Diesel Engine 4 Cylinder (1 9 L Engine)-21l10178

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Service

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Service Department. Technical Information

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10 - Removing and installing engine
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15 - Cylinder head, valve gear

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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 © 2010 Volkswagen AG, Wolfsburg D3E801CBF41

 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Removing engine (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Removing engine (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.5 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.6 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1 Assembly overview - sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .en. A. G
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3.1 Assembly overview - crankshaft . . . . .V.ol.ks.w. . . . . . . . . . . . . . . . . . e.s.n.ot.g. . . . . . . . . . . . . . . . 48
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4 Pistons and conrods . . . . . . . . .or.ise.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an.te. . . . . . . . . . . . 54
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4.1 Assembly overview - pistons and au conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.ac. . . . . . . . . 54
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4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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4.3 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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4.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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4.5 Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.3 Removing, installing and tensioning toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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2.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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2.3 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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2.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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2.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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1.3 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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2 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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2.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line . . . . . . . . . . . . . . . . . . 109
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3.1 Assembly overview - oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 109
3.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.3 Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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3.4 Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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1.1 Parts of cooling system, body side (radiator with two radiator fans) . . . . . . . . . . . . . . . . . . 115

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1.2 Assembly overview - parts of cooling system, body side (radiator with one radiator fan) . . 117
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1.3 Removing and installing fan support with fans (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . 117

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1.4 Removing and installing fan support with fans (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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1.5 Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

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1.6 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

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1.7 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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1.8 Removing and installing radiator (Golf, Golf Plus, Touran) . . . . . . . . . . . . . . . . . . . . . . . . 126
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1.9 Removing and installing radiator (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.10 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.11 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.12 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.13 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.1 Rules for cleanliness when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 137
3 Parts of fuel supply system (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.1 Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.2 Fuel tank, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.5 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.6 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3.7 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3.8 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4 Parts of fuel supply system (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.1 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.4 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.5 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.7 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.8 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5 Parts of fuel supply system (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.1 Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.2 Emptying fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.3 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

ii Contents
 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

5.4 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

5.5 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
6 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
6.1 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7 Tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7.1 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7.2 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.3 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
1.4 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.5 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1.6 Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.7 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.8 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

23 - Mixture preparation e-ninjection

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1.1 Safety ris precautions . . . . . . . . . . . . . . . . . . . .n.te.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ed
225
o
1.2 Rules
au
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for cleanliness . . . . . . . . . . . . . . . . . . . . .or.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
ss c
1.3 Removing and installing pre-wired wiring harness for unit injectors and glow plugs . . . . . . 226
ce
le
un

pt

1.4 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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d
itte

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1.5 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

rm

ab

1.6 Adjusting non-contact gap of unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

pe

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wit

1.7 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

, is n

h re

1.8 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

hole

spec

1.9 Cleaning the intake manifold flap support, Engine code BLS and BXJ . . . . . . . . . . . . . . . . 237
es, in part or in w

t to the co

1.10 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
2.1 Reading and clearing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
rrectness of i

2.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

l purpos

2.3 Removing and installing engine control unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

2.4 Removing and installing anti-theft engine control unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . 241
nform
ercia

2.5 Removing and installing engine control unit (Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.6 Removing and installing anti-theft engine control unit (Golf Plus) . . . . . . . . . . . . . . . . . . . . 244
m

a
com

tio

2.7 Removing and installing engine control unit (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

n in
r
te o

2.8 Removing and installing anti-theft engine control unit (Touran) . . . . . . . . . . . . . . . . . . . . . . 247
thi
s
iva

do

3 Engine control unit (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

r
rp

cum
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3.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

en
ng

t.
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3.2 Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
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1 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Prote AG.

1.1 Assembly overview - front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . . . 255
1.2 Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . 256
1.3 Assembly overview - silencer with mountings (vehicles with front wheel drive) . . . . . . . . . . 258
1.4 Assembly overview - silencers (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1.5 Assembly overview - silencer with mountings (vehicles with four-wheel drive) . . . . . . . . . . 262
1.6 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.1 Assembly overview - parts of exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.2 Checking mechanical exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Contents iii
 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.1 Removing, installing and checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.2 Characteristics of ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.3 Removing, installing and checking ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

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iv Contents
 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

00 – Technical data
1 Technical data
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Engine data ⇒ page 1 orise nte
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1.1 Engine number s a c
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The engine number („code letters“ and „serial number“) can be

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found at the joint between engine and gearbox.

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Additionally there is a sticker on the toothed belt guard with „en‐

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

spec
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1.2 Engine data

form
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Edition 07.2010 Version 5.0

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AVQ BJB BKC BRU BLS BXE BXF BXJ
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Golf/Golf Plus produc‐ 10.03 ► 10.03 ► 04.04 ► 02.06 ► 03.06 03.06 11.07
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Passat 05.05► 03.06 12.04► C py
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Touran 02.03 ► 10.03 ► 10.04 02.06 ► 03.06 03.06 ► 10.06 ►
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production ►
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Emissions fulfil EU4 stan‐ EU3 EU4 EU4 EU4 EU4 EU4 EU4 stan‐
dard standard standard stan‐ stan‐ stan‐ stan‐ dard
dard dard dard dard
Capacity l 1.9 1.9 1.9 1.9 1.9 1.9 1.9 1.9
Output kW at rpm 74/4000 77/ 77/ 66/ 77/ 77/ 66/ 66/
4000 4000 4000 4000 4000 4000 4000
Torque Nm at 250/1900 250/ 250/ 210/ 250/ 250/ 210/ 210/
rpm 1900 1900 1800 ...2 1900 1900 1800 1800 ...25
500 00
Bore ∅ mm 79.5 79.5 79.5 79.5 79.5 79.5 79.5 79.5
Stroke mm 95.5 95.5 95.5 95.5 95.5 95.5 95.5 95.5
Valves per cylinder 2 2 2 2 2 2 2 2
Compression ratio 19.0 19.0 19.0 19.0 18.5 18.5 19.0 19.0
Fuel according DIN EN DIN EN DIN EN DIN EN DIN EN DIN DIN EN DIN EN
to 590 590 590 590 590 EN 590 590
590
Firing or‐ 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4- 1-3-4-2 1-3-4-2
der 2
Catalytic yes yes yes yes yes yes yes yes
converter
Exhaust yes yes yes yes yes yes yes yes
gas recir‐
culation

1. Technical data 1
 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

AVQ BJB BKC BRU BLS BXE BXF BXJ

Tur‐ yes yes yes yes yes yes yes yes
bocharg‐
ing/super‐
charging
Charge air yes yes yes yes yes yes yes yes
cooler
Particulate no no no no yes no no yes
filter

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Prote AG.
Rep. gr.00 - Technical data
 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

10 – Removing and installing engine

1 Removing and installing engine
Removing engine (Golf, Golf Plus) ⇒ page 3
Removing engine (Touran) ⇒wpage
agen 9
AG. Volkswagen AG d
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Removing engine (Passat)
ed
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Securing engineauto
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Notes on installing ⇒ page 21 .

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Assembly mountings ⇒ page 22

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1.1 Removing engine (Golf, Golf Plus)

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Special tools and workshop
es, in part or in w

equipment required

t to the co
♦ Lifting tackle -2024 A-
♦ Engine bracket -T10012-

rrectness of i
♦ Support clamp -VW 313-
l purpos

♦ Engine and gearbox sup‐

port -VW 540-

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♦ Workshop hoist -V.A.G

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♦ Drip tray -V.A.G 1306-

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1. Removing and installing engine 3

 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

♦ Torque wrench -V.A.G

1331-
♦ Torque wrench -V.A.G
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Spring-type clip pliers -VAS
5024-
♦ Stepladder -VAS 5085-
♦ Guide rods -T10093-
♦ Cable ties

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♦ Before carrying out further work, disconnect battery earth

strap. First check whether a coded radio is fitted and obtain nf
ercia

anti-theft coding if necessary.

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♦ The engine is removed downwards together with the gearbox.

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♦ All cable ties which are opened or cut through when engine is
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removed must be replaced in the same position when engine

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is installed.
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4 Rep. gr.10 - Removing and installing engine

 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

WARNING

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

partment, pay attention to the following due to the cramped
conditions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.

Procedure
– With ignition switched off, disconnect earth strap from battery.
One-piece engine cover
For one-piece engine cover, pull engine cover abruptly upwards
at front and right -arrows A-, then pull forwards out of rear fas‐
tening -arrow B-.

Two-piece engine cover

For two-piece engine cover, first pull outer engine cover abruptly
upwards at -arrows-, then pull inner engine cover abruptly up‐
wards at -arrows-. gen AG
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– Remove plenum chamber bulkhead. ⇒ General dbody by
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exterior; Rep. gr. 50 ; Body - front, plenum chamber
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– Remove air filter housing with air mass meter
ss
a and connecting c
pipe.
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– Remove bolt -arrow A- and pull air filter housing upwards out
of mounting.
nf
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– Remove battery and battery tray.

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

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1. Removing and installing engine 5

 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

WARNING

♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Assembly overview - Body - front .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
– Drain coolant ⇒ page 123 .
Vehicles with air conditioner

AG. Volkswagen AG d
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To prevent damage to condenser
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or to refrigerant lines/hoses, nte
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ensure that the lines sand
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To facilitate removing and installing engine without opening re‐

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frigerant circuit:
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– Remove poly V-belt ⇒ page 25 .

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– Remove air conditioner compressor ⇒ Heating, air condition‐

h re
hole

ing; Rep. gr. 87 ; Removing and installing compressor brack‐

spec

et .
es, in part or in w

t to the co

– Secure air conditioner compressor to lock carrier so that re‐

frigerant lines/hoses are free of stress.
rrectness of i

– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐

ing and installing alternator and poly V-belt .
l purpos

Continuation for all vehicles

nf
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– Remove connecting pipes between charge air cooler and en‐

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gine.
m

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– Unbolt left and right-hand drive shafts from gearbox ⇒ Run‐

or c

ning gear, axles, steering; Rep. gr. 40 ; Removing and in‐

thi
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sd
a

stalling drive shaft .

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– Remove front exhaust pipe ⇒ page 255 .

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– Release connector from engine control unit, disconnect con‐ C py
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6 Rep. gr.10 - Removing and installing engine

 nA G. Volkswagen
Golf 2004 ➤ , GolflksPlus
wage 2005 ➤ , Passatd2006
AG o
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Vo ot g
4-cylinder
db
y diesel engine (1.9 l engine) ua- Edition 08.2010
ra
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– Open all cable guide fasteners -arrows-.
au ra
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ss

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– Remove wiring harness from cable guide on longitudinal mem‐

un

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ber and lay to side on engine.

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– Pull off or disconnect all other electrical connections from en‐

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gine and gearbox as necessary and lay to side.

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is n

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– Separate all connecting, coolant, vacuum and intake hoses

ole,

spec
from engine.

urposes, in part or in wh

t to the co
Vehicles with manual gearbox
– Remove slave cylinder for hydraulic clutch. ⇒ 6-speed manual
gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism; As‐

rrectne
sembly overview - hydraulics .

s
– Unbolt selector mechanism from gearbox ⇒ 6-speed manual

s o
gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .
cial p

f inform
Vehicles with four-wheel drive:
mer

atio
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– Remove selector mechanism from gearbox ⇒ 6-speed man‐

o

n
c

ual gearbox 02Q, four-wheel drive; Rep. gr. 34 ; Repairing

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selector mechanism .
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– Separate pressure line for hydraulic clutch control.

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– Remove front propshaft ⇒ Final drive 02D, 0AV; Rep. gr. 39 ;
Co
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Assembly overview - repairing propshaft . t. C rig
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Continuation for all vehicles:
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– Unbolt pendulum support -arrows-.

Vehicles with particulate filter
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Removing and installing drive shafts .
– Remove steering box ⇒ Running gear, axles, steering; Rep.
gr. 48 ; Removing and installing steering box .
Continuation for all vehicles:

– Insert engine bracket -T10012- in engine and gearbox jack -

V.A.G 1383 A- .

Note

Support pins must be secured to engine bracket -T10012- as

shown.

– Fit engine bracket -T10012- to cylinder block with M10 x 25/

8.8 bolt and tighten to approx. 40 Nm.
– Raise engine and gearbox slightly using engine and gearbox
jack -V.A.G 1383 A- .

1. Removing and installing engine 7

 . Volkswagen AG
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 wa➤
gen AG does
olks not
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010d by V gu
ara
e nte
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– Unbolt assembly mounting on engine side from engine bracket
au
t ra
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-arrows-. ss

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Note

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To remove securing bolts, use stepladder -VAS 5085- .

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
– Unbolt assembly mounting on gearbox side from gearbox

ss
bracket -arrows-.

o
cial p

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– Carefully lower engine with gearbox.

form
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Engine with gearbox must be guided carefully when lowered to

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8 Rep. gr.10 - Removing and installing engine

 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

1.2 Removing engine (Touran)

Special tools and workshop

equipment required
♦ Lifting tackle -2024 A-
♦ Engine bracket -T10012-
♦ Support clamp -VW 313-
♦ Engine and gearbox sup‐
port -VW 540-
♦ Workshop hoist -V.A.G
1202 A-
♦ Drip tray -V.A.G 1306-

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1. Removing and installing engine 9

 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

♦ Torque wrench -V.A.G

1331-
♦ Torque wrench -V.A.G
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Spring-type clip pliers -VAS
5024-
♦ Stepladder -VAS 5085-
♦ Guide rods -T10093-
♦ Cable ties
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c
Note
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for

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ng

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op
♦ Before carrying out further work, disconnect battery earth C py
t. rig
strap. Check whether a coded radio is fitted. Obtain anti-theft
gh ht
pyri by
coding first if necessary.
co Vo
by lksw
cted agen
Prote AG.
♦ The engine is removed downwards together with the gearbox.
♦ All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.

10 Rep. gr.10 - Removing and installing engine

 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

WARNING

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

partment, pay attention to the following due to the cramped
conditions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electricalagewiring
n AG. Voin their original
lkswagen AG
does po‐
sitions. olksw not
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ed
♦ Ensure that therethis
or sufficient clearance to all moving or
is nte
e
hot components. u or
sa ac
s

ce
le
un

pt
an
d
itte

– With ignition switched off, disconnect earth strap from battery.

y li
rm

ab
pe

– Remove engine cover. To do this, pull engine cover upwards

ility
ot

abruptly at front -arrows A- and then pull forwards out of rear

wit
, is n

h re
fastening -arrow B-.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

ti
Two-piece engine cover
on in
r
te o

thi

For two-piece engine cover, first pull outer engine cover abruptly
s
iva

upwards at -arrows-, then pull inner engine cover abruptly up‐

do
r
rp

wards at -arrows-.
um
fo

en
ng

t.
yi
– Remove plenum chamber bulkhead. ⇒ General body repairs,
Co
op py
exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
t. C rig
gh ht
pyri by
Vo
– Remove air filter housing with air mass meter and connecting
co lksw
by
cted agen
pipe. Prote AG.

– Remove bolt -arrow A- and pull air filter housing upwards out
of mounting.
– Remove battery and battery tray.
– Disconnect fuel supply and return lines as well as coolant line
on cylinder head.

1. Removing and installing engine 11

 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

WARNING

♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!

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

Rep. gr. 50 ; Body - front; Assembly overview .
– Bring lock carrier into service position. ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier service
position .
– Drain coolant ⇒ page 123
Vehicles with air conditioner

Note

To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or bent.

To facilitate removing and installing engine without opening re‐

frigerant circuit:
– Remove poly V-belt ⇒ page 25 .
– Remove air conditioner compressor. ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Removing and installing compressor brack‐
et .
AG. Volkswagen AG d
agen
– Secure air conditioner compressor to lock carrier soolthat
ksw re‐
oes
not
frigerant lines/hoses are free of stress. db
y V gu
ara
e nte
ris
– Remove alternator. ⇒ Electrical system; Rep.ut
ho gr. 27 ; Re‐ eo
ra
moving and installing alternator with poly
ss V-belt .
a c
ce
le

Continuation for all vehicles

un

pt
an
d
itte

y li

– Remove connecting pipes between charge air cooler and en‐

rm

ab

gine.
pe

ility
ot

wit
, is n

– Unbolt left and right-hand drive shafts from gearbox ⇒ Run‐

h re

ning gear, axles, steering; Rep. gr. 40 ; Removing and in‐

hole

spec

stalling drive shaft .

es, in part or in w

t to the co

– Remove front exhaust pipe.

– Remove securing nuts -arrows- for engine control unit.

rrectness of i

– Release connector from engine control unit, disconnect con‐

l purpos

nector.
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen

12
Prote AG.
Rep. gr.10 - Removing and installing engine
 Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

– Open all cable guide fasteners -arrows-.

– Remove wiring harness from cable guide on longitudinal mem‐
ber and lay to side on engine.
– Pull off or disconnect all other electrical connections from en‐
gine and gearbox as necessary and lay to side.
– Separate all connecting, coolant, vacuum and intake hoses
from engine.
– Remove slave cylinder for hydraulic clutch. ⇒ 6-speed manual
gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism; As‐
sembly overview - hydraulics .
– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .

– Unbolt pendulum support -arrows-.

Vehicles with particulate filter
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Removing and installing drive shafts .
– Remove steering box ⇒ Running gear, axles, steering; Rep.
gr. 48 ; Removing and installing steering box .
Continuation for all avehicles:
gen AG
. Volkswagen AG
do
ksw es n
Vol ot g
d by ua
ran
e
ris tee
– Insert
utho engine bracket -T10012- in engine and gearbox or jack -
V.A.G
ss
a 1383 A- . ac
ce
le
un

pt
an
d
itte

y li

Note
rm

ab
pe

ility
ot

Support pins must be secured to engine bracket -T10012- as

wit
, is n

shown.
h re
hole

spec
es, in part or in w

– Fit engine bracket -T10012- to cylinder block with

t to the co

M10 × 25/ 8.8 bolt and tighten to approx. 40 Nm.

– Raise engine and gearbox slightly using engine and gearbox
rrectness of i

jack -V.A.G 1383 A- .

l purpos

– Unbolt assembly mounting on engine side from engine bracket

-arrows-.
nform
mercia

Note
com

tion in
r
te o

thi

To remove securing bolts, use stepladder -VAS 5085- .

s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Removing and installing engine 13

Diesel Engine 4 Cylinder (1 9 L Engine)-21l10178
Full download: http://manualplace.com/download/diesel-engine-4-cylinder-1-9-l-engine-21l10178/

Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤

4-cylinder diesel engine (1.9 l engine) - Edition 08.2010

– Unbolt assembly mounting on gearbox side from gearbox

bracket -arrows-.
– Carefully lower engine with gearbox.

Note

Engine with gearbox must be guided carefully when lowered to

prevent damage to bodywork.

1.3 Removing engine (Passat)

Special tools and workshop

equipment required
♦ Lifting tackle -2024 A-
♦ Engine bracket -T10012-
♦ Support clamp -VW 313-
AG. Volkswagen AG d
♦ Engine and gearbox sup‐ agen oes
olksw not
port -VW 540- or engine d byV gu
ara
and gearbox support -VAS orise nte
eo
6095- aut
h
ra
ss c
♦ Workshop hoist -V.A.G

ce
e
nl

pt
du

1202 A- or workshop crane

an
itte

-VAS 6100-

y li
erm

ab
ility
♦ Drip tray -V.A.G 1306- or
ot p

wit
drip tray -VAS 6208-
, 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

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

14 Rep. gr.10 - Removing and installing engine

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