volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Engine codes: BGP, BGQ, BTK, CBTA and CBUA > < Engine codes: BAG, BKG, BLF, BLN, BLP and CAXA

Golf Mk5

Engine codes: AXW, AXX, BGU, BHY, BLR, BLX, BLY, BPY, BSE, BSF, BVX, BVY, BVZ, BWA, BYD, CAWB, CBFA and CCTA
Engine codes: AXW, AXX, BGU, BHY, BLR, BLX, BLY, BPY, BSE, BSF, BVX, BVY, BVZ, BWA, BYD, CAWB, CBFA and CCTA
Special tools and workshop equipment required
   
t  Torque wrench -V.A.G 1331- (5…50 Nm)
  Note
t  The ancillary bracket for air conditioner compressor and related components can be removed and installed without the refrigerant circuit being opened.
t  To remove poly V-belt: → Engine; Rep. gr.13
t  Poly V-belt routing → Fig.
  W00-0427
1 - Socket head flange bolt M10×45
q   Dowel hole
q   Observe different torques:
q   1.6 l injection engine and 2.0 l FSI engine: 52 Nm
q   2.0 l turbo FSI engine: 40 Nm
2 - Socket head flange bolt M10×45
q   Observe different torques:
q   1.6 l injection engine and 2.0 l FSI engine: 52 Nm
q   2.0 l turbo FSI engine: 40 Nm
3 - Socket head flange bolt M10×45
q   Observe different torques:
q   1.6 l injection engine and 2.0 l FSI engine: 52 Nm
q   2.0 l turbo FSI engine: 40 Nm
4 - Socket head flange bolt M10×45
q   Observe different torques:
q   1.6 l injection engine and 2.0 l FSI engine: 52 Nm
q   2.0 l turbo FSI engine: 40 Nm
5 - Air conditioner compressor
q   Removing and installing → Chapter
6 - Hexagon bolt M8x100
q   Qty. 3
q   25 Nm.
7 - Socket head flange bolt M10×45
q   Dowel hole
q   Observe different torques:
q   1.6 l injection engine and 2.0 l FSI engine: 52 Nm
q   2.0 l turbo FSI engine: 40 Nm
8 - Socket head flange bolt M10×45
q   Observe different torques:
q   1.6 l injection engine and 2.0 l FSI engine: 52 Nm
q   2.0 l turbo FSI engine: 40 Nm
9 - Dowel sleeves
q   Qty. 2
q   Ensure proper seating between ancillary bracket and air conditioner compressor.
10 - Ancillary bracket for air conditioner compressor
Number on ancillary bracket -06F 903 143 E/F-
Removing
–  Remove alternator → Electrical system; Rep. gr.27.
–  Loosen air conditioner compressor and remove hexagon bolt -6-. Remove air conditioner compressor from ancillary bracket and secure to body with suitable material (e.g.welding wire) → Fig..
–  Remove bolts -1- to -4-, -7- and -8- and remove ancillary bracket -10- from cylinder block.
Installing
t  Strictly observe tightening sequence of securing bolts:
–  Tighten socket head flange bolts, positions -1- (dowel hole), -7- (dowel hole), -4-, -8-, -3- and -2- one after the other.

   
Securing air conditioner compressor to body
If compressor is removed without opening refrigerant circuit, it should be secured to body using suitable material, for example, welding wire.
When doing this, ensure that refrigerant hoses on air conditioner compressor are not strained.
  N87-0382
Poly V-belt routing
1 - Tensioning roller
2 - Poly V-belt pulley for alternator
3 - Poly V-belt pulley for air conditioner compressor
4 - Poly V-belt
5 - Poly V-belt pulley for crankshaft
  Note
t  When installing poly V-belt, ensure that it is correctly seated on poly V-belt pulley.
t  Finally, place poly V-belt over pulley of air conditioner compressor.
  N27-10141

Engine codes: BGP, BGQ, BTK, CBTA and CBUA > < Engine codes: BAG, BKG, BLF, BLN, BLP and CAXA