TDC position:

• It must be possible to install the camshaft bar - T10068- into
– If necessary, rotate the camshafts at the hex surfaces

-arrows- to correct the position using a 32 mm open end
wrench.
Note
When turning the camshafts, the crankshaft mustswa

not
gen AG.be
Volat TDC does
kswagen AG
with any piston. Valves and/or pistons may
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– Install the camshaft adjuster on the intake side turn it all the
erm
ab
way to the left in the direction of -arrow- until it stops.

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Golf 2004 ➤
• The contact surface of the sensor wheel at the bolt head -A-
must be dry when installing.
• The mark “24E” -item 1- and the tooth -2- behind it must align
with the notch -3- in the control housing.
– Lay the camshaft timing chain in this position tightly against
intake camshaft adjuster sprocket.
– Count from the mark “24E” on the intake camshaft adjuster

exactly 16 rollers of the timing chain in the exhaust camshaft
adjuster direction.
– Insert the tooth at the exhaust camshaft adjuster mark “32A”
directly behind the 16th roller of the timing chain.
• 16 chain rollers must now lie between the teeth.
• The mark “32A” and the tooth behind it must also align here
with the notch in the control housing.
– Turn the sensor wheel -2- of the exhaust camshaft adjuster

-1- clockwise in direction of -arrow- until it stops.
– Install the exhaust camshaft adjuster, in this position to the
exhaust camshaft and tighten the bolt by hand.
• The contact surface of the sensor wheel at the bolt heads must
be dry when installing.
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– Press the tensioning rail against the camshaft timing chain.

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Golf 2004 ➤
Verify the installation marks of the camshaft adjuster with the

marks on the control housing:
If the Marks Align, the Assembly May Continue.
AG. Volkswagen AG d
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– Remove the camshaft bar - T10068- .
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– Tighten the intake camshaft adjuster bolt while counter-hold‐ itte
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ing the camshaft hex using a 32 mm open end wrench.
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– Tighten the exhaust camshaft adjuster bolt while counter-
nf
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holding the camshaft hex using a 32 mm open end wrench.
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Note
When turning the crankshaft, the tensioning rail must be pressed

strongly by hand (instead of the chain tensioner) against the cam‐
shaft timing chain -arrow- to prevent the chain from jumping off.

Golf 2004 ➤
– Set the crankshaft to the TDC mark -arrow- by turning the

crankshaft using the vibration damper bolt 2 turns in engine
rotation direction.
AG. Volkswagen AG d
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– At the same time, the Camshaft Bar - T10068- must engageby V o gu
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in both camshaft grooves. orised
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Verify the installation marks of the camshaft adjusters with the
rrectne
marks on the control housing again:
ss
o
cial p
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– If the marks are not aligned; repeat the valve timing adjustment
mer
again.
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– Clean any old sealant from the 3 mm holes -arrows- in the
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cylinder head gasket. Prote
cted AG.
agen
– Fill the 3 mm holes in the cylinder head gasket using Black

Sealant - AMV 174 04 01- .
Note
With the cylinder head installed only half of the holes in the cyl‐
inder head gasket are visible.
– Replace the seal in the cover. Refer to

⇒ Fig. ““Cover Seal, Installing”“ , page 45 .
– Clean the sealing surfaces.
• They must be free of oil and grease.

Golf 2004 ➤
– Check whether the alignment sleeves -2 and 3- are inserted

in the cover.
– Insert a new seal -1- and a new seal -4-.
– Lightly coat the clean cover sealing surfaces
-shown hatched- with sealing paste - AMV 188 001 02- .
Note
♦ Also coat the sealing surfaces below the cylinder head gasket
with some sealant do not kink the cylinder head gasket when
doing so.
♦ The cover must be installed within 5 minutes of applying the
sealing paste.
– Set the cover in place and tighten the bolts as follows:

1- Tighten the bolts -1 and 2- to 5 Nm.
2- Tighten the bolts -3- to 23 Nm.
3- Tight the bolts -1 and 2- to 10 Nm.
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– Install the camshaft timing chain tensioner -arrow-.
rm
ab
pe
ility
– Turn the crankshaft 2 times in engine rotation direction and
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check the valve timing again.
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hole
– Install the cylinder head cover. Refer to
spec
es, in part or in w
t to the co
– Install the intake manifold. Refer to
rrectness of i
– Install the coolant thermostat housing. Refer to
l purpos
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Component Nm
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Guide rail pin (without a collar) to cylinder block 10

ion in
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Camshaft adjuster to camshaft 1 60 + 90°

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3.5 Camshafts
With the Cylinder Head Installed

Golf 2004 ➤

♦ Molypaste, Lubricating Paste - G 052 723 A2-
– Removing the camshaft adjusters. Refer to
– Remove the control housing bolts -arrows-from the cylinder
head.
– Pull the control housing carefully off the camshaft seals.
A - Intake Camshaft
– First, remove bearing caps 1 and 13.
– Remove bearing caps 3 and 11.
– Remove bearing cap 7.
– Loosen and remove bearing caps 5 and 9 alternately and in a AG. Volkswagen AG d
diagonal sequence. agen oes
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B - Exhaust Camshaft
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– First, remove bearing caps 2 and 14.
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– Remove bearing caps 4 and 12.
hole
spec
– Remove bearing cap 8.
es, in part or in w
t to the co
– Loosen bearing caps 6 and 10, alternately and in diagonal se‐
quence.
rrectness of i
Continuation for Both Camshafts
l purpos
– Carefully remove he camshafts and place them on a clean

surface.
nform
ercia
– Remove the roller rocker arms together with the hydraulic lash
adjusters and place them on a clean surface.
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– Ensure the roller rocker arms and the hydraulic lash adjusters
r
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are not interchanged.

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Golf 2004 ➤
Coat the Contact Surfaces of Bearing Caps 7 and 8 Lightly with

Molypaste, Lubricating Paste - G 052 723 A2- before Installing.
Requirements
• When installing the camshafts, the cam lobes for cylinder 1
must point upward.
– Insert the hydraulic lash adjusters in the cylinder head and in‐
stall the roller rocker arms onto the respective valve stem tips
and lash adjusters.
– Make sure that all the roller rocker arms -1- properly contact
the valve stem tips and are clipped into the respective hy‐
draulic lash adjusters -2-.
– Oil the running surfaces of both camshafts.
– Place the respective camshaft carefully in the camshaft bear‐
ings in the cylinder head. While doing so, observe the cam‐
shaft identification. Refer to
⇒ Fig. ““Camshaft Identification, Valve Timing”“ , page 82 .
Note
♦ Observe the installed position of the bearing caps:

♦ The points of the bearing caps -arrow A- for the intake and
exhaust camshafts point outward.
olkswagen AG
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♦ The marks on the
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doewhen
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the intake side.
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A - Intake Camshaft
rrectness of i
– Install and tighten the nuts for bearing caps 5 and 9 alternately
and in a diagonal sequence to 5 Nm + an additional 45° (1/8)
l purpos
turn.
– Install and tighten the nuts for bearing caps 1 and 13 to 5 Nm
nf
ercia
+ an additional 45° (1/8) turn.

rm
m
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– Install and tighten the nuts for bearing cap 7 to 5 Nm + an

o
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c
additional 45° (1/8) turn.

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Prote AG.

Golf 2004 ➤
B - Exhaust Camshaft
– Install and tighten the nuts for bearing caps 6 and 10 alter‐
nately and in a diagonal sequence to 5 Nm + an additional 45°
(1/8) turn.
– Install and tighten the nuts for bearing cap 8 to 5 Nm + an
additional 45° (1/8) turn.
– Position the camshafts in the cylinder head to TDC for cylinder
1.
– It must be possible to insert the Camshaft Bar - T10068A- into

– Before installing, check the control housing strainer for con‐
tamination. Refer to
⇒ Fig. ““Checking the Control Housing Strainer for Contami‐
nants”“ , page 48 .
– Before installing the control housing, lightly coat the seal con‐
tact surfaces in the control housing.
– Lightly lubricate the camshaft seals and slowly push the con‐
trol housing over the camshafts.
– Install the control housing bolts -arrows- and tighten to 8 Nm.

– Install the camshaft adjusters. Refer to
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3.6 Valve Stem Seals

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With the cylinder head installed

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spec
♦ Valve Lever - VW541/1A-

t to the co
♦ Press Tool for VW541/1A and 2037 - VW541/6-

♦ Adjustable Rod - 2036-
rrectne
♦ Adapter Plates - 2036/1-

s
♦ Spark Plug Removal Tool - 3122B-

s o
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♦ Valve Seal Removal Tool - 3364-

form
mer
♦ Valve Stem Seal Driver - 3365-

atio
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♦ Adapter - T40012-
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Rep. Gr.15 - Cylinder Head, Valvetrain Prote
cted AG.
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Golf 2004 ➤
Removing
– Remove the camshafts. Refer to
– Remove the roller rocker arms togethergewith
AGthe
. Volkhydraulic
swagen AGlash
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adjusters and place them on a clean
Volkswsurface. not
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– Remove the spark plugs using
ris
e
the Spark Plug Removal Tool tee
ho
- 3122B- . au
t or
ac
ss
– Move the piston for the respective cylinder to the Bottom Dead
ce
le
un
pt
Center (BDC) position.
an
d
itte
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rm
– Install the Adjustable Rod - 2036- with the Adapter Plates -
ab
pe
ility
2036/1- and adjust the mountings.
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– Screw the Adapter - T40012- into the spark plug threads.
h re
hole
spec
– Connect a commercially available adapter to the compressed
es, in part or in w
air line and maintain a steady pressure of at least 6 bar positive
t to the co
pressure.
– Remove the valve springs using the Valve Lever - VW541/1A-
rrectness of i
and Press Tool for VW541/1A and 2037 - VW541/6- .
l purpos
Note
nform
ercia
Tight retainers can be loosened by tapping lightly on the valve

m
a
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t
lever.
ion in
r
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– Remove the valve stem seal using the Valve Seal Removal
s
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Tool - 3364- .
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– Place the plastic sleeve -A- on the valve stem to prevent dam‐ p by
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age to the new valve stem seal.
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cted agen
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– Oil the sealing lip of the valve stem seal -B-, insert it into the
Valve Stem Seal Driver - 3365- and carefully slide it onto the
valve guide.
– Install the camshafts. Refer to ⇒ “3.5 Camshafts”, page 77 .

Golf 2004 ➤
Checking the Camshaft Axial Play

♦ Dial Gauge
Test Sequence
Perform the measurement with the hydraulic lash adjusters and
roller rocker arms removed.
The center bearing cap of the respective camshaft is installed.
Wear limit: Maximum 0.40 mm
Camshaft Identification, Valve Timing
Camshaft Identification
Identification is located between camshaft lobes for cylinders 4
and 5 of the respective camshaft.
Camshaft Identification
A - Exhaust camshaft 022
101 Index n AG. Volkswagen AG do
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B - Intake camshaft 022d by Vo ot g
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Valve Timing, at 1 mm Valve Lift ss c
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Intake Valve Exhaust Valve

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Opens before Top --- 211.5°

ab
ility
Dead Center (TDC)

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Closes before TDC --- 6.5°

h re
hole
Opens after TDC 18.50° ---

spec
es, in part or in w
Closes after TDC 223.5° ---

t to the co
rrectness of i
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Golf 2004 ➤
4 Special Tools

equipment required
VAG1331- n AG. Volkswagen AG do
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♦ Torque Wrench (40-200 d byV
o ot g
ua
Nm) - VAG1332- o
ir se
ran
tee
th or
u
♦ Spring Type Clip Pliers - ss
a ac
VAS5024A-
ce
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nl
pt
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♦ Lifting Tackle - 3033- itte
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orm
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4. Special Tools 83
Golf 2004 ➤
♦ Valve Lever - VW541/1A-

♦ Adjustable Rod - 2036-
♦ Spark Plug Removal Tool - agen
AG. Volkswagen AG d
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3122B- Volksw not
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d by ara
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♦ Valve Seal Removal Toolhoris- nte
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3364- aut ra
c
ss
♦ Valve Stem Seal Driver -
ce
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nl
pt
du
3365-
an
itte
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ab
♦ Adapter - T40012-
ility
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es, in part or in w
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rrectness of i
l purpos
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ion
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Golf 2004 ➤
AG. Volkswagen AG d
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t to the co
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l purpos
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♦ Not Illustrated:
♦ Fitting Sleeve - 3378-
♦ Thrust Pad - 3253/6-
♦ Compression Tester - VAG1763-
♦ Press Tool for VW541/1A and 2037 - VW541/6-
♦ Adapter Plates - 2036/1-
4. Special Tools 85
Golf 2004 ➤
17 – Lubrication
1 General Information n AG. Volkswagen AG do
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⇒ “1.1 Engine Oil”, page 86 byV
olk ot g
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1.1 Engine Oil o tee
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Oil Capacities
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Refer to the Fluid Capacity Tables, Rep. Gr. 03.
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Engine Oil Specifications
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Refer to the Fluid Capacity Tables, Rep. Gr. 03.
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Note
t to the co
♦ The engine is filled at the factory with engine oil complying to
rrectness of i
VWstandard 503 00.
♦ Engine oil conforming to VWstandard 500 00, 501 01, or 502
l purpos
00 may continue to be used. These oils must be changed ev‐

ery 12 months or every 15,000 km. Service interval display
nform
ercia
must be programmed accordingly. For the procedure. Refer to

Maintenance Procedures Rep. Gr. 03 Maintenance Proce‐
m
at
om
dures.
ion
c
in t
or
♦ When changing, engine oil “ILSAC GF3 with viscosity rating
his
ate
SAE 5W-40” can be used.
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86 Rep. Gr.17 - Lubrication

Golf 2004 ➤

⇒ “2.1 Lubrication System Overview”, page 87
⇒ “2.2 Oil Filter Housing Overview”, page 90
⇒ “2.3 Oil Pump Overview”, page 91
2.1 Lubrication System Overview
Note
♦ When performing repair work, secure the engine to the Engine

and Transmission Holder - VAS6095- or the Holding Fixture -
VW540- with Spacers - VW540/1B- .
♦ The oil level must not go above the MAX mark - danger of
causing damage to the catalytic converter!
♦ If large quantities of metal particles or abraded material are
detected during engine repairs, it may mean the crankshaft or
rod bearings are damaged. To prevent further damage, per‐
form the following steps after the repair:
♦ Carefully clean the oil passages
♦ Replace the oil check valve
♦ Replace the oil injection jets
♦ Replace the oil cooler
♦ Replace the oil filter
AG. Volkswagen AG d
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es, in part or in w
t to the co
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Golf 2004 ➤
1 - Bolt
❑ 5 Nm
❑ Fastened to the intake
manifold.
2 - Oil Dipstick
❑ The oil level must not be
above the Max. mark!
❑ Marks. Refer to
⇒ Fig. ““Oil Dipstick
Marks”“ , page 90 .
3 - Guide Tube
❑ For the oil dipstick.
❑ Secured by a bolt -1- to
the intake manifold.
4 - Cylinder Block
❑ Sealing flange and dual-
mass flywheel over‐
view. Refer to
⇒ “1.2 Sealing Flange
and Dual-Mass Fly‐
wheel Overview”,
page 22 .
❑ Crankshaft overview.
Refer to
⇒ “1.3 Crankshaft Over‐ AG. Volkswagen AG d
view”, page 24 . agen oes
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❑ Piston and connecting d by ara
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rod overview. Refer to hor eo
ut
⇒ “1.4 Piston Overview”, ss a ra
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page 26 .
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pt
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5 - Oil Check Valve
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ab
ility
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ling. Refer to
⇒ “4.2 Oil Check Valve”, wit
, is n
h re
page 98 .
hole
spec

es, in part or in w
t to the co
❑ Clean if badly contaminated.

6 - Bolt
rrectness of i
❑ 10 Nm
l purpos
7 - Oil Pump Drive Cover

8 - O-Ring
nform
ercia
❑ Always replace.
m
at

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ion
c
in t
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9 - Oil Pump Drive

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ate
do
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10 - Intermediate Shaft
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11 - Guide Ring
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12 - Bolt
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❑ 8 Nm
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❑ Install using liquid locking fluid - D 000 600 A2- . Prote AG.
13 - Oil Spray Jet

❑ For crankshaft bearings 2 through 7.
❑ For piston cooling.
❑ Opening pressure - 2.0 bar.

Golf 2004 ➤
❑ Removing and installing. Refer to ⇒ Fig. ““Oil Spray Nozzle, Removing and Installing”“ , page 89 .
❑ See the note above.
14 - Input Shaft
❑ For oil pump drive
15 - Oil Pump
❑ Overview. Refer to ⇒ “2.3 Oil Pump Overview”, page 91 .
❑ Coat the oil pressure line at the cylinder block and oil pump housing with sealing paste - AMV 188 001
02- .
16 - Bolt
❑ 25 Nm
17 - Oil Drain Plug
❑ 30 Nm
❑ Always replace the seal.
18 - Oil Pan
❑ Removing and installing. Refer AtoG.⇒Vo“4.1
lkswaOil
genPan”, page 97 . n AG do
wage es n
19 - Oil Level Thermal Sensorolks
y V - G266-
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20 - Bolt thoris tee
or
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❑ 12 Nm ss
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Oil Spray Nozzle, Removing and Installing spec

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♦ 4 mm Diameter Drift
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♦ 6 mm Diameter Drift
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Note
Oil injector jets are installed in crankshaft bearings 2 through 7.
Removing
– Using a 4 mm diameter drift, press the oil spray jet -arrow-
toward the engine bearing and out.

Golf 2004 ➤
Installing
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– To install, use a 6 mm diameter drift
Vol to push the oil spray jet
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Oil Dipstick Marks utho or
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ss
1 - MAX. mark
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2 - MIN. mark
itte
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a - Area above the hatched field up to the Max. mark: Do not add
ility
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engine oil.
wit
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ole,
b - Oil level within the hatched field: Oil can be added.
spec
c - Area from the Min. mark up to the hatched field: fill with max‐
t to the co
imum of 0.5 liter of engine oil.
2.2 Oil Filter Housing Overview
rrectness
1 - Oil Pressure Switch - F1-
o
cial p
f in
❑ 20 Nm
form
mer
❑ 1.4 bar (20.30 psi)
atio
om
❑ Black
n
c
i
or
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❑ If the sealing ring is leak‐

t
sd
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ing cut it off and replace

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it.
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⇒ “3.1 Oil Pressure and t. C rig
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Switch, Checking”, yri
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page 94 .
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❑ With a check valve.
❑ Opening pressure - 0.05
bar (0.72 psi).
3 - O-Ring
❑ Always replace.
❑ Coat with oil before in‐
stalling.
4 - Oil Cooler
❑ Make sure there is
enough space to the
surrounding compo‐
nents.
❑ Coat all contact surfa‐
ces outside of the seal
with sealing paste -
AMV 188 001 02- .
❑ See the note in
⇒ “2.1 Lubrication Sys‐
tem Overview”,
page 87 .
⇒ “2.1 Coolant Hose Connection Diagram”, page 103 .
5 - Seal
❑ Always replace.

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Golf 2004 ➤
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and Ignition - Edition 07.2015
s a c
s
6 - Oil Cooler Cover
ce
le
un
pt
an
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❑ 25 Nm
itte
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7 - O-Ring
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❑ Insert onto the oil cooler before installing. Refer to
is n
h re
⇒ Fig. ““Installation of the Oil Cooler O-ring”“ , page 91 .
ole,
spec
❑ Always replace.
t to the co
8 - Bolt
rrectne
❑ 25 Nm
9 - Oil Filter Element
ss
❑ Observe the change intervals.
o
cial p
f in
❑ See the note in ⇒ “2.1 Lubrication System Overview”, page 87 .
form
mer
atio
10 - Oil Filter Cap
om
n
c
❑ 25 Nm
i
or
n thi
e
❑ Drain before removing.

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pr
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❑ With a bypass valve opening pressure: 2.50 bar (36.25 psi).
um
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11 - Oil Drain Plug
Co
Cop py
.
❑ 10 Nm
ht rig
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py by
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Installation of the Oil Cooler O-ring

– Install the oil soaked O-ring in the oil cooler as illustrated. Ob‐
serve the installed location -arrow-.
2.3 Oil Pump Overview
Note
Note the following when installing the oil pump: First, tighten all
the bolts by hand. Then, tighten the suction pipe at the cylinder
block and then at the oil pump. Finally, tighten the oil pump bolts
last.

Golf 2004 ➤
1 - Input Shaft
❑ For the oil pump drive.
2 - Oil Pump Housing
3 - Bolt
❑ 25 Nm
4 - Gears
❑ Checking backlash. Re‐
fer to
⇒ Fig. ““Checking the Oil
Pump Backlash”“ , page AG. Volkswagen AG d
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❑ Checking axial play. Re‐ed b y ara
nte
fer to thoris
eo
⇒ Fig. ““Checking sthe
a Oil
u ra
c
Pump Axial Clear‐s
ce
e
nl
ance”“ , page 93 .
pt
du
an
itte
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5 - Oil Pump Cover with Pres‐
erm
ab
sure Relief Valve
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❑ Opening pressure - 5.3
, is n
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to 5.7 bar (76.87 to
hole
spec
82.67 psi).
es, in part or in w
❑ Clean the screen if it is
t to the co
dirty.
6 - Bolt
rrectness of i
❑ 8 Nm
l purpos
❑ Install using Liquid

Locking Fluid - D 000
600 A2- .
nform
ercia
7 - Suction Pipe
m
at
om
io
❑ Coat at the cylinder

n
c
in t
or
block and at the oil

his
te
pump housing with

a
do
riv
Sealing Paste - AMV

p
cum
or
188 001 02-

f
en
ng
t.
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❑ Fasten with new “micro-encapsulated” bolts. Cop py
t. rig
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8 - Bolt p by
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❑ 10 Nm
agen
Prote AG.
9 - Seal
Checking the Oil Pump Backlash

♦ Feeler Gauge

Golf 2004 ➤
Wear limit: 0.20 mm

Checking the Oil Pump Axial Clearance

♦ Straight Edge AG. Volkswagen AG d
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♦ Feeler Gauge byV
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Wear limit: 0.10 mm tho r eo
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.

Golf 2004 ➤

⇒ “3.1 Oil Pressure and Switch, Checking”, page 94
3.1 Oil Pressure and Switch, Checking

⇒ “3.1.1 Oil Pressure Switch, Checking”, page 95
⇒ “3.1.2 Oil Pressure, Checking”, page 96
♦ Adapter - VAG1342/14-
♦ Oil Pressure Gauge - VAG1342-
♦ Voltage Tester - VAG1527B-
♦ Connector Test Set - VAG1594C-
Function of the Dynamic Oil Pressure Warning Indicator
When not under pressure, the oil pressure switch is open and will
close when the operating pressure is attained.
The oil pressure warning is activated approximately 10 seconds
after turning on the ignition.
Switch on delay of oil pressure warning is approximately 3 sec‐
onds.
Switch off delay of oil pressure warning is approximately 5 sec‐
onds.
Note
Function test and servicing the optical and acoustic oil pressure
indicator. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐
ponent locations. agen
AG. Volkswagen AG d
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Checking the Warning Lamp orise nte
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ut ra
After turning on the ignition without starting the engine, the
ss oil
a c
pressure warning lamp in the instrument cluster insert must illu‐
ce
le
un
pt
minate for approximately 3 seconds and then turn off. The test
an
d
itte
will be discontinued when the engine is running.

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rm
ab
pe
Criteria for a Warning ility

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The optical oil pressure warning switches on (oil pressure warning h re

hole
lamp lights up continuously) and the buzzer sounds three times

spec
for the acoustical warning under one of the following conditions.

es, in part or in w
t to the co
• “Ignition on”, engine stationary, oil pressure switch closed

• Engine speed above 1500 RPM, oil pressure switch open
rrectness of i
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Prote AG.

Golf 2004 ➤
Note
♦ If the oil pressure switch is closed, the warning lamp will re‐
swa
gen AG
. Volkswagen AG
does
main on if the engine speed is above 5000 RPM The bwarning yV
olk not
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lamp will be turned off again if the engine speed is rbelow
ise
d 5000 ara
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RPM. ut
ho eo
ra
sa c
♦ If the oil pressure switch is open for 0.3 to 3.0s seconds when
ce
le
the engine speed is above 1500 RPM, it will be stored in the
un
pt
an
d
combi-processor in the instrument panel insert. If this condi‐
itte
y li
tion occurs three times when the engine is running, the oil
erm
ab
ility
pressure warning will be activated and will not be cancelled
ot p
even below 1500 RPM. The oil pressure warning will be can‐
wit
is n
h re
celled when the oil pressure switch is closed for longer than 5 ole,
seconds at an engine speed above 1500 RPM or when the
spec
ignition is turned off.
t to the co
3.1.1 Oil Pressure Switch, Checking
rrectne
Test Conditions
s
• The engine oil level is OK. Checking. Refer to
s o
⇒ Fig. ““Oil Dipstick Marks”“ , page 90 .
cial p
f inform
• The oil pressure indicator lamp - K3- must light up for approx‐
mer
imately 3 seconds when the ignition is turned on
atio
om
n
c
i
• The engine oil temperature is at least 80 °C (176 °F) (coolant
or
n thi
e
fan must have run once)

t
sd
iva
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pr
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Test Sequence
um
r
fo
en
ng
t.
yi
– Remove the noise insulation, along with the left and right
Co
op py
sides. Refer to “Body, Front” in ⇒ Body Exterior; Rep. Gr. 50 ;
t. C rig
gh ht
yri
Description and Operation . p by
co Vo
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cted agen
– Remove the Oil Pressure Switch - F1- and screw it into the Oil Prote AG.
Pressure Gauge - VAG1342- .
– Screw the Oil Pressure Gauge - VAG1342- with the Adapter -
VAG1342/14- into the oil filter housing in place of the oil
pressure switch.
Note
Note the installed position of the adapter: The conical connecting

neck of the adapter is screwed to the pressure hose of the tester.
– Connect the brown wire from the tester to ground (-).

– Connect the Voltage Tester - VAG1527B- using an adapter
cable from the Connector Test Set - VAG1594C- to B+ and
the oil pressure switch. The light Emitting Diode (LED) must
not light up.
If the LED lights up:
– Replace the oil pressure switch.
If the LED does not light up:
– Start the engine and run at idle speed. At 1.2 to 1.6 bar (17.4
to 23.2 psi) pressure the LED must light up; otherwise replace
the oil pressure switch.

AG. Volkswagen AG d
agen oes
olksw not
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Golf 2004 orise➤ nte
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Engine
s a Mechanical, Fuel Injection and Ignition - Edition
ut r a 07.2015
c
s
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nl
3.1.2 Oil Pressure, Checking
pt
du
an
itte
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ab
Test Conditions
ility
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♦ Engine oil temperature at least 80 °C (176 °F) (coolant fan
, is n
h re
must have run once)
hole
spec
Test Sequence
es, in part or in w
t to the co
– Check the oil pressure at different speeds:
1500 RPM: 1.7 bar (24.65 psi)
rrectness of i
2000 RPM: 3.0 to 5.5 bar (43.51 to 79.77 psi)
l purpos
Above 2000 RPM: maximum 7.0 bar (101.52 psi)
nform
ercia
If the specified values are not obtained:

m
– Correct the mechanical damage, for example, bearing dam‐
at
om
io
age.
n
c
in t
or
his
e
At higher engine speeds the oil pressure must not exceed 7.0 bar
at
do
riv
(101.52 psi)
p
cum
for
If the specification is exceeded:
en
ng
t.
yi Co
op py
– Check the oil passages. t. C rig
gh ht
pyri by
– If necessary, replace the oil pump. Refer to
co Vo
by lksw
cted
⇒ “2.3 Oil Pump Overview”, page 91 .
agen
Prote AG.

Golf 2004 ➤

⇒ “4.1 Oil Pan”, page 97
⇒ “4.2 Oil Check Valve”, page 98
4.1 Oil Pan

♦ Hand Drill with Plastic Brush Attachment
♦ Flat Scraper
♦ Protective Eyewear
♦ Silicone Sealant - D 176 404 A2-
Removing AG. Volkswagen AG d
agen oes
lksw not
– Remove the noise insulation, along withd the by left and right
Vo gu
ara
sides. Refer to “Body, Front” in ⇒ Body oris Exterior; Rep. Gr. 50 ;
e nte
Description and Operation . aut
h eo
ra
ss c
– Disconnect the 3 pin connector from the Oil Level Thermal
ce
e
nl
pt
Sensor - G266- .
du
an
itte
y li
– Remove the holder for the Secondary Air Injection Pump Mo‐
erm
ab
ility
tor - V101- from the oil pan.
ot p
wit
, is n
– Drain the engine oil.
h re
hole
spec
es, in part or in w
t to the co
Note
Observe disposal regulations!
rrectness of i
l purpos
– Remove the oil pan bolts.

– Loosen the oil pan with light blows from a rubber mallet if nec‐
nf
ercia
essary.
orm
m
– Remove the sealant residue from the cylinder block with a flat
atio
m
scraper.
o
n in
or c
thi
e
– Remove the sealant residue from the oil pan with a rotating
t
sd
iva
brush, for example, a hand drill with a plastic brush attachment

o
r
rp
cu
(wear eye protection).

o
m
f
en
ng
t.
yi Co
– Clean the sealing surfaces, they must be free of oil and grease. . Cop py
rig
ht ht
rig
Installing py by
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Prote AG.
Note
♦ Note the expiration date of the sealant.

♦ The oil pan must be installed within 5 minutes of applying the
silicone sealant.

lk swage es n
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byV ua
d ran
Golf 2004 ➤ ho
ir se tee
t or
Engine Mechanical, Fuel Injection
au and Ignition - Edition 07.2015 ac
ss
ce
e
nl
– Cut the sealant tube nozzle at the front mark (nozzle diameter:
pt
du
an
itte
approximately 3 mm).
y li
erm
ab
– Apply the silicone sealant as illustrated. The sealant bead
ility
ot p
must be:
wit
, is n
h re
hole
♦ 2 to 3 mm thick
spec
es, in part or in w
♦ and run on the inside of the bolt holes -arrows-
t to the co
Note
rrectness of i
l purpos
The sealant bead must not be thicker than specified. Otherwise,

the excess sealant could get into oil pan and clog the strainer in
the suction pipe for the oil pump.
nform
mercia
at
om
i
– Apply the silicone sealant bead as illustrated to the clean seal‐
on
c
in t
ing surface of the oil pan.
or
his
ate
do
riv
– Install the oil pan immediately and tighten all oil pan bolts
p
cum
lightly.
for
en
ng
t.
yi
– Tighten the oil pan bolts to 12 Nm.
Co
Cop py
t. rig
gh
– Tighten the oil pan to transmission bolts to 45 Nm.
ht
pyri by
Vo
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cted agen
Prote AG.
Note
After installing the oil pan the sealant must be allowed to dry for
approximately 30 minutes. Only after then may the engine oil be
added.
Further installation is in the reverse order of removal.
4.2 Oil Check Valve

Removing
– Screw approximately 4 threads of a commercially available M8
x 1.5 bolt into the valve -arrow- and pull it from the bore.
Installing
– Coat the O-ring with oil before installing. Press the valve by
hand into the oil passage.

Golf 2004 ➤
5 Special Tools

equipment required
♦ Oil Pressure Gauge -
VAG1342-
AG. Volkswagen AG d
♦ Voltage Tester - ksw
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VAG1527B- by
Vo gu
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♦ Connector Test Set - ut
hor eo
VAG1594C- ss a ra
c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
5. Special Tools 99
Golf 2004 ➤
19 – Cooling System
1 General Information
⇒ “1.1 Draining and Filling”, page 100
1.1 Draining and Filling

♦ Refractometer - T10007-
agen
AG. Volkswagen AG d
o w es n
olks ot g
♦ Cooling System ChargeedUnit
by - VAS6096-
V ua
ran
ris tee
Draining autho or
ac
ss
ce
le
un
WARNING
pt
an
d
itte
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erm
ab
Hot steam may escape when opening the expansion tank cap.
ility
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Wear protective goggles and protective clothing to prevent

wit
is n
damage to eyes and scalding. Cover the cap with a cloth and
h re
ole,
open carefully.
spec
t to the co
– Open the cap on the coolant expansion tank.

rrectne

Description and Operation .
ss
– Pull the coolant hose retaining clip -arrow- off, downward and
o
cial p
f i
remove the coolant hose from the radiator.

nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
100 Rep. Gr.19 - Cooling System

Golf 2004 ➤
– In addition, to drain the coolant from the engine, disconnect

the coolant hose -arrow- at the oil cooler.
Note
Observe disposal regulations!
Filling
Note
♦ Only use coolant additive G 12 according to “TL VW774 F”.

Identifying feature: violet
♦ "G 12" and coolant additives marked in accordance with “TL
VW774 F” prevent frost and corrosion damage, scaling and
also raise the boiling point of the coolant. For this reason the
system must be filled all year round with frost and corrosion
protection additives.
♦ G 12 purple (according to TL VW 774 F) may be mixed with
previous coolant additive G 12 red!
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Protection against frost must be assured to about -25 °C (-13
°F) (in arctic climatic countries to about -35 °C (-31 °F)).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The anti-
freeze ratio must be at least 40%.
♦ If for climatic reasons a greater frost protection is required, the
amount of G 12 can be increased, but only up to 60% (frost
protection to about -40 °C (-40 °F)), as otherwise frost protec‐
tion is reduced again and cooling effectiveness is also re‐G. Volkswagen
duced. lksw
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♦ If the radiator, heater core, cylinder head ior
se cylinder head
db ua
ran
gasket is replaced, do not reuse the old
ut
hocoolant.
r tee
or
sa ac
♦ To fill the coolant circuit, use of the Cooling
s System Charge
ce
le
Unit - VAS6096- recommended.

un
pt
an
d
itte
y li
rm
ab
Recommended Mixture Ratios

pe
ility
ot
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Frost Protection Anti-Freeze Por‐ G 12 1 Water 1

h re
to tion
hole
spec
-25 °C (-13 °F) 40% 3.7 L 5.5 L

es, in part or in w
t to the co
-35 °C (-31 °F) 50% 4.6 L 4.6 L

♦ 1 The quantity of coolant can vary depending upon the vehicle
rrectness of i
equipment.
l purpos
Procedure
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
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rig ht
py by
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101
by lksw
cted agen
Prote AG.
1. General Information
Golf 2004 ➤
– Install the lower coolant hose and secure with the retaining clip
-arrow-.
– Push the coolant hose -arrow- onto the oil cooler connection
and fasten with the spring type clip.
With the Cooling System Charge Unit - VAS6096-
– Install the adapter - VAG1274/8- on the expansion tank.
– Fill the coolant circuit using the cooling system charge unit -
AG. Volkswagen AG d
VAS6096- . Refer to the lkswoperating instructions for
agen oes the cooling
not
system charge unit.d byV
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ris tee
Without the Cooling
ut
ho System Charge Unit - VAS6096- or
a ac
ss
ce
e
nl
pt
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an
itte
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erm
ab
– Fill the coolant to the MAX. mark on the expansion tank.

ility
ot p
wit
– Install the expansion tank cap.

, is n
h re
hole
– Turn of the heater and Air Conditioning (A/C).

spec
es, in part or in w
– Start the engine and maintain an engine speed of about 2000

t to the co
RPM for approximately 3 minutes.

– Allow the engine to run at idle speed until the lower coolant
rrectness of i
becomes hot.
l purpos
– Check the coolant level and fill as necessary. When the engine
is at normal operating temperature, the coolant level must be
on the MAX. mark, and when the engine is cold, it must be
nf
ercia
between the MIN. and MAX. marks.

rm
m
atio
om
n in
or c
thi
te
sd
iva
o
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f
en
ng
t.
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.

Golf 2004 ➤

⇒ “2.1 Coolant Hose Connection Diagram”, page 103
⇒ “2.2 Cooling System Components Overview, Body Side”, page
105
⇒ “2.3 Cooling System Components Overview, Engine Side”,
AG. Volkswagen AG d
page 106 ksw
agen oes
n ol ot g
yV u
⇒ “2.4 Coolant Thermostat
ise
db Housing Overview”, page 108aran
r tee
ho
ut or
2.1 ss
a Coolant Hose Connection Diagram ac
ce
e
nl
pt
du
an
itte
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Note
erm
ab
ility
ot p
♦ When the engine is warm the cooling system is under pres‐
wit
, is n
sure. If necessary release pressure before beginning any
h re
hole
repair work.
spec
es, in part or in w
♦ Hoses are secured with spring type clips. In cases of repair
t to the co
only use spring type clips.
♦ Use the Spring Type Clip Pliers - VAS5024A- to install the
rrectness of i
spring clips.
l purpos
♦ When installing coolant hoses route them free of stress, so

that they do not come into contact with other components (ob‐
serve the marks on the coolant connection and hose).
nform
mercia
at
Perform a leak test of the cooling system using the Cooling Sys‐
om
ion
tem Tester - VAG1274- , Adapter - VAG1274/8- and Adapter -

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VAG1274/9- .
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Golf 2004 ➤
1 - Expansion Tank
2 - Upper Coolant Line
3 - Throttle Valve Control Mod‐
ule - J338-
4 - Heater Core
5 - Coolant Thermostat Hous‐
ing
6 - Lower Coolant Hose
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13 - Coolant Line
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14 - Coolant Pump
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15 - Cylinder Head
16 - Lower Coolant Line
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Golf 2004 ➤
2.2 Cooling System Components Overview, Body Side
1 - Radiator
ling. Refer to
⇒ “4.3 Radiator”,
page 114 .
❑ After replacing, replace
the entire amount of
coolant.
2 - O-Ring
3 - Upper Coolant Hose
❑ Secured to the radiator
with a quick coupling.
⇒ “2.1 Coolant Hose agen
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6 - Nut
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❑ 10 Nm
7 - Support
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8 - Washer
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9 - Fan Shroud
10 - Right Coolant Fan - V35-
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11 - Coolant Fan - V7-

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14 - Retaining Clip
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15 - Lower Coolant Hose
❑ Secured to the radiator with a quick coupling.
16 - Connector
❑ For the coolant fan control thermal switch.

Golf 2004 ➤
17 - Coolant Fan Control Thermal Switch - F18-

❑ 35 Nm
❑ For the electric fans.
❑ Switch temperatures:
❑ 1st stage:
On: 92 to 97 °C (197.6 to 206.6 °F)
Off: 84 to 91 °C (183.2 to 195.8 °F)

❑ 2nd stage :
On: 99 to 105 °C (210.2 to 221 °F)
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1 - To the Heater Core
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Connection Diagram”,
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page 103 .
2 - Cap
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❑ Check using the cooling
system tester -
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VAG1274- and the

adapter - VAG1274/9- .
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❑ Pressure relief valve

must open at a pressure
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❑ Test pressure 1.4 to 1.6
bar (20.30 to 23.20 psi).
5 - Bolt
❑ 10 Nm
6 - Upper Coolant Line
❑ Clipped to the bulkhead.
7 - From the Heater Core
Connection Diagram”,
page 103 .
8 - Lower Coolant Line
❑ Fastened at the intake manifold support and shield.

Golf 2004 ➤
9 - Throttle Valve Control Module - J338-

❑ Coolant heated.
10 - To the Radiator Upper Connection
11 - Seal
❑ Always replace.
12 - Bracket
14 - From the Radiator Lower Connection
15 - O-Ring
❑ Always replace.
16 - Coolant Tube
17 - O-Ring
❑ Always replace.
❑ With the oil cooler.
19 - Bolt
❑ 25 Nm
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❑ Fastened to the cylinder block with a bracket.
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❑ Checking. Refer to ⇒ “3.1 After-Run Coolant Pump, Checking”, page 109 .

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❑ Check for ease of movement.

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❑ Removing and installing. Refer to ⇒ “4.2 Coolant Pump”, page 112 .

23 - Coolant Pump Pulley
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❑ Removing and installing the ribbed belt. Refer to ⇒ “3.1 Ribbed Belt”, page 32 .
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24 - Bolt
❑ 20 Nm
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❑ Use the water pump wrench - VAG1590- to loosen and tighten. Refer to
⇒ “4.2 Coolant Pump”, page 112 .
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Golf 2004 ➤
2.4 Coolant Thermostat Housing Overview
1 - O-Ring
2 - Retaining Clip
3 - Coolant Thermostat Hous‐
ing
ling. Refer to
⇒ “4.1 Coolant Thermo‐
stat Housing”,
page 111 .
4 - Bracket
5 - Bolt
❑ 10 Nm
6 - Coolant Thermostat
❑ Pay attention to the in‐
stalled position.
❑ Checking: Heat up the
thermostat in water.
❑ Opening begins at ap‐
proximately 80 ℃ (176 °
F).
❑ Ends at approximately
105 °C (221 °F).
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10 - Plug
❑ If necessary release pressure in the cooling system before removing.
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Routing of the coolant hoses to the thermostat housing. Refer to

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page 106 .
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Golf 2004 ➤

⇒ “3.1 After-Run Coolant Pump, Checking”, page 109
⇒ “3.2 Coolant Fan, Checking”, page 110
3.1 After-Run Coolant Pump, Checking

♦ Wiring Diagram
Test Conditions
• Fuse 16 must be OK.
Test Sequence
– Disconnect the 2 pin connector from the After-Run Coolant

Pump - V51- -arrow-.
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– Connect the contacts of the after-run coolant pump to the bat‐

h re
ole,
tery, using adapter cables from the Connector Test Set -

spec
VAG1594C- . The after-run coolant pump must start running.

t to the co
If the after-run coolant pump does not start running:

– Replace the after-run coolant pump.
rrectne
If the after-run coolant pump does starts running:

ss
– Turn the ignition off and then on again.

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Golf 2004 ➤
– Connect the Voltage Tester - VAG1527B- to the disconnected

connector of the after-run coolant pump, using adapter cables
from the Connector Test Set - VAG1594C- . The Light Emitting
Diode (LED) must light up.
Note
This test must be performed inside of 10 min. after the ignition

has been turned off.

– Determine and eliminate the open circuit according to the wir‐
ing diagrams. Refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations.
3.2 Coolant Fan, Checking

Special tools and workshop equipment required AG. Volkswagen AG d
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• The Coolant Fan Control Thermal Switch - F18- is OK.
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spec
thermal switch.
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– Bridge the terminals -1 and 2- of the connector using an adapt‐
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mer
er wire from the Connector Test Set - VAG1594C- . Stage 1

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of the Coolant Fan - V7- and Right Coolant Fan - V35- must
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– Determine and eliminate the open circuit according to wiring
diagrams. Refer to ⇒ Wiring diagrams, Troubleshooting &
Component locations
If no fault is detected in the wiring:
– Replace the coolant fan or right coolant fan.

Golf 2004 ➤
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⇒ “4.2 Coolant Pump”, page 112
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⇒ “4.3 Radiator”, page 114
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– Remove the air filter housing.
es, in part or in w
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– Disconnect the connector from the Engine Coolant Tempera‐
ture Sensor - G62- .
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– Remove the bolts -arrows-.

– Swing the Secondary Air Injection (AIR) system hose bracket
forward.

Golf 2004 ➤
– Remove the bolt -arrow- at the wiring harness bracket.
Caution
Press the coolant pipe in the direction of the coolant pump us‐
ing a pry bar when removing the coolant thermostat housing
so that is not pulled off.
– Remove the coolant thermostat housing -2- while pressing the

coolant pipe -1- toward the coolant pump with a pry bar.
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– Remove the engine cover. by c lksw
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– Disconnect the crankcase breather connecting hose between
the cylinder head cover and intake hose on cylinder head cov‐
er.
Note
Press the buttons together on the hose connection to do so.

Golf 2004 ➤

– Install the engine support bridge - 10-222A- with the bracket
for engine - 10-222A/1- .
– Insert the hook from the engine support bridge - 10-222A- in
the right lifting eye of the cylinder block and slightly tension the
engine.
– Remove the engine mount to engine mount bracket bolts

-arrows-.
Note
Use the Step Ladder - VAS5085- to remove the bolts.
– Lower the engine using the support bridge only as far and as
necessary to remove the coolant pump. agen
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– Remove the pulley. Hold the pulley using the Water Pump
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Wrench - VAG1590- when doing this.
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es, in part or in w
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Golf 2004 ➤ olkswagen A
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– Remove the coolant
horis pump bolts -1- and then remove thencool‐
tee
ant pump s-2-.
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t or
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– Lubricate the new O-ring with coolant.
is n
h re
ole,
– Insert the coolant pump into the cylinder block and tighten the
spec
bolts. Tightening specification: 8 Nm
t to the co
– Install the pulley and tighten the bolts. Tightening specifica‐
tion: 20 Nm
rrectne
– Align the engine mount. Refer to
page 3 .
ss o
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mer
Note
atio
om
n
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Tightening specification for the engine mount. Refer to
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⇒ “2.1 Fastener Tightening Specifications”, page 4 .
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4.3 Radiator
AG.

Removing
– Remove the front bumper cover. Refer to “Front Bumper” in ⇒
Body Exterior; Rep. Gr. 63 ; Removal and Installation .
eration .
– Disconnect the quick acting couplings on the coolant hoses
from the radiator.
– Remove the connectors from the thermal switch and radiator
fans.
– Remove the bolts from the radiator and remove the radiator
with fans downward.

Golf 2004 ➤
Air Conditioning (A/C) Additional Information and Procedures
WARNING
Do not open the A/C refrigerant circuit.
Note
To prevent damage to the A/C condenser and also to the refrig‐

erant lines/hoses, ensure that the lines/hoses are not stretched,
kinked or bent.
– Remove the retaining clamp(s) from the refrigerant lines.

– Remove the A/C condenser from the radiator and secure it to
the lock carrier.
Installing
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Golf 2004 ➤ ut
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Engine Mechanical, Fuel Injection ands Ignition - Edition 07.2015
s c
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5 Special Tools
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VAG1331-
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VAS5024A-
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♦ Cooling System Charge
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Unit - VAS6096-
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Golf 2004 ➤

AG. Volkswagen AG d
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♦ Water Pump Wrench - VAG1590-
5. Special Tools 117

AG. Volkswagen AG d
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Golf 2004 ➤ olksw not
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Engine Mechanical, Fuel Injection andris Ignition - Edition 07.2015
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20 – Fuel Supply
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⇒ “1.1 Safety Precautions”, page 118
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1.1 Safety Precautions
♦ For safety reasons, fuse number 28 must be removed from the
rrectness of i
fuse holder before opening the fuel system as the fuel pump
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can be activated by a door contact switch in the driver's door.
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WARNING
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The fuel system is under pressure! Wear protective goggles
ion in
and protective gloves to avoid damage and contact with skin.
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Wrap a cloth around the connection before removing a fuel
s
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hose. Then release pressure by carefully disconnecting the
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fuel level sensor or the fuel pump (fuel delivery unit) from a full or by c lksw
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partially filled fuel tank: Prote AG.
♦ Always before starting work, switch on the exhaust extraction

system and place an extraction hose close to the fuel tank
installation opening to extract escaping fuel fumes. If no ex‐
haust extraction system is available, a radial fan (as long as
motor is not in air flow) with a displacement greater than 15
m3/h can be used.
♦ Prevent fuel from contacting skin! Wear fuel resistant gloves!
1.2 Clean Working Conditions

When working on the fuel supply/injection system, pay careful at‐
tention to the following “5 rules” of cleanliness:
♦ Always clean the connection locations and the area around
them before loosening.
♦ Place removed parts on a clean surface and cover them. Use
lint free cloths.
♦ Carefully cover or seal unpacked components, if repairs can‐
not be performed immediately.
♦ Only install clean components: Remove the replacement parts
from their packaging just prior to installing them. Do not use
parts that have been stored loose (for example, in a tool box,
etc.).
♦ When the system is open: Avoid working with compressed air
if possible. Do not move the vehicle unless absolutely neces‐
sary.
118 Rep. Gr.20 - Fuel Supply

Golf 2004 ➤

⇒ “2.1 Emergency Fuel Shut-Off”, page 119
⇒ “2.2 Electronic Power Control System Function”, page 119
⇒ “2.3 EVAP System Function”, page 120
⇒ “2.4 Accelerator Pedal Overview”, page 121
⇒ “2.5 Fuel Tank and Attachments Overview”, page 121
⇒ “2.6 EVAP System Components Overview”, page 124
⇒ “2.7 Leak Detection Pump Overview”, page 126
2.1 Emergency Fuel Shut-Off

Function
Vehicles with an airbag are equipped with an emergency fuel agen
AG. Volkswagen AG d
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shut-off system. It reduces the risk of fire in an accidentVobecause lksw not
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the fuel pump relay switches the fuel pump off. This d bsetup also ara
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makes it easier to start the engine. When opening thor the driver’s eo
door, the fuel pump is activated for 2 seconds ss a to build pressure
u ra
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in the fuel system.
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When opening the fuel system:
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Follow all safety precautions. Refer to
pe
ility
⇒ “1.1 Safety Precautions”, page 118 .
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– Check the fuel pump relay. Refer to ⇒ Wiring diagrams, Trou‐
hole
spec
bleshooting & Component locations.
es, in part or in w
t to the co
2.2 Electronic Power Control System Func‐
tion
rrectness of i
For Electronic Power Control (EPC), the throttle valve is not op‐
l purpos
erated by a cable from the accelerator pedal. There is no me‐

chanical connection between the accelerator pedal and the
throttle valve.
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ercia
The position of the accelerator pedal is transmitted to the Engine

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a
Control Module (ECM) via two accelerator pedal position sensors
com
tion in
(adjustable resistances, accommodated in one housing), that are
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connected to the accelerator pedal.

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The position of the accelerator pedal (driver controlled) is a main

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input for the ECM.

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Operation of the throttle valve occurs via an electric motor (throttle C py
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valve actuator) in the throttle valve control module. This applies
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across the entire engine speed and engine load spectrum.
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The throttle valve is operated by the throttle drive according to the
instructions of the ECM.
With the engine at a stand still and the ignition turned on, the ECM
activates the throttle valve actuator precisely according to the
specifications of the accelerator pedal position sensor. This
means, if the accelerator pedal is pressed half way, the throttle
drive opens the throttle valve to the same degree; for example,
the throttle valve is then opened approximately half way.
With the engine running (under load) the ECM can open and close
the throttle valve independently of the accelerator pedal position
sensor.
That way, for example, the throttle valve can already be com‐
pletely opened, although the accelerator pedal is only pressed
half way. An advantage of this is that throttle losses at the throttle
valve are avoided.

Golf 2004 ➤
Aside from that, it results in clearly better pollutant output and

consumption values under certain load conditions.
The ECM calculates after evaluation of torque requirements of
the different components (for example, Air Conditioning (A/C)
system, automatic transmission, Anti-lock Brake System (ABS)/
Electronic Stabilization Program (ESP), etc.) a throttle valve
opening angle optimal for the respective situation.
Follow the guidelines for cleanliness. Refer to
⇒ “1.2 Clean Working Conditions”, page 118 .
2.3 EVAP System Function

Depending on air pressure and ambient temperature, varyinggen AG
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quantities of fuel vapors develop in the fuel tank.Volkswa not
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The Evaporative Emission (EVAP) systemoprevents
ris
e
these Hy‐ tee
drocarbon (HC) emissions from enteringauthe environment.
th or
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ss
Fuel vapors disperse from the highest point of the fuel tank (at the
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filler neck) through the gravity valve (which closes at an inclination
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by 45°) into the EVAP canister.
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The activated charcoal in the canister stores these gases like a
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sponge.
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When driving with active Lambda regulation (engine warm), the
spec
EVAP Canister Purge Regulator Valve 1 - N80- is activated based
es, in part or in w
t to the co
on load and speed. The opening time is dependent on input sig‐
nals.
EVAP canister purge regulator valve 1 is closed without current
rrectness of i
(for example, a open circuit). The EVAP canister is not purged.
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Functional Description of Leak Diagnosis

The EVAP system (including fuel tank) is equipped with leak di‐
nf
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o
agnosis. The leak diagnosis will detect whether the system is
rm
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leaking. atio
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The diagnosis operates by pressurizing the system and should

or
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detect leaks where the damage exceeds 1 mm in diameter.

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Before every leak diagnosis the EVAP Canister Purge Regulator

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Valve 2 - N115- is briefly opened to relieve any possible pressure.

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During the diagnostic, the Leak Detection Pump - V144- gener‐ t. C rig
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ates a positive pressure of approximately 30 mbar (0.43 psi) in yri
p by
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the EVAP system. The pump will turn off when the pressure is
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attained. When the pressure falls to below a certain figure, the
Prote AG.
pump will turn on again. On Board Diagnostic (OBD) monitors the

on/off intervals and stores a Diagnostic Trouble Code (DTC) in
the DTC memory if the intervals are too short.
Note
♦ Hose connections are secured with either spring type or clamp

type clips.
♦ Always replace clamp type clips with spring type clips.
♦ Fuel hoses in the engine compartment must only be secured
with spring type clips. The use of clamp or screw type clips is
not permissible.
♦ Use spring type clip pliers - VAS5024A- to install spring clips.

Golf 2004 ➤

Follow the guidelines for cleanliness. Refer to
2.4 Accelerator Pedal Overview
1 - Bracket
ling. Refer to ⇒ Brake
System; Rep. Gr. 46 ;
Description and Opera‐
tion .
2 - Connector
❑ Black, 6 pin
3 - Nut
❑ 10 Nm
4 - Accelerator Pedal Position
agen
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Sensor - G79-Volksw not
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❑ Not ris adjustable
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❑s auRemove
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the footwell ra
c
s cover to remove the
ce
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sensor.
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spec
es, in part or in w
t to the co
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2.5 Fuel Tank and Attachments Overview
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Note
AG.
♦ Hose connections are secured with either spring type or clamp

type clips.
♦ Always replace clamp type clips with spring type clips.
♦ Fuel hoses at the engine must only be secured with spring type
clips. The use of clamp or screw type clips is not permissible.
♦ Use Spring Type Clip Pliers - VAS5024A- to install spring clips.

Golf 2004 ➤
1 - Connector
❑ Black, 4 pin
❑ For the fuel level sensor
- G- and transfer fuel
pump - G6- .
2 - Connector
❑ Black, 2 pin
3 - Bracket for the Return Line
❑ Clipped to the side of the
fuel delivery unit.
4 - Return Line
5 - Gravity/Expansion Valve
❑ To remove the valve,
unclip upward out of the
support.
❑ Test valve for through
flow.
❑ Valve vertical: Open.
❑ Valve angled at 45°:
Closed.
6 - Vent Line
❑ Secure with spring type
clips.
7 - O-Ring
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8 - Securing Clip lksw
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9 - Cap rise
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10 - Seal s au ra
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11 - Bolt
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12 - Fuel Filler Door Unit

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❑ With the rubber seal.

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13 - Breather Valve
spec
❑ To remove the valve, unclip sideways out of the support.

t to the co
❑ Before installing, unscrew the cap -item 9-.

❑ Checking. Refer to ⇒ Fig. ““Checking the Breather Valve”“ , page 124 .
rrectne
14 - Ground Connection
s

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15 - Bolt
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❑ 10 Nm
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16 - Lock Ring
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❑ 80 Nm
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❑ Use the ring nut spanner - 3217- for removal and installation.
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17 - Fuel Level Sensor 2 - G169-

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❑ Pay attention to the installed position on the fuel tank. Refer to
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⇒ Fig. ““Installed Position of the Fuel Delivery Unit Flange ”“ , page 124 .
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❑ Checking. Refer to ⇒ Wiring diagrams, Troubleshooting & Component locations. Prote
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Golf 2004 ➤
18 - Seal
❑ Install the seal into the fuel tank opening dry.
❑ Lubricate with fuel only when installing the flange.
19 - Vent Line
20 - Fuel Tank
❑ Support the fuel tank using the Engine/Gearbox Jack - VAG1383A- .
❑ Removing and installing. Refer to ⇒ “4.4 Fuel Tank”, page 136 .
21 - Bolt
❑ 25 Nm
22 - Securing Strap
23 - Retainer
24 - Heat Shield
25 - Support Brace
26 - Supply Line
❑ Black
❑ Secure with spring type clips.
❑ To the fuel supply line at the fuel rail. Refer to ⇒ “2.6 Fuel Rail Overview”, page 153 .
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27 - Fuel Filter ksw
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❑ Installed position: The arrow points in the direction ofedflow.
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28 - Screw Clamp ho eo
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29 - Supply Line
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30 - Fuel Delivery Unit
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❑ With the fuel level sensor.
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❑ Removing and installing. Refer to ⇒ “4.2 Fuel Delivery Unit”, page 133 .
wit
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❑ Fuel pump, checking. Refer to ⇒ “3.1 Fuel Pump, Checking”, page 127 .
hole
spec
❑ Clean the screen if it is dirty.
es, in part or in w
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31 - Supply Line
❑ Black
❑ Make sure it is secure. rrectness of i
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❑ Attached to the side of the fuel tank.

32 - Return Line
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❑ Blue or with a blue mark.

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❑ Secure with spring type clips.

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❑ To the fuel supply line at the fuel rail. Refer to ⇒ “2.6 Fuel Rail Overview”, page 153 .
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Golf 2004 ➤
Installed Position of the Fuel Delivery Unit Flange

The mark on the sender must align with the mark on fuel tank
-arrow-.
Blue or blue marked return line -1- to the connection with identi‐
fication -R-.
Black supply line -2- to the connection with identification -V-.
Note
After installing the fuel pump flange, check whether the supply,
return and ventilation lines are still clipped in at the fuel tank.
Checking the Breather Valve

Lever in the rest position: Closed n AG. Volkswagen AG do
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Lever pushed in the direction of -arrow-:bOpenyV
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Before installing the breather valve, unscrew the cap from the fill
an
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tube.
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hole
spec
2.6 EVAP System Components Overview
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
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or
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ate
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Golf 2004 ➤
1 - Hose Clamp
2 - Connecting Hose
❑ For breather lines.
3 - Vent Line
❑ Connected to the Evap‐
orative Emission
(EVAP) canister.
4 - Connector
❑ Black, 2 pin
❑ For the EVAP canister
purge regulator valve 2.
5 - Bolt
6 - Filter Housing
7 - EVAP Canister Purge Reg‐
ulator Valve 2 - N115-
8 - Filter
9 - EVAP Canister wage
es n
lks
❑ Removing and instal‐ d by Vo ot g
ua
ling. Refer to o
ir se
ran
tee
⇒ “4.5 Leak Detection
auth or
ac
Pump and EVAP ss Canis‐
ter”, page 138 .
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10 - Stud Bolt
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❑ 23 Nm
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11 - Cover
h re
hole
spec
12 - Nut
es, in part or in w
❑ 8 Nm
t to the co
13 - Vent Line
❑ From the leak detection pump - V144- to the EVAP canister purge regulator valve - N80- .
rrectness of i
❑ Clipped in, in the wheel housing.

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14 - Separating Point
❑ For the vent line.
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❑ To separate, press together the front release button.

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15 - Expansion Tank
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16 - Cover Plate
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❑ Secured in the wheel housing.

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17 - Nut
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❑ 15 Nm
t rig
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18 - To the Leak Detection Pump
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19 - Vent Line
❑ For the fuel tank.

Golf 2004 ➤
20 - Gasket
. Volkswagen AG
❑ Between the vehicle floor and the cover -item 11-.
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2.7 Leak Detection Pump Overview au ra
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itte
1 - Bolt
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ility
2 - Bracket ot p
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❑ For the leak detection
h re
ole,
pump.
spec
3 - Nut
t to the co
❑ 15 Nm
4 - Leak Detection Pump -
rrectne
V144-
ss
ling. Refer to
o
cial p
f
⇒ “4.5 Leak Detection
inform
Pump and EVAP Canis‐
mer
ter”, page 138 .
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5 - Connector
c
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❑ Black, 3 pin
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pr
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❑ For the leak detection
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pump.
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6 - To the EVAP Canister
C py
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Purge Regulator Valve 1 -
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N80-
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Prote AG.
❑ See the vent line
-item 13- in the
⇒ “2.6 EVAP System
Components Over‐
view”, page 124 .
7 - Vent Line
❑ For the fuel tank.
8 - Filter Housing
9 - Cover
❑ Clipped onto the filter
housing.
10 - Filter
❑ For the leak detection pump.

Golf 2004 ➤

⇒ “3.1 Fuel Pump, Checking”, page 127
3.1 Fuel Pump, Checking

⇒ “3.1.1 Function and Voltage Supply, Checking”, page 127
⇒ “3.1.2 Delivery Quantity, Checking”, page 128
⇒ “3.1.3 Fuel Pump Check Valve, Checking”, page 130
♦ Fuel Inj. Pressure Gauge-CIS - VAG1318-
♦ Hose Adapter - VAG1318/16-
♦ Adapter Set - VAG1318/17-
♦ Fuel Line Feed Adapter - VAG1318/23-
♦ Adapter Lead - VAG1348/3-2-
♦ Remote Control - VAG1348/3A-
♦ Multi-Meter - VAG1715- AG. Volkswagen AG d
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♦ Ring Nut Spanner - 3217- d byV
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♦ Measuring Container ut
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♦ Wiring Diagram s
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3.1.1 Function and Voltage Supply, Checking

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Test Conditions
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• Battery voltage is at least 11.5 volts

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hole
spec
• Fuse No. 28 is OK
es, in part or in w
t to the co
Note
rrectness of i
Note the description of the emergency fuel shut-off function. Refer

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to ⇒ “2.1 Emergency Fuel Shut-Off”, page 119 .
– Remove the cover from the fuel delivery unit.

nform
mercia
– Briefly operate the starter. The fuel pump must activate audi‐
a
com
ti
bly.
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– Turn off the ignition.

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If the fuel pump does not activate:

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– Remove the cover in front of the fuse holder.
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– Pull fuse No. 28 from the fuse holder. rig ht
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Golf 2004 ➤
Engine Mechanical, Fuel Injection gand Ignition
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– Connect the remote control - isVAG1348/3A-
ed b with adapter lead ara
nte
- VAG1348/3-2- to contactuth28a for the fuel pump and battery
or eo
positive (+). ss
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le
– Operate the remote control.
un
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If the fuel pump is activated:
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ility
– Check the activation of the fuel pump relay according to the
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wiring diagram using the connector test set - VAG1594C- .
h re
Refer to ⇒ Wiring diagrams, Troubleshooting & Component
hole
spec
locations.
es, in part or in w
t to the co
If the fuel pump is not activated:
– Disconnect the 4 pin connector from the flange at the fuel de‐
livery unit.
rrectness of i
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– Connect the voltage tester - VAG1527B- using an adapter ca‐

ble from the connector test set - VAG1594C- to the outer
terminals of the connector.
nform
mercia
– Operate the remote control. the Light Emitting Diode (LED)
a
com
ti
must light up
on in
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– Determine and eliminate the open circuit according to the wir‐
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ing diagram. Refer to ⇒ Wiring diagrams, Troubleshooting &
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ng
t.
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Component locations.
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If the LED lights up (voltage supply is OK):
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– Use the Ring Nut Spanner - 3217- to remove the lock ring.
– Check if the electrical wiring between the flange and fuel pump
is connected.
If no open circuits are found:
– The fuel pump is faulty, replace the fuel delivery unit. Refer to
⇒ “4.2 Fuel Delivery Unit”, page 133 .
3.1.2 Delivery Quantity, Checking

Test Conditions
• The voltage supply is OK
• The remote control - VAG1348/3A- is connected
Test Sequence
– Remove the fuel cap from the fuel fill tube.
WARNING
the connection.

Golf 2004 ➤
n AG. Volkswagen A
– Disconnect the supplyohose
lksw -3- (with the white mark)
age G do
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lect any fuel that may
d by leak out with a cloth.
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Press the buttons together on the hose connections to do so.

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spec
es, in part or in w
t to the co
– Connect the Fuel Inj. Pressure Gauge-CIS - VAG1318- to the
fuel supply line using the Fuel Line Feed Adapter -
rrectness of i
VAG1318/23- and the Adapter Set - VAG1318/17- .
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– Install the Hose Adapter - VAG1318/16- onto the Adapter -

VAG1318/11- on the Fuel Inj. Pressure Gauge-CIS -
nform
ercia
VAG1318- and hold the other end of the hose in a measuring

container.
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– Open the shut off lever on the Fuel Inj. Pressure Gauge-CIS -
n in
r
VAG1318- . The lever then points in the direction of flow.

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– Operate the Remote Control - VAG1348/3A- . Slowly close the
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shut off lever, until the pressure gauge shows 3 bar (43.5 psi).
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From this point on do not move the position of the shut off
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lever. C py
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– Empty the measuring container. copy Vo
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– The delivery rate of the fuel pump is dependent on battery
AG.
voltage. Therefore, connect the Multi-Meter - VAG1715- to the

vehicle’s battery using an adapter cable from the Connector
Test Set - VAG1594C- .
– Operate the remote control for 30 seconds and measure the
battery voltage.
– Compare the quantity of fuel delivered with the specification.

-*) - Minimum delivery rate cm3/30 seconds
-**) - Voltage at the fuel pump with the engine stopped and the
pump running (approximately 2 volts less than battery voltage).
Example:
During the test, a voltage of 13 volts is measured at the battery.
Since the voltage at the pump is approximately 2 volts less than
battery voltage, there is a minimum delivery rate of 1,100 cm3/30
s.
If the minimum delivery rates are not obtained:
– Check the fuel lines for possible restrictions (kinks) or block‐
ages.

Golf 2004 ➤
– Disconnect the supply hose -1- from the fuel filter input.
– Connect the Fuel Inj. Pressure Gauge-CIS - VAG1318- with
the Adapter Set - VAG1318/17- to the hose.
– Resume testing the delivery quantity.
If the minimum delivery rate is now obtained:
– Replace the fuel filter:
If the minimum delivery rate is again not obtained:
– Remove the fuel delivery unit and check the filter strainer for
dirt.
Only when up to now no malfunction has been detected:
– Replace the fuel delivery unit.
If the delivery rate has been attained but nevertheless you sus‐
pect a fuel supply system malfunction (for example, a intermittent
failure of fuel supply system):
– Check the current draw of the fuel pump as follows:
– Reconnect all disconnected fuel lines. lkswage es n
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byV ua
d ran
ir se tee
– Connect the multi-meter - VAG1715-uto th the wire -arrow- for
o
or
contact 1 of 4 pin connector using sthe
s current pickup clamp.
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– Start the engine and run at idle speed.
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– Measure the current draw of the fuel pump. Specified value:
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Max. 8 amps.
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Note
spec
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If the malfunction in the fuel system is sporadic, the test can also
be performed during a road test, but a second person is required.
If the current draw is exceeded: rrectness of i

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3.1.3 Fuel Pump Check Valve, Checking

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Test Conditions
or
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ate
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The remote control - VAG1348/3A- is still connected.

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The fuel inj. pressure gauge-CIS - VAG1318- is still connected.

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Test Sequence
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Note
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This test also checks the connections of the fuel supply line from
the fuel delivery unit to the connection point of the fuel inj. pres‐
sure gauge-CIS - VAG1318- for leaks.

Golf 2004 ➤
– Close the fuel inj. pressure gauge-CIS - VAG1318- shut off

lever (lever at a right angle to the direction of flow).
– Operate the Remote Control - VAG1348/3A- at short intervals,
until a pressure of approximately 3 bar (43.5 psi) has built up.
WARNING
Danger of spraying when opening the shut off lever; wear pro‐
tective goggles and protective clothing to prevent injuries and
contact with skin. Hold a container in front of the open con‐
nection of the pressure gauge.
– If pressure builds up too high, lower the excess pressure by

carefully opening the shut off lever.
– Watch pressure drop on the gauge. After 10 minutes the pres‐
sure must not drop below a 2.5 bar (36.25 psi) decrease.
If the pressure drops further: n AG. Volkswagen AG do
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– Check the line connections for leaks.d by V ua
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If no fault is detected in the wiring:autho
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es, in part or in w
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rrectness of i
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at
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ion
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or
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ate
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Golf 2004 ➤
wage
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⇒ “4.1 Suction Jet Pump”, page 132
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⇒ “4.2 Fuel Delivery Unit”, page 133
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⇒ “4.3 Fuel Level Sensor”, page 135
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⇒ “4.5 Leak Detection Pump and EVAP Canister”, page 138
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4.1 Suction Jet Pump
On vehicles with all-wheel drive, the shape of the fuel tank dic‐
rrectness of i
tates that a suction jet pump unit is required to pump fuel to the
fuel delivery unit from the area of the fuel level sensor 2 . The l purpos
suction jet pump works based on physical principles. It is driven
via the fuel supply through an additional fuel pump connection.
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A test is only to be performed when the engine shuts off through
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♦ Fuel Extracting Device - VAS5190-
Requirements
• The fuel tank must be drained
• Both fuel level sensors must be checked with Guided Fault
Finding and be OK. Refer to ⇒ Wiring diagrams, Trouble‐
shooting & Component locations.
Procedure
– Read the safety precautions before starting. Refer to
Note

battery.
– Remove the cover under the bench seat.
WARNING

connection.

Golf 2004 ➤
– Disconnect the 4 pin connector and the fuel hoses from the
fuel delivery unit (right side of vehicle), and remove the fuel
delivery unit. Refer to ⇒ “4.2 Fuel Delivery Unit”, page 133 .
– Remove the Fuel Level Sensor 2 - G169- lock ring on the left
side of the vehicle.
– Lift the fuel level sensor 2 upward as far as possible.
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– Separate the cable
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spread apart sthe mount for the suction jet pump on the fuel
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level sensor 2 in the direction of -arrows-.

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– Now, unclip and remove the suction jet pump with supply and
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return lines from the fuel level sensor 2.

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– Check that the fuel hoses/lines on the suction jet pump are
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– Additionally check the suction jet pump for contamination/dirt

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if necessary.
If no malfunctions are found:
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– Install the suction jet pump and fuel level sensor 2 in reverse
order.
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Note
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♦ Before installing the fuel delivery unit and fuel level sensor 2,
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make sure that the seal is dry when setting it into the fuel tank
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Golf 2004 ➤
Removing
Note
Drain the fuel tank using the Fuel Extracting Device - VAS5190- .

Note

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– Remove the iright
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– Disconnect the 4 pin connector and the supply and return lines
from the flange.
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at
– Use the Ring Nut Spanner - 3217- to remove the lock ring.
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Golf 2004 ➤
– Pull apart the 2 pin connection -1-, and the supply line hose
connection -2- to the suction jet pump.
– Lift the fuel delivery unit slightly and pull the bracket with return
line -arrow- off upward.
– Pull the fuel delivery unit and seal out of the opening in the fuel
tank.
Note
If the delivery unit is to be replaced then drain the old delivery unit
before disposal.
Installing
– Installation of the fuel delivery unit is the reverse order of re‐
moval. wage
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into the opening of the fuel tank dry.

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♦ Lubricate the seal with fuel only when installing the fuel deliv‐
es, in part or in w
ery unit and fuel level sensor 2.

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♦ Make sure the fuel hoses are secure.

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♦ After installing the fuel delivery unit, check that the supply, re‐
turn and vent lines are still clipped onto the fuel tank.
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♦ Note the installed position of the fuel delivery unit flange! The
marks on the flange must align with the mark on the fuel tank
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4.3 Fuel Level Sensor

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remove the fuel level sensor 2 - G169- . Refer to cop Vo
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♦ Drain the fuel tank using the fuel extracting device -

VAS5190- .

Golf 2004 ➤
Removing
WARNING

connection.
– Remove the fuel delivery unit. Refer to

– Disengage the connector prongs of wires -3 and 4- and dis‐
connect.
– Lift the retaining tabs -1 and 2- with a screwdriver and pull the
fuel level sensor - G- downward and off -arrow-.
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– Insert the fuel level sensor into the guides on thedfuel by delivery
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– When installing, verify that the seals for the
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♦ Lubricate the seal with fuel only when installing the fuel deliv‐
ery unit and fuel level sensor 2.
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4.4 Fuel Tank
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♦ Engine/Gearbox Jack - VAG1383A- f inform

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battery.
– Open the fuel tank flap.

Golf 2004 ➤
– Insert the suction hose -arrow- from the fuel extracting device
- VAS5190- about 100 to 120 cm into the fuel fill neck and
extract the fuel.
– Remove the bolt and remove the fuel flap unit with rubber seal.
– Remove the bolts fro the fill neck.
– Remove the rear right wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 ; Removal and Installation .
– Clean the area surrounding the fuel filler tube.
– Fold the rear seat bench forward.
– Remove the right and left covers under the bench seat.
– Remove the heat shield under the fuel tank AG. Volkswagen AG d
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– Remove the rear subframe. Refer to ⇒ Suspension, Wheels, ed b ara
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Steering; Rep. Gr. 42 ; Removal and Installation . thor eo
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– Disconnect the Return line -2- (blue), supply line -1- (black)
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and vent line -3- (white) at their connection points.
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Golf 2004 ➤
– Remove the bolts/nuts -arrows-.

– Remove the securing straps. Support the fuel tank using the
Engine/Gearbox jack - VAG1383A- while doing so
– Lower the fuel tank.
Installing
lowing:
♦ Make sure the ventilation and fuel lines are not kinked when
installed.
♦ Secure the fuel hoses with spring type clamps.
♦ Route the fuel hoses free of kinks.
♦ Make sure the fuel hoses are secure.
♦ Do not interchange the supply and return hoses (return hose
is blue or with a blue mark, the supply hose is black).
Note
After installing the fuel tank, check that the supply, return and vent
lines are still clipped onto the fuel tank.
4.5 Leak Detection Pump and EVAP Canis‐

ter
The Leak Detection Pump - V144- is installed in the right rear
wheel housing. It is connected to the EVAP Canister Purge Reg‐
ulator Valve 1 - N80- in the engine compartment and the EVAP
canister via connecting lines. The EVAP canister is installed be‐
low the vehicle floor in the area of the spare tire well.
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– Raise the vehicle.
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– Remove the rear right wheel housing liner. Refer to ⇒ Body

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Exterior; Rep. Gr. 66 ; Removal and Installation .

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– Unbolt he cover plate in front of tank fill tube.

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– Disconnect the connector -1- from the leak detection pump ,

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and separate the vent line -2- at the connection.

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Golf 2004 ➤
– Unclip the vent line to EVAP canister purge regulator valve 1

-3- in the wheel housing and separate the connection.
– Now the nuts -4- can be removed and remove the leak detec‐
tion pump.
Removing the EVAP Canister
– Remove the muffler. Refer to
⇒ “2.4 Muffler and Mounts Overview”, page 174 .
– Remove the heat shield above muffler from the floor.
– Remove the right and left stabilizer bar mounts from the un‐
derbody. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr.
42 ; Description and Operation .
– Remove the cover under the EVAP canister.
– Disconnect the connector -1- from the EVAP canister purge
regulator valve 2 - N115- .
– Remove the three stud bolts -arrows-, and remove the EVAP
canister from the well.
Installing
– Installation of the EVAP canister is performed in the reverse
order.
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Golf 2004 ➤
5 Special Tools

equipment required agen
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♦ Fuel Inj. Pressure Gauge-
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♦ Fuel Line Feed Adapter -
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VAG1318/23-
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VAS5024A-
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Golf 2004 ➤

Nm) - VAG1332-
♦ Adapter Lead -
VAG1348/3-2-
♦ Remote Control -
VAG1348/3A-
♦ Voltage Tester -
VAG1527B-
♦ Connector Test Set -
VAG1594C-
♦ Multi-Meter - VAG1715-
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♦ Engine/Gearbox Jack - VAG1383A-
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Golf 2004 ➤
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Golf 2004 ➤
24 – Multiport Fuel Injection

⇒ “1.2 Clean Working Conditions”, page 143
⇒ “1.3 Fuel Injection System”, page 144

♦ For safety reasons, fuse No. 28 must be removed from the
fuse holder before opening the fuel system as the fuel pump
can be activated by the door contact switch in the driver's door.
WARNING
The fuel system is under pressure! Always wear protective

eyewear and protective clothing to prevent injuries and fuel
from coming in contact with your skin. Wrap a cloth around the
connection before removing a fuel hose. Then release pres‐
sure by carefully disconnecting the connection.
To reduce the risk of personal injury and/or damage to the fuel

injection and ignition system, always observe the following:
♦ Do not touch or remove ignition wires when the engine is run‐
ning or turning at starter speed.
♦ Only disconnect and reconnect wires for the injection and ig‐
nition system, including test leads, when the ignition is turned
off.
If test and measuring equipment is required during a road test,
note the following:
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♦ Test and measuring instruments must be secured to the Vol
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passenger seat and the vehicle is involved in an s accident, there
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is a possibility that the person sitting in this seat may receive se‐
un
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rious injuries when the airbag is triggered.

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♦ If the engine is to be turned at starter speed, without starting:

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– To do so, place the Assembly Tool - T10118- on the locking

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button -arrow- and carefully pull up the harness connector.

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1.2 Clean Working Conditions

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When working on the fuel supply/injection system, pay careful at‐ op
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1. General Information
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♦ Always clean the connection locations and the area around
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♦ Place removed parts on a clean surface and cover them. Use
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♦ Carefully cover or seal unpacked components if repairs cannot
spec
be performed immediately. es, in part or in w
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♦ Only install clean components: Remove the replacement parts
from their packaging just prior to installing them. Do not use
parts that have been stored loose (for example, in a tool box,
rrectness of i
etc.).
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♦ When the system is open: Avoid working with compressed air

if possible. Do not move the vehicle unless absolutely neces‐
sary.
nform
mercia
1.3 Fuel Injection System
a
com
tion in
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Ignition system, servicing. Refer to

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⇒ “1.2 Ignition, Servicing”, page 178 .
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♦ The Engine Control Module (ECM) is equipped with On Board
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Diagnostics (OBD). Before repairs such as fault finding, check

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♦ Fuel hoses in the engine compartment must only be secured
with spring type clips. The use of clamp or screw type clips is
not permissible.
♦ For trouble free operation of the electrical components a volt‐
age of at least 11.5 volts is necessary.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine, will not be burnt in the engine and will
damage the oxygen sensor.
Safety precautions. Refer to
Clean working conditions. Refer to
Technical data. Refer to ⇒ “3.1 Technical Data”, page 156 .
144 Rep. Gr.24 - Multiport Fuel Injection

AG. Volkswagen AG d
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Golf 2004 ➤
s
s Engine Mechanical, Fuel Injection and Ignition - Edition 07.2015
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⇒ “2.1 Functions and Components, Adapting”, page 145
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⇒ “2.2 Engine Control Module DTC Memory, Checking and Eras‐
spec
ing”, page 145
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t to the co
⇒ “2.3 Component Location Overview”, page 146
⇒ “2.4 Fuel Injection System Component Overview”, page 149
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⇒ “2.5 Intake Manifold Overview”, page 152
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⇒ “2.6 Fuel Rail Overview”, page 153
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⇒ “2.7 Air Filter Housing Overview”, page 154

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2.1 Functions and Components, Adapting
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♦ Vehicle Diagnostic, Testing, and Information System -

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♦ Diagnosis Cable - VAS5051/1- or -VAS5051/3- C py
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On the Vehicle Diagnostic, Testing, and Information System -
AG.
VAS5051B- , select “Guided Fault Finding”.

Once all control modules have been checked:
– Press “Go to” button
– Select “Function/component selection”
– “Select drive train”
– Select “engine code”
– Select “01-Systems capable of On Board Diagnostic (OBD)”
– Select “engine management system”
– Select “Functions”
– Select “Function or component”
2.2 Engine Control Module DTC Memory,

Checking and Erasing
VAS5051B-
♦ Diagnosis Cable - VAS5051/1- or -VAS5051/3-
Procedure
– Connect the Vehicle Diagnosis, Testing And Information Sys‐
tem - VAS5051A- as follows:

Golf 2004 ➤
– Connect the diagnostic cable connector -2- -VAS5051/1- or -

VAS5051/3- to the Data Link Connector (DLC) -arrow-.
Only when the engine does not start:
Selecting the Operating Mode:
– Press the button on the display for “Vehicle On Board Diag‐
nostic (OBD)”.
Selecting the Vehicle System:
– Press button “01 - Engine electronics” on the display.
The control module identification with code -2- as well as chassis

number and immobilizer identification number will be indicated on
the display.
Note
A printout is available. Press the “print” button if required.
Selecting Diagnosis Function:

– Press the button “02 - Check DTC memory” on the display.
AG. Volkswagen
– If no malfunction is stored in the ksw Engine Control Module
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(ECM), “0 DTC(s) detected” y Voisl displayed. ot g
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– If malfunctions are ustored
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– Press the ← button.

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– Press button “05 - Erase DTC memory” on display.

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If an emissions test is to be performed after the fault memory is

erased, generate a readiness code. Refer to “Guided Functions”
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in the vehicle diagnostic tester

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2.3 Component Location Overview

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Golf 2004 ➤

❑ Installed location: Ex‐
haust side of the cylin‐
der block.
❑ See -item 6- in
⇒ “2.1 Ignition System
Components Over‐
view”, page 179 .
2 - Heated Oxygen Sensor -
G39- AG. Volkswagen AG d
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❑ 50 Nm ed byV gu
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❑ Installed location: in the
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front exhaust pipe for
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cylinder 1, 2 and 3.
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3 - Oxygen Sensor after Three

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❑ 50 Nm
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rear catalytic converter.
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4 - Heated Oxygen Sensor 2 -
G108-
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❑ 50 Nm
s
front exhaust pipe for
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cylinder 4, 5 and 6.
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5 - Oxygen Sensor 2 after Cat‐
mer
alytic Converter - G131-
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❑ 50 Nm
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rear catalytic converter.

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6 - Connector yi
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❑ Release to disconnect.
7 - Motronic Engine Control Module - J220-
❑ Installed location: in the plenum chamber.
❑ Coolant heated.
9 - Protective Housing
❑ For the Secondary Air Injection Pump Relay - J299- .
10 - Mass Airflow Sensor - G70- with Intake Air Temperature Sensor - G42-
11 - Air Filter Housing
12 - Camshaft Adjustment Valves
❑ See -items 12 and 13- in ⇒ “1.1 Cylinder Head Overview”, page 40 .
13 - Ignition Coil - N152-
❑ Not available on this engine.
❑ On this engine (code BJS) there is one ignition coil with power output stage installed per cylinder. See
-item 1- in ⇒ “2.1 Ignition System Components Overview”, page 179 .

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16 - Vacuum Actuator
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❑ For the variable intake manifold.
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17 - Engine Coolant Temperature Sensor - G62-
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❑ Blue
❑ For the Engine Control Module (ECM)
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❑ With the Engine Coolant Temperature Gauge Sensor - G2- .
❑ If necessary release the pressure in the cooling system before removing.
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❑ Installed location: intake side of the cylinder block
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❑ See -item 15- in ⇒ “2.1 Ignition System Components Overview”, page 179 .
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20 - Secondary Air Injection Solenoid Valve - N112-
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21 - Intake Manifold Tuning Valve - N156-

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22 - Secondary Air Injection Pump Motor - V101-
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23 - Cylinder 1 Fuel Injector - N30-
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❑ Cylinder 2 fuel injector - N31- .

24 - EVAP Canister Purge Regulator Valve 1 - N80-

Golf 2004 ➤
2.4 Fuel Injection System Component Overview
1 - Intake Manifold
❑ Overview. Refer to
⇒ “2.5 Intake Manifold
Overview”, page 152 .
2 - Throttle Valve Control Mod‐
ule - J338-
❑ When replacing, adapt
the Engine Control Mod‐
ule (ECM) to the throttle
valve control module.
Refer to “Guided Func‐
tions” in the vehicle di‐
agnostic tester.
3 - Mounting Pin
❑ For the engine cover.
4 - Connector
❑ For the ECM.
❑ Release to disconnect
❑ Only disconnect and
connect the connector
with the ignition turned
off.
5 - Motronic Engine Control Volkswa
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6 - Mounting Frame
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7 - Vacuum Connection from the Fuel Pressure Regulator

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8 - Vacuum Connection for the Brake Booster

9 - Connection for the EVAP Canister
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10 - Retaining Clip
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13 - Engine Coolant Temperature Sensor - G62-
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❑ Blue identification
❑ For the ECM.
❑ With the Engine Coolant Temperature Gauge Sensor - G2- .

Golf 2004 ➤
❑ If necessary release the pressure in the cooling system before removing.
❑ Wiring terminal 3 and wiring terminal 4 for the Engine Coolant Temperature (ECT) sensor.
❑ Contacts are gold plated.
14 - To the Connections on the Cylinder Head
❑ For air shrouded fuel injectors.
15 - Mass Airflow Sensor - G70- with Intake Air Temperature Sensor - G42-
❑ Sensor contacts and connector contacts are gold plated.
❑ Overview. Refer to ⇒ “2.7 Air Filter Housing Overview”, page 154 .
17 - Bolt
❑ 10 Nm
19 - Oxygen Sensor 2 after Catalytic Converter - G131-
❑ 50 Nm agen
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❑ Use the Ring Spanner 7-Piece Set - 3337- for removal and installation.
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❑ Voltage supply for the sensor heater via the Fuel Pump Relay - J17- .
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20 - Heated Oxygen Sensor 2 - G108-
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❑ 50 Nm
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❑ Installed location: in the left front side of the exhaust pipe.

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slots on the sensor body.
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❑ Voltage supply for the sensor heater via the fuel pump relay.
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21 - Oxygen Sensor after Three Way Catalytic Converter - G130-

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❑ 50 Nm
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❑ Installed location: in the right rear side of the catalytic converter.

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❑ 50 Nm
❑ Installed location: in the right front side of the exhaust pipe.
❑ Grease only the threads with Hot Bolt Paste - G 052 112 A3- , the hot bolt paste must not get into the
❑ Voltage supply for the sensor heater via the fuel pump relay.
23 - Connecting Hose
❑ For the crankcase ventilation.
❑ From the ventilation housing on the cylinder head cover.

Golf 2004 ➤
24 - Positive Crankcase Ventilation Heating Element - N79-

❑ For crankcase ventilation.
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❑ Check the specified value of the voltage supply for the PCV heating element between contacts 1 and 2
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with the engine running: minimum 11.5 volts.
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26 - To the Vacuum Connection
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❑ See -item 7-.
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27 - Fuel Rail
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❑ Black side of the valve faces the junction piece of the fuel pressure regulator.
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30 - To the Vacuum Reservoir
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31 - To the Vacuum Actuator

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32 - To the Combination Valve
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33 - Connector
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35 - Secondary Air Injection Solenoid Valve - N112- C py
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36 - Wiring Harness
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❑ With harness connectors for the fuel injectors.

37 - To the Intake Manifold Tuning Valve,

Golf 2004 ➤
2.5 Intake Manifold Overview
1 - Intake Manifold
2 - Sealing Cap
❑ Not available on this en‐
gine.
3 - Bolt agen
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❑ 10 Nm d byV gu
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5 - Seal
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6 - Bolt
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❑ 25 Nm
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7 - Vacuum Connection
8 - To the EVAP Canister
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Purge Regulator Valve 1 -
N80-
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9 - To the Expansion Tank

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❑ For coolant.
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10 - To the Vacuum Actuator

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❑ For the exhaust door valve 1.
❑ For the Evaporative Emission (EVAP) system.
❑ Terminals of the harness connector are gold plated.
❑ Coolant heated.
❑ When replacing, adapt the Engine Control Module (ECM) to the throttle valve control module. Refer to
“Guided Function” “Adapting throttle valve control module” in the vehicle diagnostic tester.
17 - Ground Wire
18 - Bolt
❑ 10 Nm
20 - To the Intake Manifold Tuning Valve - N156-
21 - Control Lever
❑ For the change-over roller.

Golf 2004 ➤
22 - Change-Over Roller
23 - Gasket
❑ For the Secondary Air Injection (AIR) system.
25 - Alignment Sleeve n AG. Volkswagen AG do
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26 - Bolt ss
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1 - Bolt
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❑ 10 Nm
2 - Supply Line Connection
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3 - Return Line Connection
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4 - Cylinder 1 Fuel Injector -

N30-
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❑ Cylinder 2 fuel injector -

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5 - Seal
❑ Always replace.
6 - Retaining Clip
7 - Fuel Rail
⇒ “4.2 Fuel Pressure
Regulator and Residual
Pressure, Checking”,
page 159 .
❑ To the check valve/intake manifold junction piece.

Golf 2004 ➤
10 - Connector
❑ Black, 2 pin
11 - Wiring Harness
❑ With harness connectors for the fuel injectors.
❑ Clipped into the cable runner.
2.7 Air Filter Housing Overview agen

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2 - Connector
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❑ Black, 2 pin
❑ For the Positive Crank‐
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case Ventilation (PCV)
heating element.
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3 - Connecting Hose
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4 - Mass Airflow Sensor - G70-
with Intake Air Temperature
Sensor - G42-
❑ Sensor contacts and
connector contacts are
gold plated.
5 - Connector
❑ Black, 5 pin.
connector contacts are gold plated.
6 - Seal
7 - Upper Air Filter Housing
8 - Bolt
❑ 6 Nm

Golf 2004 ➤
9 - Air Filter Element

10 - Lower Air Filter Housing
11 - Intake Pipe
12 - Bolt/Nut
❑ 10 Nm
13 - Vent Hose
❑ For crankcase ventilation.
❑ From the ventilation housing on the cylinder head cover.
❑ Press together at the front to release.
14 - From the Cylinder Head Cover
15 - To the Crankcase ventilation Valve
❑ Under the PCV heating element.
16 - To the Throttle Valve Control Module - J338-
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Golf 2004 ➤
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Technical Data
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Engine Code BJS
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Engine idle speed 1 RPM 650 to 750
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Engine Control Module (ECM)
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System designation Motronic ME71.1
Replacement part number Refer to the Parts Catalog
rrectness of i
Engine speed (RPM) limitation RPM from approximately 6500
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♦ 1 Not adjustable
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Golf 2004 ➤

⇒ “4.1 Fuel Injector, Checking”, page 157
⇒ “4.2 Fuel Pressure Regulator and Residual Pressure, Check‐
ing”, page 159 agen
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♦ Adapter Lead - VAG1348/3-2-
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♦ Adapter Cable (121-Point) - VAG1598/31-
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♦ Injection Rate Tester - VAG1602-
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4.1.1 Fuel Injectors, Checking Injection Quan‐
tity and for Leaks
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Test Conditions
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• Fuel pressure must be OK. Checking. Refer to

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Test Sequence
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– Remove the fuel rail completely (fuel lines remain connected).
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Checking for Leaks
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– Remove the cover in front of the fuse holder.

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– Pull fuse No. 28 from the fuse holder.
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– Connect the Remote Control - VAG1348/3A- with the Adapter
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Lead - VAG1348/3-2- to contact 28a for the fuel pump and
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battery positive (+).
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– Operate the remote control.
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If the fuel pump is activated:
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– Check the injectors for leaks (visual inspection). Only 1 to 2
es, in part or in w
drops per minute may emit from each injector when the fuel
t to the co
pump is running.
If the fuel loss is greater:
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– Replace the defective fuel injector.

When installing the fuel injector, observe the following:
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♦ Replace the O-rings on all injectors and lightly lubricate with

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clean engine oil.
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♦ Insert the fuel injectors into the fuel rail perpendicular and in
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the correct position, and secure them with the retaining clips.
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♦ Position the fuel rail with the secured fuel injectors on the in‐
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take manifold and apply a uniform pressure to press it in.
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– Connect the Adapter Cable (121-point) - VAG1598/31- to the
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Engine Control Module (ECM) wiring harness. The ECM re‐

mains disconnected.
– Disconnect the connectors from the fuel injectors.
– Bridge sockets 2 and 65 of the Adapter Cable, 121-point -
VAG1598/31- with adapter wires from the Connector Test Set
- VAG1594C- . The fuel pump must run.
Note
This step allows the fuel pump to run when the engine is not run‐
ning.
– Place a fuel injector to be tested into a graduated measuring

glass from the Injection Rate Tester - VAG1602- .

Golf 2004 ➤
– Using adapter cables from the Connector Test Set -

VAG1594C- , connect one terminal of the fuel injector to be
checked to engine ground (-).
– Connect the second fuel injector terminal with an adapter ca‐
ble to the Remote Control - VAG1348/3A- using Adapter Lead
- VAG1348/3-2- .
– Connect the alligator clip to battery positive (+).
– Operate the Remote Control - VAG1348/3A- for 30 seconds.
– Repeat the check on the other injectors. To do this use new
measuring beakers.
– After all injectors have been activated, place the measuring
glasses on a horizontal surface and compare the injected
quantity. Specified value for:
Engine Code BJS: 128 to 140 ml per injector
If the measured value of one or more fuel injectors is below or
above the indicated specified value:
– Replace the defective fuel injector. agen
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When installing the fuel injector, observe the following:d by gu
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♦ Insert the fuel injectors into the fuel rail perpendicular and in
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the correct position, and secure them with the retaining clips.
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♦ Position the fuel rail with the secured fuel injectors on the in‐
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4.2 Fuel Pressure Regulator and Residual
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Pressure, Checking
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♦ Fuel Inj. Pressure Gauge-CIS - VAG1318-
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♦ Valve Adapter - VAG1318/9-

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The fuel pressure regulator controls the fuel pressure and is de‐
at
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pendent on intake manifold pressure.

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The specification for the check is dependent upon the working

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pressure of the fuel pump.

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For Engine Code BJS: Approximately 3.5 bar (50.76 psi)

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• The fuel pump delivery rate is OK. Checking. Refer to
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– Remove fuse 28 for the fuel pump from the fuse holder.
WARNING

Before opening the system place a cloth around the connec‐
tion. Then release pressure by carefully disconnecting the
connection.

Golf 2004 ➤
– Disconnect the fuel supply hose -1- (black or with a black

mark) off the fuel rail and collect any fuel that leaks out with a
cloth.
– Connect the Fuel Inj. Pressure Gauge-CIS - VAG1318- to the

supply line and hose to the fuel rail using Valve Adapter -
VAG1318/9- and Adapter Set - VAG1318/17- .
– Open the shut off lever on the Fuel Inj. Pressure Gauge-CIS -
VAG1318- . The lever points in the direction of flow.
– Insert fuse No. 28 for the fuel pump into the fuse holder.
– Measure the fuel pressure.
Specified value for engine code BJS:
Approximately 3.5 bar (50.76 psi)
– Disconnect the vacuum hose -arrow- off from the fuel pressure
regulator.
The fuel pressure must increase to approximately 4.0 bar (58.01
psi)
If the specification is not obtained:
– Check the delivery quantity of the fuel pump. Refer to
⇒ “3.1 Fuel Pump, Checking”, page 127 .
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– Turn off the ignition. horise nte
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– Check for leaks and residual pressure. Observe
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If the holding pressure drops below these specifications:

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When the fuel pump has built up pressure again:

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Rep. Gr.24 - Multiport Fuel Injection
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Golf 2004 ➤
– Wait until the pressure has built up, then turn off the ignition.
Simultaneously close the shut off lever on the Fuel Inj. Pres‐
sure Gauge-CIS - VAG1318- (lever perpendicular to direction
of flow -arrow-).
– Observe the pressure drop again on the pressure gauge.
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– Test the check valve of the fuel upump.
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– Replace the fuel pressure regulator.
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When removing the Fuel Inj. Pressure Gauge-CIS - VAG1318-
after completing the test:
ss
– Hold a cloth around the connections when loosening the
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adapters and removing the pressure gauge.
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Golf 2004 ➤

⇒ “5.1 Intake Manifold”, page 162
⇒ “5.2 Motronic Engine Control Module J220 ”, page 164
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– All cable ties which are opened or cut off when removing, must
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– Remove the ignition coils with power output stages for cylin‐
a
com
tio
ders 1 through 6 using the puller for ignition coil - T10095A- .
n in
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Refer to
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– Disconnect the 6 pin connector from the throttle valve control

module -arrow-.
– Unscrew the ground connection from the throttle valve control
module.
WARNING
Hot steam may escape when opening the expansion tank cap.
Wear protective goggles and protective clothing to prevent
damage to eyes and scalding. Cover the cap with a cloth and
open carefully.
– Open and close the cap on the expansion tank, to relieve the
cooling system pressure.
– Disconnect the coolant hoses from the throttle valve control
module and plug the hose ends.
– Remove the coolant and connecting lines as well as the vac‐
uum connections, behind the intake manifold.

Golf 2004 ➤
– Disconnect the vacuum lines -arrows- from the intake mani‐

fold.
– Unbolt the intake manifold supports from the right and left of
the intake manifold.
– Remove the bolt -1- for the intake manifold support.
WARNING
The fuel system is under pressure! Always wear protective

eyewear and protective clothing to prevent injuries and fuel
from coming in contact with your skin. Wrap a cloth around the
connection before removing a fuel hose. Then release pres‐
sure by carefully disconnecting the connection.
– Disconnect the supply line -1- (white or with a white mark) and
return line -2- (blue or with a blue mark) and catch any leaking
fuel with a shop cloth.
Note
– Seal the lines so that the fuel system is not contaminated by

dirt, etc.
– Unclip the fuel and vacuum lines at the cylinder head cover.
– Remove the two sideways bolts for the intake manifold sup‐
port.
– Remove the front bumper cover. Refer to “Front Bumpers” in
⇒ Body Exterior; Rep. Gr. 63 ; Removalwage
olks and Installation
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– Remove the retaining clamp(s)
ris from the refrigerant lines.
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Do not open the Air Conditioning (A/C) refrigerant circuit.

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– disconnect the vent hose from the cylinder head cover.

– Disconnect the vacuum hose from the combination valve.
rrectne
– Unclip the pressure hose and all additional lines from the re‐
tainers on the intake manifold and cylinder head cover.
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Golf 2004 ➤
– Remove the oil dipstick guide tube bolt -1- from the intake
manifold.
– Unclip the Secondary Air Injection (AIR) solenoid valve -2- and
the variable intake manifold valve -3- at the vacuum reservoir.
Note
The connectors for the valves can remain connected.
– Disconnect the vacuum hose from the intake manifold change-

over vacuum actuator.
– Remove the bolts for the intake manifold from the cylinder
head.
– Remove the intake manifold and place it on a suitable surface
so that vacuum actuator is not damaged.
Note
Seal the intake passages in the intake manifold and in he cylinder

head with clean cloths.
Installing
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♦ Make suressthe fuel hoses are secure.
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– Fill with coolant. Refer to

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5.2 Motronic Engine Control Module - J220-

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If the Engine Control Module (ECM) will be replaced, connect the

es, in part or in w
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vehicle diagnosis, testing and information system - VAS5051B-

and perform the Guided Function “Replace control module”.
Removing
rrectness of i

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– Remove the wiper arms and wind cowl. Refer to ⇒ Electrical

Equipment; Rep. Gr. 92 ; Removal and Installation .
nf
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– Release the connector from the ECM and pull it off.

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Golf 2004 ➤
– Press the ECM in the direction of -arrow- and pull it out from
the securing frame.
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– Insert the ECM and press it in so far rearward until
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The further installation is performed in reverse order of removal.
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“Guided Functions” in the vehicle diagnostic tester.
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Golf 2004 ➤
6 Special Tools

equipment required
♦ Adapter Lead -
VAG1348/3-2-
♦ Remote Control -
VAG1348/3A-
♦ Connector Test Set - lkswage es n
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VAG1594C- byV ua
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♦ Adapter Cable (121-Point)a-uth or
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VAG1598/31- ss
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♦ Injection Rate Tester -
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Golf 2004 ➤
♦ Fuel Inj. Pressure Gauge-

CIS - VAG1318- AG. Volkswagen AG d
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♦ Adapter Set - VAG1318/17- aut ra
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Golf 2004 ➤

VAS5051B-
♦ Diagnosis Cable - VAS5051/1- or -VAS5051/3-
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Golf 2004 ➤
26 – Exhaust System, Emission Controls

⇒ “1.1 Exhaust System”, page 169
1.1 Exhaust System
Note
♦ After working on the exhaust system ensure that the system

is not under stress, and that it has sufficient clearance to the
body. If necessary, loosen the double clamps and align the
exhaust pipe so that sufficient clearance is maintained to the
body and the mounts carry uniform loads.
♦ Replace the self-locking nuts.

♦ Ring Spanner 7-piece Set - 3337-
♦ Body Repair Saw - VAG1523A-
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1. General Information 169

Golf 2004 ➤

⇒ “2.1 Secondary Air Injection System Function”, page 170
⇒ “2.2 Secondary Air Injection System Components Overview”,
page 170
⇒ “2.3 Exhaust Manifold, Front Exhaust Pipe, Catalytic Converter
and Attachments Overview”, page 172
⇒ “2.4 Muffler and Mounts Overview”, page 174
2.1 Secondary Air Injection System Func‐

tion
During a cold start (15 to 35 °C (59 to 95 °F) coolant temperature),
air is blown behind exhaust valve by the Secondary Air Injection
(AIR) system for 65 seconds. This produces an oxygen rich ex‐
haust gas, causes after burning AG.and
Volksreduces
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phase of the catalyticVoconverter. agen Activation is does
triggered
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jection PumphRelayoris - J299- to Secondary Air Injection Solenoid nte
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Valve - N112-sa
ut
and combination valve. In addition, the AIR system ra
c
is switched on with a delay of approximately 20 seconds during
s
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idle for 5 seconds after every subsequent engine start (up to Max.
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85 ℃ (185 °F) engine temperature) and is checked via On Board

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Diagnostic (OBD).
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2.2 Secondary Air Injection System Compo‐

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Note
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For the installed location of the Secondary Air Injection Pump

Relay - J299- . Refer to
⇒ Fig. ““AIR Pump Relay -arrow- ”“ , page 172 .
ss o
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170 Rep. Gr.26 - Exhaust System, Emission Controls

Golf 2004 ➤
1 - Intake Manifold
2 - Vacuum Actuator for the
Variable Intake Manifold
3 - To the Intake Manifold
4 - To the Fuel Pressure Reg‐
ulator
5 - Combination Valve
⇒ “3.1 Combination
Valve, Checking”,
page 176 .
6 - Gasket
❑ Always replace.
7 - Air Passage
❑ In the cylinder head.
8 - Bolt/Nut
❑ 10 Nm
9 - Adapter
❑ For the combination agen
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10 - Bolt rise nte
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❑ 5 Nm ss a ra
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❑ Make sure it is secure

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❑ Replace if damaged. h re
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13 - Connection
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14 - Bracket
❑ For the Secondary Air
Injection (AIR) pump motor.
rrectness of i
❑ With a brace to the oil pan.

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15 - Bolt
❑ 20 Nm
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16 - Connector
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❑ For the AIR pump motor.

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17 - Rubber Bushing
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18 - Secondary Air Injection Pump Motor - V101-

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❑ Clean if there are contaminants.
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20 - Clamp
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21 - Intake Pipe
❑ The white connector faces towards the AIR solenoid valve/intake manifold tuning valve
23 - Connector
❑ Black, 2 pin

Golf 2004 ➤

25 - Secondary Air Injection Solenoid Valve - N112-
26 - Vacuum Reservoir
AIR Pump Relay -arrow-
Note
♦ If tools are necessary to pull the relay or control module out of

the relay plate, first disconnect the battery ground cable.
♦ Obtain the radio code for radios with an anti-theft code before
disconnecting the battery.
2.3 Exhaust Manifold, Front Exhaust Pipe, Catalytic Converter and Attach‐
ments Overview swa
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1 - Shield tho eo
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2 - Bolt/Nut ss
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❑ M10 - 40 Nm
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3 - Gasket
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spec
❑ Always replace.
es, in part or in w
t to the co
4 - Exhaust Manifold
5 - Front Exhaust Pipe
rrectness of i
❑ For removal, remove
the front driveshaft. Re‐
l purpos
fer to ⇒ Manual Trans‐

mission; Rep. Gr. 39 ;
Removal and Installa‐ nf
ercia
o
tion .
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6 - Connector
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❑ Black, 6 pin
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7 - Heated Oxygen Sensor -

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agen
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bolt paste must not get
into the slots on the sen‐
sor body.
❑ Use the ring spanner 7-
piece set - 3337- for re‐
moval and installation.
8 - Heated Oxygen Sensor 2 -
G108-
❑ 50 Nm

Golf 2004 ➤
❑ Grease only the threads with hot bolt paste - G 052 112 A3- , the hot bolt paste must not get into the
❑ Use the ring spanner 7-piece set - 3337- for removal and installation.
9 - Connector
❑ Brown, 6 pin
10 - Connector
❑ Brown, 4 pin AG. Volkswagen AG d
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11 - Catalytic Converter byV
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12 - Connector ss c
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13 - Oxygen Sensor after Three Way Catalytic Converter - G130-
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❑ 50 Nm
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14 - To the Front Muffler
15 - Oxygen Sensor 2 after Catalytic Converter - G131-
rrectne
❑ 50 Nm
ss o
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form
mer
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16 - Wiring Router
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❑ Fastened to the subframe.
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17 - Washer
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Golf 2004 ➤
2.4 Muffler and Mounts Overview
1 - Double Clamp
❑ 40 Nm
❑ Note the installed posi‐
tion. Refer to
⇒ Fig. ““Installed Loca‐
tion of the Double
Clamp, in Driving Direc‐
tion”“ , page 175 .
2 - Bracket
3 - Nut
❑ M6 - 10 Nm
❑ M8 - 25 Nm
❑ M10 - 40 Nm
4 - Retaining Ring
❑ Grey color identification.
5 - Front Muffler
❑ Note the installed posi‐
tion. Refer to
⇒ Fig. ““Aligning the Ex‐
haust System”“ ,
page 175 .
6 - Suspended Mount
❑ With the retaining ring.
❑ Replace if damaged. n AG. Volkswagen AG do
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7 - Exhaust Tailpipe d byV
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8 - Tensioning Clamp utho
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9 - Rear Muffler
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10 - Bolt
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❑ M6 - 10 Nm
spec
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❑ M8 - 25 Nm
t to the co
❑ M10 - 40 Nm
11 - To the Vacuum Control Module
rrectness of i
❑ Installed location: in the left rear wheel housing.

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❑ Individual components. Refer to

⇒ Fig. ““Installed Location of the Vacuum Control Module”“ , page 175 .
nform
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at
❑ Use the hand vacuum pump - VAS6213- to check the operation.

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13 - Retaining Ring
o
his
ate
❑ Red color identification.

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Golf 2004 ➤
Aligning the Exhaust System

• Engine must be cold.
– Align the exhaust system to the mount so that it reflects di‐
mension -a-. The -arrow- indicates the direction of travel.
Dimension -a- = 10 +/- 2 mm
Installed Location of the Double Clamp, in Driving Direction

1 - The end of the bolt must not project beyond the lower edge of
the clamp.
2 - Angle 10° + 5°
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Installed Location of the Vacuum Control Module aut ra
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1 - From the check valve to intake manifold

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2 - From the Exhaust Door Valve 1 - N321- to the vacuum actuator
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3 - Check valve (white side faces the vacuum reservoir)
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Golf 2004 ➤

⇒ “3.1 Combination Valve, Checking”, page 176
3.1 Combination Valve, Checking

♦ Hand Vacuum Pump - VAS6213-
Test Conditions
♦ Vacuum lines and hose connections are free of leaks
♦ Vacuum lines are not blocked or kinked
Test Sequence
– Disconnect the vacuum hose from the combination valve -1-.
– Connect the Hand Vacuum Pump - VAS6213- to the vacuum
hose from the combination valve -1-.
Note
Do not use compressed air during the following check!
– Disconnect the pressure hose from the combination valve at

connection -arrow- and pressurize slightly by blowing into the
AG. Volkswagen AG d
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– Operate the Hand Vacuum Pump - VAS6213- . Theiscombina‐
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If the combination valve does not open: ss
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Replace the combination valve. pt

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Golf 2004 ➤
AG. Injection
Volkswage and
nA Ignition - Edition 07.2015
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4 Special Tools thoris tee
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Special tools and workshop equipments required
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♦ Body Repair Saw - VAG1523A-
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♦ Hand Vacuum Pump - VAS6213-

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♦ Ring Spanner 7-piece Set - 3337-

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Golf 2004 ➤ tho tee
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Engine Mechanical, Fuel Injection and Ignitionss - Edition 07.2015
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28 – Ignition/Glow Plug System
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⇒ “1.2 Ignition, Servicing”, page 178
rrectne
To reduce the risk of personal injury and/or damage to the fuel
ss
injection and ignition system, always observe the following:
o
cial p
f in
♦ Do not touch or remove ignition wires when the engine is run‐
form
ning or turning at starter speed. mer
atio
m
♦ Only disconnect and reconnect wires for the injection and ig‐
o
n
c
i
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♦ Test and measuring instruments must be secured to the rear

seat and operated by a 2nd person from this location.
If test and measuring instruments are operated from the front
passenger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive se‐
rious injuries when the airbag is triggered.
1.2 Ignition, Servicing

Ignition System General Information
♦ Only the components which specifically relate to the ignition
system are dealt with here.
♦ For trouble free operation of the electrical components a volt‐
age of at least 11.5 volts is necessary.
♦ During some checks it is possible that the control module will
detect and store a malfunction. Therefore after completing all
checks and repairs the Diagnostic Trouble Code (DTC) mem‐
ory must be checked and if necessary erased.
178 Rep. Gr.28 - Ignition/Glow Plug System

Golf 2004 ➤

⇒ “2.1 Ignition System Components Overview”, page 179
2.1 Ignition System Components Overview
1 - Ignition Coil 1 with Power

Output Stage - N70-
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gold plated.
❑ Installed location: Exhaust side of the cylinder block.
7 - Bolt
❑ 20 Nm
❑ Tightening specification influences the function of the knock sensor.
❑ With sensor wheel for the Camshaft Position (CMP) sensor 2.
9 - Cover
❑ Overview. Refer to ⇒ “1.2 Cover Overview”, page 44 .
10 - Seal
❑ Always replace.

Golf 2004 ➤
11 - Camshaft Position Sensor 2 - G163-

12 - Bolt
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❑ With sensor wheel for the CMP sensor.
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18 - Spark Plug
❑ Remove and install using the spark plug removal tool - 3122B- .
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Golf 2004 ➤
3 Specifications
⇒ “3.1 Test Data and Spark Plugs”, page 181
3.1 Test Data and Spark Plugs

Engine code BJS 2
Ignition sequence 1-5-3-6-2-4
Spark plugs 1
VW/Audi Refer to Parts Catalog.

Manufacturer designation IZK R7B
Electrode gap maximum 1.1 mm
Tightening specification 20 Nm
Change intervals 60000 km
♦ 1Remove and install the spark plugs using the Spark Plug
Removal Tool - 3122B- and a suitable extension.
♦ 2 Use only the Puller for Ignition Coil - T10095A- to remove the
ignition coils with power output stage.
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3. Specifications 181
Golf 2004 ➤

⇒ “4.1 Ignition Coils with Power Output Stages”, page 182
4.1 Ignition Coils with Power Output Stages

Removing
– Place the assembly tool - T10118- against the release button
-arrow-, and carefully remove the connector from the respec‐
tive ignition coil with power output stage.
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Golf 2004 ➤
– Slide on the puller for ignition coil - T10095A- from the straight
connector side in the direction of -arrow- and press the ignition
coil with power output stage onto the spark plugs.
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Golf 2004 ➤
5 Special Tools
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Golf 2004 ➤
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DRUCK NUMBER:
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6. Revision History 185

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Cautions & Warnings ra
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Please read these WARNINGS and CAUTIONS before proceeding with maintenance
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WARNINGS and CAUTIONS before you will be allowed to view this information.
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•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
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wholly or in part by any of the extensive warranties issued by Volkswagen.
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•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
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Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
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are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
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check with your authorized Volkswagen retailer parts department for the latest information.
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•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
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reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
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Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
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a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
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vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
AG. Volkswagen AG d
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grinding, sanding, or by cleaning with compressed air. Avoid breathing
oes asbestos fibers and asbestos dust.
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Breathing asbestos can cause seriousdb
y Vdiseases such as asbestosis ort cancer,
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ar and may result in death.
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•= Finger rings should be removed u
a so that they cannot cause electrical shorts, get rcaught
ac in running machinery, or be
ss
crushed by heavy parts.
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•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
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instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
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replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
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•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
t to the co
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
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•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
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fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
listed.
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•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
m
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ignited, it will ignite gas trapped in the cells and cause the battery to explode.
on
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Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
a
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the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
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govern the disposal of wastes.

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The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
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serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
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automotive chemical refrigerants.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times beforeAG. Volkswagen G d
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When driving or riding in an airbag-equipped vehicle, never hold test equipment in your rhands
a or lap while the
vehicle is in motion. Objects betweens you and the airbag can increase the risk of injury incan accident.
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I have read and I understand these Cautions and Warnings.
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Page 3 of 3
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D3E8001E712-Engine Mechanical Fuel Injection and Ignition

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Engine Mechanical, Fuel Injection and Ignition

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg D3E8001E712

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.2 Engine, Securing to the Engine and Transmission Holder VAS6095 . . . . . . . . . . . . . . . . 9

13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.1 Chain Drive and Cylinder Block Overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.3 Crankshaft Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.1 Ribbed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

3.1 After-Run Coolant Pump, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

4.1 Coolant Thermostat Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

4.3 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1.2 Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

5.1 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

5.2 Motronic Engine Control Module J220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

2.1 Secondary Air Injection System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

2.2 Secondary Air Injection System Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 170

3 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

3.1 Combination Valve, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

2.1 Ignition System Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

00 – General, Technical Data

The engine code is also included on the vehicle data label.

2.1 Engine Data

Bore diameter mm 84.0

Compression ratio 11.25

Research Octane Num‐ minimum 98 unleaded 3

♦ 3 In exceptional circumstances min. 95 RON, however with nf

Engine Code BJS

Fuel injection, ignition Motronic ME7.1.1

Ignition sequence 1-5-3-6-2-4

2 Rep. Gr.00 - General, Technical Data

♦ Engine Support Bridge - 10-222A-

♦ Engine Support Adapter - 10-222A/3-

Tightening specifications for the engine and transmission mounts.

1. Description and Operation 3

3- Transmission mount to transmis‐ 100 Nm

4 Rep. Gr.10 - Engine Assembly

3 Removal and Installation

Special tools and workshop equipment required

♦ Engine/Gearbox Jack - VAG1383A-

♦ Step Ladder - VAS5085-

ted from the battery. Check whether a coded radio is installed. If

– Disconnect the ignition coil connectors and unclip ignition coil

3. Removal and Installation 5

Press the buttons together on the connections to do so.

– Seal the lines so that the fuel system is not contaminated by

⇒ “3.1 Ribbed Belt”, page 32 .

and place it to the side; the hoses remain connected. Refer to