Volkswagen Workshop Service and Repair Manuals

Procedures for Golf, Golf Plus, Touran –  Read fault memories of all control units before removal → Diagnosis tester VAS 5051; Guided fault finding; Vehicle system test or VAS 5052; Vehicle self-diagnosis. –  With ignition switched off, disconnect earth strap from battery. → Electrical system; Rep. gr.27.

–  Remove engine cover. To do this, pull engine cover upwards abruptly at front and right -arrows A- and then pull forwards out of rear fastening -arrow B-. –  Remove plenum chamber bulkhead. → General body repairs, exterior; Rep. gr.50.

–  Remove air filter housing with air mass meter and connecting pipe. Remove bolt -arrow A- and pull air filter housing upwards out of mounting. –  Remove battery and battery tray. –  Remove insulation tray → General body repairs, exterior; Rep. gr.50. –  Bring lock carrier into service position → General body repairs; Rep. gr.50. –  Drain coolant → Chapter   WARNING t  The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! t  The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! t  Wear eye and hand protection when performing any type of repair work on the fuel system! –  Disconnect fuel supply and return lines as well as coolant line on cylinder head. –  Pull fuel filter module upwards out of bracket and lay it with hoses to side. Vehicles with air conditioner   Note To prevent damage to condenser and also to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent. To facilitate removing and installing engine without opening refrigerant circuit: –  Remove poly V-belt → Chapter. –  Separate air conditioner compressor from compact bracket. → Heating, air conditioning; Rep. gr.87. –  Secure air conditioner compressor to lock carrier so that refrigerant lines are relieved. Continuation for all vehicles –  Remove exhaust pipe and coolant hoses from supplementary heater. –  Remove connecting pipes between charge air cooler and engine. –  Pull retainer for wiring harness of oil level and oil temperature sender -G266- off subframe. –  Remove right drive shaft and unscrew left drive shaft from gearbox → Running gear, axles, steering; Rep. gr.40. –  Remove left wheel housing liner. –  Disconnect front exhaust pipe from turbocharger, loosen double clamp and slide exhaust pipe back → Chapter. –  Pull engine wiring harness connector off control unit:    Golf → Chapter    Golf Plus, Touran → Chapter

–  Open cable guide catches on longitudinal member -arrows-. –  Remove wiring harness from cable guide and lay to side on engine.

For engine code BMN: –  Separate connections at engine bulkhead for: t  -1-Exhaust gas temperature sender 2 -G448- t  -2-Temperature sender after particulate filter -G527- t  -3-Exhaust gas temperature sender 1 -G235- t  -4-Lambda probe -G39- t  -5-Charge pressure control solenoid valve -N75- Continuation for all vehicles –  Pull off or disconnect all other electrical connections from engine and gearbox as necessary and lay to side. –  Separate all connecting, coolant, vacuum and intake hoses from engine. For engine code BMN: –  Release connecting clamp for front exhaust pipe/front silencer. –  Remove subframe and steering → Running gear, axles, steering; Rep. gr.40.   Note The engine is lowered downwards with particulate filter fitted. Engine codes AZV, BKD: –  Disconnect front exhaust pipe from turbocharger, loosen double clamp and slide exhaust pipe back → Chapter. Continuation for all vehicles: –  Disconnect selector mechanism from gearbox → 6-speed manual gearbox 02Q; Rep. gr.34. –  Separate pressure line for hydraulic clutch control. –  Remove pendulum support.

–  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. The threaded support pin must be on the gearbox side. –  Fit engine bracket -T10012- to cylinder block with M10 x 25/ 8.8 bolt and tighten to approx. 40 Nm. –  Lift engine and gearbox lightly using engine and gearbox jack -V.A.G 1383/A-.

–  Unbolt engine side of assembly mounting from engine support from above -arrows-.

–  Unbolt gearbox side of assembly mounting from gearbox bracket from above -arrows-.   Note t  To remove securing bolts, use stepladder VAS 5085. t  Engine with gearbox must be guided carefully when lowered to prevent damage to bodywork. –  Carefully lower engine with gearbox.