Golf Mk5: Power unit
Also for this vehicle: Golf (5K1) L4-2.0L DSL Turbo (CJAA) (2011), Golf (5K1) L5-2.5L (CBUA) (2011), Golf GL L4-2.0L (AEG) (2001), Golf GL L4-2.0L (AVH) (2002), Golf GL L4-2.0L (AZG) (2001), Golf GLS L4-1.8L Turbo (AWW) (2001), Golf GLS L4-2.0L (AEG) (2001), Golf GLS L4-2.0L (AVH) (2002), Golf GLS L4-2.0L (AZG) (2001), Golf GTI L4-1781cc 1.8L SOHC (HT) (1985), Golf GTI L4-1781cc 1.8L SOHC (RD) (1987), Golf GTI L4-1984cc 2.0L DOHC (9A) (1990), Golf GTI L4-2.0L (ABA) (1997), Golf GTI V6-2792cc 2.8L DOHC (AAA) SFI (1998), Golf III L4-1984cc 2.0L SOHC (1993), Golf III L4-2.0L (ABA) (1995), Golf L4-1.8L Turbo (AWD) (2000), Golf L4-1.8L Turbo (AWW) (2003), Golf L4-1.9L DSL Turbo (AHU) (1997), Golf L4-1.9L DSL Turbo (ALH) (1999), Golf L4-1.9L DSL Turbo (BEW) (2004), Golf L4-1588cc 1.6L DSL SOHC (1987), Golf L4-1588cc 1.6L DSL SOHC Turbo (1985), Golf L4-1781cc 1.8L SOHC (1987), Golf L4-1781cc 1.8L SOHC (ACC) Can (1993), Golf L4-1781cc 1.8L SOHC (RV) (1990), Golf L4-1781cc 1.8L SOHC (RV, PF) (1989), Golf L4-1896cc 1.9L DSL Turbo (1Z) (1997), Golf L4-2.0L (ABA) (1996), Golf L4-2.0L (AEG) (1999), Golf L4-2.0L (AVH) (2003), Golf L4-2.0L (AZG) (2004), Golf L4-2.0L (BEV) (2004), Golf L4-2.0L DSL Turbo (CJAA) (2010), Golf L5-2.5L (CBUA) (2010), Golf Mk1, Golf Mk2, Golf Mk3, Golf Mk4, Golf Mk6.
Steering & suspension
Body & interior
General
Transmission
Engine
Heating & A/C
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
6-cylinder injection engine149 pages
Technical data2 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons22 pages
Pistons and conrods6 pages
Engine cylinder head, valve gear23 pages
Cylinder head12 pages
- Assembly overview - cylinder head
Removing and installing cylinder head4 pages
- Assembly overview - cover
- Checking valve timing
- Removing and installing camshaft adjuster
- Removing and installing camshaft timing chain and intermediate shaft drive chain
- Removing and installing cylinder head cover
- Checking compression
Valve gear11 pages
Engine lubrication › Parts of lubrication system10 pages
Engine cooling › Removing and installing parts of cooling system16 pages
- Assembly overview - parts of cooling system, body side
- Assembly overview - cooling system, engine side (vehicles with manual gearbox)
- Assembly overview - cooling system, engine side (vehicles with DSG®)
- Assembly overview - thermostat housing
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing fan support with fans
- Removing and installing radiator
- Checking continued coolant circulation pump
- Removing and installing coolant pump
- Removing and installing thermostat housing
- Removing and installing thermostat
- Removing and installing coolant pipe
Fuel supply, gas operation30 pages
- Safety precautions when working on fuel supply system
- Rules for cleanliness
Fuel tank9 pages
Repairing fuel supply13 pages
Electronic power control (EPC)3 pages
Activated charcoal filter system3 pages
Mixture preparation system, electronic inj.,Gas20 pages
Repairing injection system11 pages
Checking components6 pages
- Checking vacuum unit for intake manifold flaps
Checking injectors for leaks and quantity injected3 pages
- Checking fuel pressure regulator and holding pressure
Exhaust system15 pages
Exhaust manifold, front exhaust pipe with catalytic converters and Lambda probes5 pages
Silencer with mountings4 pages
Ignition system, glow plug system › Ignition system6 pages
4-cylinder injection engine (1.6 l roller rocker finger)187 pages
Technical data2 pages
Engine assy,cylinder block,crankcase › Removing and installing engine6 pages
Enginecrankshaft group, pistons32 pages
Dismantling and assembling engine7 pages
Removing and installing sealing flanges and flywheel or drive plate13 pages
- Assembly overview - sealing flange
Removing and installing crankshaft sealing flange (flywheel end)3 pages
- Removing and installing flywheel
- Removing and installing drive plate
Crankshaft6 pages
Dismantling and assembling pistons and conrods6 pages
Assembly overview - pistons and conrods3 pages
- Checking pistons, piston rings and cylinder bores
- Piston and cylinder dimensions
Engine cylinder head, valve gear29 pages
Cylinder head11 pages
Removing, installing and tensioning toothed belts3 pages
- Checking semi-automatic toothed belt tensioner
- Compression test
Repairing valve gear18 pages
Engine lubrication › Parts of lubrication system9 pages
Engine cooling18 pages
Removing and installing parts of cooling system17 pages
- Assembly overview - parts of cooling system - engine side, engine codes BGU, BSE and BSF
- Assembly overview - parts of cooling system, engine side, engine codes CCSA, CMXA
- Assembly overview - parts of cooling system, body side (radiator with 2 radiator fans)
- Assembly overview - parts of cooling system, body side (radiator with one radiator fan)
- Coolant hose schematic diagram - engine codes BGU, BSE and BSF
- Coolant hose schematic diagram - engine codes CCSA, CMXA
- Removing and installing thermostat
- Removing and installing radiator fan V7 and radiator fan 2 V177
- Removing and installing radiator
- Checking cooling system for leaks
- Assembly overview - engine preheating (engine codes CCSA, CMXA)
Fuel supply, gas operation32 pages
Fuel tank9 pages
Repairing fuel supply15 pages
Electronic power control (EPC)4 pages
Activated charcoal filter system4 pages
Mixture preparation system, electronic inj.,Gas30 pages
Injection system18 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical data
- Assembly overview - intake manifold with attachments, engine code BGU
- Assembly overview - intake manifold with attachments, engine codes BSE, BSF, CCSA, CMXA
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter with attachments
Removing and installing intake manifold lower part, engine code BGU3 pages
- Removing and installing intake manifold lower part, engine codes BSE, BSF, CCSA, CMXA
- Removing and installing complete intake manifold, engine codes BSE, BSF, CCSA, CMXA
- Removing and installing injectors
Checking components9 pages
Checking injectors for leaks and quantity injected5 pages
- Checking fuel pressure regulator and holding pressure
Checking intake manifold change-over2 pages
Engine control unit J623 (Golf 2004 ?)3 pages
Exhaust system24 pages
Exhaust system, engine codes BGU, BSE, BSF, CCSA8 pages
- Assembly overview - exhaust system
- Separating centre and rear silencers
- Removing and installing front exhaust pipe with catalytic converter
- Removing and installing exhaust manifold
- Aligning exhaust system stress free
- Removing and installing Lambda probe G39
- Removing and installing Lambda probe after catalytic converter G130
Exhaust system, engine code CMXA9 pages
- Assembly overview - exhaust manifold and front exhaust pipe with catalytic converter
- Assembly overview - exhaust system
- Separating centre and rear silencers
- Removing and installing front exhaust pipe with catalytic converter
- Removing and installing exhaust manifold
- Aligning exhaust system free of stress
- Removing and installing Lambda probe G39
- Removing and installing Lambda probe after catalytic converter G130
Exhaust gas recirculation system, engine code BGU2 pages
Secondary air system, engine codes BGU, BSE, CCSA, CMXA5 pages
Ignition system, glow plug system › Repairing ignition5 pages
4-cylinder diesel engine (2.0 l engine, 4 valve)175 pages
Engine assy,cylinder block,crankcase › Removing and installing engine6 pages
Enginecrankshaft group, pistons28 pages
Dismantling and assembling engine6 pages
Removing and installing sealing flange and flywheel13 pages
Renewing crankshaft sealing flange - flywheel end9 pages
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Renewing crankshaft oil seal - pulley end
- Removing and installing sealing flange - pulley end
- Removing and installing engine speed senderG28
Engine cylinder head, valve gear24 pages
Cylinder head10 pages
- Assembly overview - cylinder head
- Removing and installing cylinder head cover
Removing, installing and tensioning toothed belt3 pages
- Checking compression
Valve gear14 pages
- Assembly overview - valve gear
Removing and installing roller rocker finger3 pages
- Removing and installing camshaft oil seal
Engine lubrication13 pages
Parts of lubrication system (Golf, Golf Plus, Touran)3 pages
Oil filter bracket, oil cooler, oil pressure and oil supply line7 pages
Engine cooling › Parts of cooling system16 pages
- Parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side (Golf, Golf Plus, Touran)
Coolant hose schematic diagram4 pages
- Removing and installing fan support with fans
- Removing and installing radiator
- Removing and installing coolant pump
- Removing and installing thermostat
- Checking cooling system for leaks
- Checking oil cooler for leaks
Fuel supply, gas operation36 pages
Parts of fuel supply system (Golf, Golf Plus)22 pages
Fuel tank, vehicles with front-wheel drive3 pages
Fuel tank, vehicles with four-wheel drive5 pages
Emptying fuel tank3 pages
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Removing and installing fuel cooler
Accelerator mechanism3 pages
Tandem pump7 pages
Exhaust turbocharger, G-charger › Charge air system with turbocharger17 pages
- Safety precautions
- Rules for cleanliness
Assembly overview - turbocharger with attachments3 pages
- Removing and installing turbocharger
Assembly overview - charge air cooling3 pages
- Checking charge air system for leaks
Vacuum hose schematic diagram3 pages
Fuel preparation system Diesel injection16 pages
Diesel direct injection system13 pages
- Safety precautions
- Rules for cleanliness
Assembly overview - intake manifold with attachments3 pages
- Assembly overview - pre-wired wiring harness for unit injectors and glow plugs
- Removing and installing pre-wired wiring harness for unit injectors and glow plugs
- Assembly overview - unit injector
- Removing and installing unit injector
- Cleaning unit injectors (engine codes BMN, BKP, BMA, BUZ and BMR)
- Removing and installing O-rings for unit injector
- Assembly overview - air filter
Engine control unit (Golf)3 pages
Exhaust system13 pages
Exhaust gas recirculation system4 pages
Assembly overview - exhaust gas recirculation3 pages
Ignition system, glow plug system › Optical characteristics of metal or ceramic glow plugs3 pages
4-cylinder injection engine (1.4 l engine)155 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons21 pages
Dismantling and assembling engine4 pages
Cylinder block, sealing flange14 pages
- Assembly overview - aluminium cylinder block
- Renewing crankshaft oil seal - pulley end
- Poly V-belt pulley securing bolt tightening procedure
Renewing crankshaft sealing flange - flywheel end9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Crankshaft dimensions
Engine cylinder head, valve gear24 pages
Cylinder head16 pages
- Assembly overview
- Checking valve timing
Checking semi-automatic toothed belt tensioning roller3 pages
- Checking compression
Valve gear8 pages
Engine lubrication › Parts of lubrication system12 pages
Engine cooling › Parts of cooling system17 pages
- Assembly overview - parts of cooling system (radiator with two fans), body side
- Assembly overview - parts of cooling system (radiator with one fan), body side
- Assembly overview - parts of cooling system - thermostat side
- Assembly overview - parts of cooling system - coolant pump side
- Coolant hose schematic diagram
- Removing and installing radiator fanV7 and radiator fan 2V177
- Removing and installing radiator
- Removing and installing coolant pump
Fuel supply, gas operation34 pages
Parts of fuel supply system28 pages
- Assembly overview - dismantling and assembling fuel tank with add-on parts and fuel filter
- Safety precautions when working on fuel supply system
- Rules for cleanliness
Emptying fuel tank3 pages
- Removing and installing fuel gauge senderG
- Assembly overview - fuel filter with add-on parts (engine code BCA)
- Removing and installing fuel filter
- Crash fuel shut-off
Checking fuel pump (vehicles ? model year 2006)5 pages
Checking fuel pump (vehicles model year 2006 ?)5 pages
- Bleeding fuel system
Electronic power control (EPC)3 pages
Activated charcoal filter system3 pages
Mixture preparation system, electronic inj.,Gas26 pages
Injection system14 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Assembly overview - intake manifold (engine code BCA)
- Assembly overview - intake manifold (engine codes BUD and CGGA)
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter housing (engine code BCA)
- Assembly overview - air filter housing (engine codes BUD and CGGA)
- Removing and installing air filter housing (engine codes BUD and CGGA)
- Cleaning throttle valve moduleJ338
Checking components9 pages
- Checking intake air preheater (only engine codes BCA)
Checking injectors for leaks and quantity injected (vehicles ? model year 2006)3 pages
Checking injectors for leaks and quantity injected (vehicles model year 2006 ?)3 pages
- Checking fuel pressure regulator and holding pressure
Exhaust system7 pages
Ignition system, glow plug system › Ignition system6 pages
4-cylinder injection engine (1.4 and 1.6 l direct injection)142 pages
Engine assy,cylinder block,crankcase › Removing and installing engine (Golf, Golf Plus)7 pages
Enginecrankshaft group, pistons39 pages
Dismantling and assembling engine9 pages
Sealing flange and flywheel or drive plate25 pages
- Assembly overview
- Removing and installing engine speed senderG28
- Renewing crankshaft oil seal - belt pulley end
- Poly V-belt pulley securing bolt tightening procedure
- Characteristics of the sealing flange and the assembly deviceT10017 and T10134
Renewing crankshaft sealing flange - flywheel end (assembly toolT10134)9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Renewing crankshaft sealing flange - flywheel end (assembly toolT10017)9 pages
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling sealing flange with sender wheel on assembly toolT10017
- B - Attaching assembling toolT10017 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10017 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10017
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Crankshaft dimensions
Dismantling and assembling pistons and conrods5 pages
Engine cylinder head, valve gear17 pages
Cylinder head11 pages
- Assembly overview
- Checking valve timing
- Adjusting valve timing
- Removing and installing timing chain and chain drive for oil pump (engine codes BAG, BLP, BLF)
- Removing and installing timing chain and chain drive for oil pump (engine codes BKG, BLN)
- Removing and installing cylinder head
- Checking compression
Engine lubrication › Removing and installing parts of lubrication system6 pages
Engine cooling › Removing and installing parts of cooling system10 pages
- Assembly overview - parts of cooling system, body side, radiator with two fans (Golf, Golf Plus)
- Assembly overview - parts of cooling system, body side, radiator with one fan (Golf, Golf Plus)
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator fanV7 and radiator fan 2V177
- Removing and installing radiator
- Removing and installing coolant pump
- Checking cooling system for leaks
Fuel supply, gas operation26 pages
- Rules for cleanliness
Fuel tank (Golf, Golf Plus)6 pages
Repairing fuel supply system (Golf, Golf Plus, Eos)10 pages
Electronic power control; EPC (Golf, Golf Plus, Passat, Eos)3 pages
Activated charcoal filter system (Golf, Golf Plus, Eos)3 pages
Mixture preparation system, electronic inj.,Gas21 pages
Injection system14 pages
- General notes on injection
- Technical data
- Assembly overview - air filter
- Removing and installing air filter
- Assembly overview - intake manifold (engine codes BAG, BKG)
- Assembly overview - intake manifold (engine codes BLF, BLN, BLP)
- Assembly overview - fuel rail with injectors
- Cleaning throttle valve moduleJ338
- Removing and installing high-pressure pump (engine codes BAG, BKG)
- Removing and installing high-pressure pump (engine codes BLF, BLN, BLP)
Engine control unitJ623 (Golf, Eos)3 pages
Exhaust system7 pages
Parts of exhaust system (Golf, Golf Plus, Touran)4 pages
Exhaust gas recirculation system3 pages
Ignition system, glow plug system › Repairing ignition system6 pages
4-cylinder diesel engine (1.9 l engine)194 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons36 pages
Dismantling and assembling engine7 pages
Removing and installing sealing flange and flywheel19 pages
- Assembly overview - sealing flanges and flywheel
- Removing and installing dual-mass flywheel
Renewing crankshaft sealing flange - flywheel end9 pages
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Removing and installing engine speed senderG28
Crankshaft4 pages
Assembly overview - crankshaft3 pages
Engine cylinder head, valve gear22 pages
Cylinder head10 pages
- Assembly overview - cylinder head
- Removing and installing cylinder head cover
Removing, installing and tensioning toothed belts3 pages
- Checking compression
Valve gear12 pages
Engine lubrication16 pages
Parts of lubrication system5 pages
Oil filter bracket, oil pressure, engine oil cooler and oil supply line8 pages
Engine cooling › Parts of cooling system20 pages
- Parts of cooling system, body side (radiator with two radiator fans)
- Removing and installing fan support with fans (Golf, Golf Plus, Touran)
- Parts of cooling system, engine side
- Coolant hose schematic diagram
Removing and installing radiator (Golf, Golf Plus, Touran)3 pages
- Checking engine oil cooler for leaks
Fuel supply, gas operation36 pages
Parts of fuel supply system (Golf, Golf Plus)22 pages
Fuel tank, vehicles with front-wheel drive3 pages
Fuel tank, vehicles with four-wheel drive5 pages
Emptying fuel tank3 pages
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender
- Removing and installing fuel cooler
Accelerator mechanism3 pages
Tandem pump7 pages
Exhaust turbocharger, G-charger › Charge air system with turbocharger18 pages
- Safety precautions
- Rules for cleanliness
- Removing and installing turbocharger
Assembly overview - parts of charge air cooling3 pages
- Checking charge air system for leaks
Vacuum hose schematic diagram3 pages
Fuel preparation system Diesel injection21 pages
Diesel direct injection system18 pages
- Safety precautions
- Rules for cleanliness
- Removing and installing pre-wired wiring harness for unit injectors and glow plugs
- Assembly overview - unit injector
- Adjusting non-contact gap of unit injectors
Assembly overview - intake manifold4 pages
- Cleaning the intake manifold flap support, Engine code BLS and BXJ
- Assembly overview - air filter
Engine control unit3 pages
Exhaust system13 pages
Exhaust system7 pages
- Assembly overview - front exhaust pipe with catalytic converter
- Assembly overview - front exhaust pipe with particulate filter
Assembly overview - silencer with mountings (vehicles with front wheel drive)2 pages
- Assembly overview - silencer with mountings (vehicles with four-wheel drive)
- Aligning exhaust system free of stress
Exhaust gas recirculation system6 pages
Assembly overview - parts of exhaust gas recirculation4 pages
- Checking mechanical exhaust gas recirculation valve
Ignition system, glow plug system › Checking glow plug system4 pages
4-cylinder injection engine (2.0 l engine, turbocharger)182 pages
Technical data2 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons26 pages
Dismantling and assembling engine7 pages
Sealing flange and flywheel or drive plate7 pages
Crankshaft6 pages
Pistons and conrods6 pages
Assembly overview - pistons and conrods3 pages
- Checking pistons, piston rings and cylinder bores
- Piston and cylinder dimensions
Engine cylinder head, valve gear24 pages
Cylinder head13 pages
- Assembly overview - cylinder head
- Removing and installing cylinder head cover
Removing and installing toothed belt, vehicles without split toothed belt guard3 pages
Removing and installing toothed belt, vehicles with split toothed belt guard3 pages
- Checking compression
Valve gear11 pages
Engine lubrication › Parts of lubrication system16 pages
- Engine oil
- Draining oil filter housing
- Removing and installing sump
Removing and installing oil pump with balancer shaft gear assembly4 pages
- Removing and installing oil filter bracket
- Removing and installing oil pressure switchF1
- Checking oil pressure and oil pressure switch (single pin oil pressure switch)
- Checking oil pressure and oil pressure switch (2-pin oil pressure switch)
Engine cooling › Parts of cooling system18 pages
- Assembly overview - parts of cooling system, engine side
- Assembly overview - coolant circulation pumpV50 (vehicles with bypass thermostat)
- Assembly overview - coolant circulation pumpV50 (vehicles with no bypass thermostat)
- Assembly overview - parts of cooling system, body side
- Coolant hose schematic diagram (vehicles to 06.2005)
- Coolant hose schematic diagram (vehicles from 06.2005)
- Bypass thermostat
- Removing and installing coolant pump
- Removing and installing coolant pipes
- Removing and installing coolant thermostat housing with thermostat
- Removing and installing radiator fanV7 and radiator fan 2V177
- Removing and installing radiator, Golf and Eos
Fuel supply, gas operation38 pages
- Rules for cleanliness
Fuel tank, Golf10 pages
Repairing fuel supply system, Golf, Eos9 pages
Electronic power control (EPC)4 pages
Activated charcoal filter system (Golf, Eos)11 pages
- Assembly overview - activated charcoal filter system (engine codes AXX, BWA)
- Checking fuel tank breather (engine codes AXX, BWA)
- Schematic diagram of activated charcoal filter system (engine code BPY)
- Assembly overview - activated charcoal filter system (Golf with engine code BPY)
- Removing and installing activated charcoal filter (engine code BPY)
- Removing and installing fuel system diagnostic pumpV144 (Golf with engine code BPY)
Checking fuel system for leaks4 pages
Exhaust turbocharger, G-charger17 pages
Mixture preparation system, electronic inj.,Gas24 pages
Injection system20 pages
- General notes on injection
- Technical data
- Assembly overview - engine cover/air filter
- Removing and installing engine cover/air filter
- Removing and installing air filter element
- Assembly overview - intake manifold
- Removing and installing intake manifold
- Removing and installing intake manifold flap motorV157 and intake manifold flap potentiometerG336
- Assembly overview - fuel rail (vehicles up to 05.2006)
- Assembly overview - fuel rail (vehicles from 05.2006)
- Removing and installing fuel rail
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Assembly overview - high-pressure pump
- Removing and installing high-pressure pump
- Removing and installing fuel pressure senderG247
- Checking fuel pressure senderG247
- Removing and installing injectors
- Renewing Teflon seal on injector
- Checking components
Engine control unitJ623, Golf, Eos3 pages
Exhaust system › Removing and installing parts of exhaust system6 pages
Ignition system, glow plug system › Repairing ignition system6 pages
4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)160 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons31 pages
Dismantling and assembling engine5 pages
Removing and installing sealing flange and flywheel14 pages
- Assembly overview - sealing flange and flywheel
- Renewing crankshaft oil seal - pulley end
- Removing and installing sealing flange - pulley end
Renewing crankshaft sealing flange - flywheel end10 pages
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling sealing flange with sender wheel on assembly appliance T10134
- B - Attaching assembly tool T10134 with sealing flange to crankshaft flange
- C - Bolting assembly tool T10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly tool T10134
- E - Checking sender wheel installation position on crankshaft
- F - Pressing sender wheel on fully
- Removing and installing engine speed sender G28
Pistons and conrods8 pages
Engine cylinder head, valve gear22 pages
Cylinder head10 pages
- Assembly overview - cylinder head
- Removing and installing cylinder head cover
Removing, installing and tensioning toothed belts3 pages
- Checking compression
Repairing valve gear12 pages
Engine lubrication9 pages
Parts of lubrication system3 pages
Oil filter bracket, oil pressure and oil cooler3 pages
Engine cooling › Parts of cooling system14 pages
Fuel supply, gas operation41 pages
- Safety precautions when working on the fuel supply system
- Rules for cleanliness
Fuel tank, vehicles with front wheel drive14 pages
Fuel tank, vehicles with four-wheel drive10 pages
Repairing fuel supply system15 pages
Exhaust turbocharger, G-charger › Charge air system with turbocharger9 pages
Fuel preparation system Diesel injection14 pages
Exhaust system9 pages
Parts of the exhaust system6 pages
- Assembly overview - front exhaust pipe with particulate filter
Assembly overview - silencer with mountings (vehicles with front wheel drive)2 pages
- Assembly overview - silencer with mountings (vehicles with four-wheel drive)
- Aligning exhaust system stress free
Exhaust gas recirculation system3 pages
Ignition system, glow plug system › Checking glow plug system3 pages
4-cylinder injection engine (2.0 l engine, direct injection)193 pages
Technical data2 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons33 pages
Cylinder block attachments, engine codes BLX, BLY, BLR, BVX, BVY, BVZ7 pages
Assembly overview - cylinder block attachments5 pages
- Removing and installing poly V-belt
Sealing flange and flywheel or drive plate9 pages
- Assembly overview - sealing flanges
- Renewing crankshaft oil seal - pulley end
- Removing and installing sealing flange - pulley end
Removing and installing crankshaft sealing flange - flywheel end3 pages
- Removing and installing flywheel
- Removing and installing drive plate
Crankshaft5 pages
Engine cylinder head, valve gear31 pages
Cylinder head16 pages
- Assembly overview - cylinder head
- Removing and installing cylinder head cover
Removing and installing toothed belt, engine code AXW3 pages
Removing and installing toothed belt, Golf without split toothed belt guard (BLR, BLX, BLY, BVX, BVY, BVZ)3 pages
Removing and installing toothed belt, Golf with split toothed belt guard (BVX, BVY, BVZ)3 pages
- Checking compression
Valve gear15 pages
Engine lubrication › Parts of lubrication system15 pages
- Engine oil
Assembly overview - parts of lubrication system4 pages
- Draining oil filter housing
- Removing and installing sump, engine codes AXW, BLX, BLY, BLR
- Removing and installing sump, engine codes BVX, BVY, BVZ
Removing and installing oil pump with balancer shaft gear assembly4 pages
- Removing and installing oil filter bracket
- Checking oil pressure and oil pressure switch
Engine cooling › Parts of cooling system20 pages
- Assembly overview - parts of cooling system, engine side, engine codes AXW, BLX, BLY, BLR
- Assembly overview - parts of cooling system, engine side, engine codes BVX, BVY, BVZ
- Assembly overview - parts of cooling system, body side
- Coolant hose schematic diagram, engine codes AXW, BLX, BLY, BLR
- Coolant hose schematic diagram, engine codes BVX, BVY, BVZ
- Removing and installing coolant pump
- Removing and installing coolant pipe
Mapped cooling, engine codes AXW, BLX, BLY, BLR4 pages
- Removing and installing coolant distributor housing with thermostat, engine codes BVX, BVY, BVZ
- Removing and installing radiator fan V7 and radiator fan 2 V177
- Removing and installing radiator
Fuel supply, gas operation42 pages
Fuel tank (Golf with front-wheel drive)8 pages
Fuel tank (Golf with four-wheel drive)12 pages
Repairing fuel supply system (Golf)11 pages
- Rules for cleanliness
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge sender G
Checking fuel pump G67 pages
Electronic power control (EPC)4 pages
Activated charcoal filter system (Golf)4 pages
Mixture preparation system, electronic inj.,Gas24 pages
Injection system22 pages
- General notes on injection
- Rules for cleanliness
- Technical data
Assembly overview - fuel rail with intake manifold flap motor V157 , engine code AXW3 pages
- Assembly overview - fuel rail with intake manifold flap motor V157 , engine codes BLR, BLX, BLY
- Assembly overview - fuel rail with intake manifold flap motor V157 , engine codes BVX, BVY, BVZ
- Assembly overview - air filter
- Removing and installing intake manifold
- Removing and installing fuel rail with intake manifold flaps
- Assembly overview - high-pressure pump, engine code AXW
- Assembly overview - high-pressure pump, engine codes BLR, BLX, BLY, BVX, BVY, BVZ
- Removing and installing high-pressure pump
- Removing and installing fuel pressure sender G247
- Checking fuel pressure sender G247
- Removing and installing injectors
- Renewing Teflon seal on injector
- Cleaning throttle valve module J338
- Engine control unit J623 (Golf)
- Checking components
Exhaust system15 pages
Parts of exhaust system13 pages
- Assembly overview - exhaust manifold with catalytic converter, engine codes AXW, BLX, BLR, BVX
- Assembly overview - exhaust manifold with catalytic converter, engine code BVY
- Assembly overview - exhaust manifold, engine codes BLY, BVZ
- Removing and installing exhaust manifold
- Assembly overview - exhaust system, engine codes BLR, BVY
- Assembly overview - exhaust system, engine codes AXW, BLX
- Assembly overview - exhaust system, engine codes BLY, BVZ
- Assembly overview - exhaust system, Golf with four-wheel drive
- Removing and installing front exhaust pipe with catalytic converter
- Separating centre and rear silencers
- Aligning exhaust system free of stress
- Installation position and specified torque of clamp
Exhaust gas recirculation system, engine codes AXW, BLX, BLR, BVX, BVY2 pages
Ignition system, glow plug system › Repairing ignition system6 pages
4-cylinder diesel engine (2.0 l engine, 2-valve, SDI)155 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons32 pages
Dismantling and assembling engine5 pages
Removing and installing sealing flange and flywheel18 pages
- Assembly overview - sealing flange and flywheel
Renewing crankshaft sealing flange - flywheel end10 pages
- Pressing out sealing flange with sender wheel
- Pressing in sealing flange with sender wheel
- A - Assembling sealing flange with sender wheel on assembly appliance T10134
- B - Attaching assembling tool T10134 with sealing flange to crankshaft flange
- C - Bolting assembly tool T10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly tool T10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
- Removing and installing engine speed sender G28
Pistons and conrods6 pages
Engine cylinder head, valve gear24 pages
Cylinder head12 pages
- Assembly overview - cylinder head
Removing, installing and tensioning toothed belts3 pages
- Checking compression
Repairing valve gear12 pages
Engine lubrication12 pages
Parts of lubrication system5 pages
Oil filter bracket, oil cooler and oil pressure3 pages
Engine cooling › Parts of cooling system21 pages
Fuel supply, gas operation › Removing and installing parts of fuel supply system29 pages
Fuel preparation system Diesel injection18 pages
Repairing diesel direct injection system12 pages
Engine control unit6 pages
Exhaust system9 pages
Removing and installing parts of exhaust system5 pages
- Assembly overview - exhaust manifold with catalytic converter and front exhaust pipe
Assembly overview - silencer with mountings3 pages
Exhaust gas recirculation system4 pages
4-cylinder injection engine, 2005?127 pages
Engine assy,cylinder block,crankcase › Removing and installing engine5 pages
Enginecrankshaft group, pistons16 pages
Dismantling and assembling engine7 pages
Dismantling and assembling pistons and conrods6 pages
Assembly overview - pistons and conrods3 pages
- Checking pistons, piston rings and cylinder bores
- Piston and cylinder dimensions
Engine cylinder head, valve gear21 pages
Removing and installing cylinder head9 pages
Repairing valve gear12 pages
Engine lubrication › Removing and installing parts of the lubrication system8 pages
Engine cooling › Removing and installing parts of cooling system12 pages
Fuel supply, gas operation29 pages
Repairing fuel supply13 pages
Checking electronic power control (EPC)4 pages
Active charcoal filter system4 pages
Mixture preparation system, electronic inj.,Gas23 pages
Repairing injection system18 pages
- General notes on injection
- Safety precautions
- Rules for cleanliness
- Technical data
- Dismantling and assembling intake manifold - Upper part
- Dismantling and assembling intake manifold - lower part
- Fuel rail
- Dismantling and assembling air cleaner
- Removing and installing intake manifold
- Renewing Teflon seal on injector
- Cleaning throttle valve module J338
Engine control unit5 pages
Exhaust system › Removing and installing parts of exhaust system5 pages
Ignition system, glow plug system › Repairing ignition system5 pages
4-cylinder injection engine (1.4 l direct injection engine, turbocharger)147 pages
Engine assy,cylinder block,crankcase › Removing and installing engine (Golf, Golf Plus, Eos, Scirocco)7 pages
Enginecrankshaft group, pistons34 pages
Dismantling and assembling engine10 pages
- Assembly overview - parts l and ll
- Assembly overview - part I, belt drive
- Assembly overview - part II, cylinder block
Removing and installing valve timing housing (Golf, Golf Plus, Golf Cabriolet, Eos, Scirocco)3 pages
- Removing and installing ancillary bracket
Removing and installing sealing flanges and flywheel or drive plate14 pages
- Assembly overview
- Removing and installing engine speed senderG28
- Renewing crankshaft oil seal - belt pulley end
- Removing and installing crankshaft pulley
Renewing crankshaft sealing flange - flywheel end9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Dismantling and assembling pistons and conrods6 pages
Engine cylinder head, valve gear16 pages
Engine lubrication › Removing and installing parts of lubrication system7 pages
Engine cooling › Removing and installing parts of cooling system10 pages
- Assembly overview - parts of cooling system, body side
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram
- Draining and filling coolant
- Removing and installing radiator fanV7 and radiator fan 2V177 (Golf, Golf Plus, Golf Cabriolet, Eos, Scirocco)
- Checking cooling system for leaks
- Removing and installing radiator (Golf, Golf Plus, Golf Cabriolet, Scirocco, Eos)
- Removing and installing coolant pump
- Removing and installing coolant circulation pumpV50
Fuel supply, gas operation28 pages
- Separating push-on couplings
Fuel tank (Golf, Golf Plus, Golf Cabriolet, Scirocco)6 pages
Repairing fuel supply system (Golf, Golf Plus, Golf Cabriolet, Scirocco, Eos)11 pages
Repairing electronic power control (EPC)3 pages
Activated charcoal filter system (Golf, Golf Plus, Golf Cabriolet, Eos, Scirocco)4 pages
Exhaust turbocharger, G-charger11 pages
Mixture preparation system, electronic inj.,Gas21 pages
Injection system18 pages
- Assembly overview - parts l and II, intake manifold
- Assembly overview - part I, intake manifold
- Assembly overview - part II, intake manifold
- Assembly overview - fuel rail with injectors
- Assembly overview - air filter
- Removing and installing air filter
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Removing and installing intake manifold
- Assembly overview - high-pressure pump
- Checking fuel pressure senderG247
- Removing and installing high-pressure pump
- Removing and installing injectors
- Renewing Teflon seal and support washer on injector
- Safety precautions
- Rules for cleanliness
- Technical data
Exhaust system › Removing and installing parts of exhaust system5 pages
Ignition system, glow plug system › Repairing ignition system5 pages
4-cylinder injection engine (1.8 and 2.0 l engine, chain drive)207 pages
Technical data2 pages
Engine assy,cylinder block,crankcase9 pages
Removing and installing engine5 pages
Enginecrankshaft group, pistons22 pages
Crankshaft11 pages
Engine cylinder head, valve gear26 pages
Chain drive14 pages
- Assembly overview - timing chain covers
- Removing and installing inlet camshaft control valve 1N205
- Removing and installing upper timing chain cover
- Removing and installing lower timing chain cover (Golf, Eos, Scirocco)
- Renewing oil seal for vibration damper
- Camshaft timing chain - exploded view
- Removing and installing camshaft timing chain
- Assembly overview - balancer shaft timing chain
- Removing and installing balancer shaft module
- Removing and installing inlet side balancer shaft
- Removing and installing exhaust side balancer shaft
Engine lubrication18 pages
Sump and oil pump7 pages
- Engine oil
Oil filter, engine oil cooler and oil pressure switch (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA)4 pages
Oil filter, engine oil cooler and oil pressure switch (engine codes CCZA, CCZB, CCZC, CCZD, CDAA, CDAB)6 pages
Engine cooling22 pages
Coolant pump, thermostat, coolant pipes12 pages
- Coolant pump and thermostat - exploded view
- Removing and installing coolant pump
- Removing and installing toothed belt for coolant pump
- Renewing oil seal for coolant pump drive
- Removing and installing thermostat
- Removing and installing coolant temperature senderG62
- Assembly overview - coolant pipes
- Removing and installing coolant pipes (front)
- Removing and installing small coolant pipe
- Continued coolant circulation pumpV51 - exploded view
- Removing and installing continued coolant circulation pumpV51
Radiator and radiator fans6 pages
Assembly overview - radiator, fan cowl and radiator fan (Passat, CC, Golf, Eos, Scirocco)2 pages
- Removing and installing radiator cowl
- Removing and installing radiator fanV7 and radiator fan 2V177
- Removing and installing radiator (Passat, CC, Golf, Eos, Scirocco)
Fuel supply, gas operation40 pages
- Rules for cleanliness
Fuel tank (Golf, Scirocco)9 pages
- Assembly overview - fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA)
- Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB)
Draining fuel tank (engine codes BZB, CAWA, CAWB, CGYA, CCZA, CCZB, CDAA)4 pages
- Emptying fuel tank (engine codes CBFA, CCTA, CCTB)
- Removing and installing fuel tank
Repairing fuel supply system (Golf, Eos, Scirocco)11 pages
- Removing and installing fuel delivery unit
- Removing and installing fuel gauge senderG
Checking fuel pumpG68 pages
- Checking function and voltage supply
- Checking fuel pressure
- Checking fuel pressure when the engine is running (engine codes CCZA, CCZB, CDAA, CDAB)
- Checking holding pressure
- Checking fuel delivery rate (engine codes CAWA, CAWB, CBFA, CCTA, CCTB, BZB, CGYA)
- Checking fuel delivery rate (engine codes CCZA, CCZB, CDAA, CDAB)
- Checking current draw
Electronic power control (EPC)3 pages
Activated charcoal filter system (Golf, Eos, Scirocco with engine codes CAWA, CAWB, BZB, CGYA, CCZA, CCZB, CDAA)3 pages
Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB)9 pages
Exhaust turbocharger, G-charger20 pages
Turbocharger13 pages
Charge air system7 pages
Mixture preparation system, electronic inj.,Gas27 pages
Injection system19 pages
- Technical data
- Overview of fitting locations
- Assembly overview - air filter
- Removing and installing air filter
- Removing and installing air filter element
- Removing and installing air mass meterG70
- Assembly overview - intake manifold
- Fuel rail - exploded view
Removing and installing intake manifold with fuel rail2 pages
- Removing and installing injectors
- Renewing Teflon seal on injector
- Cleaning injectors
- Removing and installing fuel pressure senderG247
- Removing and installing throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Assembly overview - high-pressure pump with fuel pressure regulating valveN276
- Removing and installing high-pressure pump
Checking components3 pages
Engine control unitJ623 (Golf, Eos to 11/08)3 pages
Exhaust system13 pages
Exhaust system (Golf, Eos, Scirocco)9 pages
- Assembly overview - exhaust system (engine code CAWB)
- Assembly overview - exhaust system (Golf 2004 ?, Eos, Scirocco, engine codes CCTA, CCZA, CCZB)
- Assembly overview - exhaust system (engine code CBFA)
- Separating centre and rear silencers
- Aligning exhaust system free of stress
- Installation position and specified torque of clamp
- Removing and installing catalytic converters with front exhaust pipe
- Checking exhaust system for leaks
Secondary air system - engine code CBFA4 pages
Ignition system, glow plug system › Repairing ignition system8 pages
4-cylinder injection engine (1.4 l direct injection engine, turbocharger and supercharger)150 pages
Engine assy,cylinder block,crankcase › Removing and installing engine (Golf, Golf Plus, Touran)7 pages
Enginecrankshaft group, pistons34 pages
Dismantling and assembling engine10 pages
Removing and installing sealing flanges and flywheel or drive plate14 pages
- Assembly overview
- Removing and installing engine speed senderG28
- Removing and installing crankshaft seal on belt pulley end
- Removing and installing crankshaft pulley
Removing and installing crankshaft sealing flange on flywheel end9 pages
- Pressing sealing flange with sender wheel off crankshaft
- Pressing sealing flange with sender wheel onto crankshaft
- A - Assembling seal with sender wheel on assembly toolT10134
- B - Attaching assembling toolT10134 with sealing flange on crankshaft flange
- C - Bolting assembly toolT10134 onto crankshaft flange
- D - Pressing sender wheel onto crankshaft flange using assembly toolT10134
- E - Checking sender wheel installation position on crankshaft
- F - Re-pressing sender wheel
Dismantling and assembling pistons and conrods6 pages
Engine cylinder head, valve gear16 pages
Engine lubrication › Removing and installing parts of lubrication system6 pages
Engine cooling › Removing and installing parts of cooling system11 pages
- Assembly overview - parts of cooling system, body side (engine codes BLG, BMY)
- Assembly overview - parts of cooling system, engine side
- Coolant hose schematic diagram (engine codes BLG, BMY)
- Draining and filling coolant
- Checking cooling system for leaks
- Removing and installing radiator fanV7 and radiator fan 2V177 (engine codes BLG, BMY)
- Removing and installing radiator (engine codes BLG, BMY)
- Removing and installing coolant pump
- Removing and installing coolant pump pulley
- Removing and installing coolant circulation pumpV50
Fuel supply, gas operation26 pages
Fuel tank6 pages
Removing and installing parts of fuel supply system11 pages
- Rules for cleanliness
- Crash fuel shut-off
- Removing and installing fuel delivery unit (Golf, Golf Plus)
- Removing and installing fuel gauge sender G (Golf, Golf Plus)
Checking fuel pumps (Golf, Golf Plus)6 pages
Repairing electronic power control (EPC)3 pages
Activated charcoal filter system3 pages
Exhaust turbocharger, G-charger16 pages
Mixture preparation system, electronic inj.,Gas21 pages
Injection system18 pages
- Assembly overview - parts l and II, intake manifold
- Assembly overview - part I, intake manifold
- Assembly overview - part II, intake manifold
- Assembly overview - fuel rail with injectors
- Checking vacuum reservoir for leaks
- Assembly overview - air filter
- Removing and installing air filter
- Removing and installing regulating flap control unitJ808 and throttle valve moduleJ338
- Cleaning throttle valve moduleJ338
- Assembly overview - high-pressure pump
- Checking fuel pressure in high-pressure section
- Removing and installing high-pressure pump
- Removing and installing injectors
- Renewing Teflon seal and support washer on injector
- Safety precautions
- Rules for cleanliness
- Technical data
Exhaust system › Removing and installing parts of exhaust system4 pages
Ignition system, glow plug system › Repairing ignition system6 pages
4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH14 pages
- Engine cooling › Parts of cooling system
Fuel supply, gas operation › Fuel tank (front-wheel drive)7 pages
Exhaust turbocharger, G-charger2 pages
Mixture preparation system, electronic inj.,Gas › Engine control unitJ623 (Golf 2004 ?)3 pages
- Exhaust system › Exhaust system
6-cylinder injection engine Volkswagen R GmbH14 pages
Fuel supply, gas operation › Fuel tank9 pages
- Mixture preparation system, electronic inj.,Gas › Repairing injection system
Exhaust system › Silencer with mountings4 pages
Fuel supply system - Petrol engines56 pages
Technical data6 pages
Fuel supply, gas operation50 pages
Fuel tank (front-wheel drive)11 pages
Assembly overview - fuel tank3 pages
Removing and installing fuel tank3 pages
Fuel delivery unit, fuel gauge sender3 pages
- Detaching push-on connectors
Fuel filter5 pages
Activated charcoal filter system16 pages
Assembly overview - activated charcoal filter system3 pages
Removing and installing activated charcoal filter2 pages
Checking fuel tank breather2 pages
Checking fuel system for leaks4 pages
Overview of activated charcoal filter system2 pages
Removing and installing fuel system diagnosis pump2 pages
Accelerator mechanism3 pages
Fuel pump11 pages
Checking fuel pump10 pages
- Checking function and voltage supply (engine codes CAVA, CAVB, CAVC, CAVD)
- Checking function and voltage supply (engine codes CBTA, CBUA, BGP, BGQ)
- Checking fuel pressure (engine codes CAVA, CAVB, CAVC, CAVD)
- Checking holding pressure (engine codes CAVA, CAVB, CAVC, CAVD)
- Checking fuel delivery rate (engine codes CAVA, CAVB, CAVC, CAVD)
- Checking fuel delivery rate (engine codes CBTA, CBUA, BGP, BGQ)
- Checking current draw
- Checking fuel pressure regulator and holding pressure (engine codes CBTA, CBUA, BGP, BGQ)
- Checking fuel pump non-return valve (engine codes CBTA, CBUA, BGP, BGQ)