Golf L4-1.8L Turbo (AWW) (2003): Engine, Cooling and Exhaust

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 L4-1.9L 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 Mk5, Golf Mk6.

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1. 01Relays and ModulesRelays and Modules: Sections
2. 02Sensors and SwitchesSensors and Switches: Sections
3. 03MaintenanceMaintenance: Sections
4. 04Engine, Cooling and ExhaustEngine, Cooling and Exhaust: Sections
   • Engine344 pages

     • Actuators and Solenoids - Engine › Camshaft Adjuster/Chain Tensioner <--> [Variable Valve Timing Actuator] › Component Information17 pages

       • Technical Service Bulletins › Engine - Rattling Noise On Start Up (Normal Condition)
       • Diagrams › Diagram Information and Instructions23456789101112
       • Testing and Inspection › With Generic Scan Tool234
     • Compression Check › System Information › Specifications23
     • Camshaft, Lifters and Push Rods31 pages

       • Camshaft Bearing › Component Information › Service Precautions
       • Camshaft Gear/Sprocket › Component Information › Specifications2
       • Camshaft, Engine › Component Information › Service Precautions23456789
       • Lifter / Lash Adjuster, Valve › Component Information › Service Precautions2
       • Camshaft Adjuster/Chain Tensioner <--> [Variable Valve Timing Actuator] › Component Information17 pages

         • Technical Service Bulletins › Engine - Rattling Noise On Start Up (Normal Condition)
         • Diagrams › Diagram Information and Instructions23456789101112
         • Testing and Inspection › With Generic Scan Tool234
     • Cylinder Block Assembly34 pages

       • Connecting Rod Bearing › Component Information5 pages

         • Specifications › Rod Bearing Cap Torque2
         • Service and Repair › Pistons and Connecting Rods, Assembly Overview23
       • Connecting Rod, Engine › Component Information5 pages

         • Specifications › Rod Bearing Cap Torque2
         • Service and Repair › Bearing Shells, Installation Position23
       • Crankshaft Gear/Sprocket › Component Information › Specifications
       • Crankshaft Main Bearing › Component Information › Specifications › Main Bearing Clearance, Standard & Limit234
       • Crankshaft, Engine › Component Information8 pages

         • Specifications › Crankshaft Journal Diameter & Limits234
         • Tools and Equipment › Crank Sprocket Lock - AST Tool # 3099234
       • Sealing Flange, Engine Front <--> [Front Engine Plate] › Component Information › Service and Repair23
       • Harmonic Balancer - Crankshaft Pulley › Component Information › Specifications
       • Piston, Engine › Component Information5 pages

         • Locations2
         • Testing and Inspection › Checking Ring to Groove Clearance23
       • Piston Ring, Engine › Component Information › Testing and Inspection › Piston Ring Gap, Checking2
     • Cylinder Head Assembly16 pages

       • Valve Clearance › System Information › Specifications
       • Fuel Pressure Release › System Information › Service Precautions
       • Valve Cover › Valve Cover Gasket › Component Information › Technical Service Bulletins6 pages

         • Customer Interest for Valve Cover Gasket: › 1505-01 › Nov › 05 › Engine - Upper Engine Oil Leak Diagnostic Guidelines23
         • All Technical Service Bulletins for Valve Cover Gasket: › 1505-01 › Nov › 05 › Engine - Upper Engine Oil Leak Diagnostic Guidelines23
       • Valve Guide › Component Information › Testing and Inspection
       • Valve Seat › Component Information › Service and Repair2
       • Valve Spring › Component Information › Tools and Equipment › Valve Spring Comp. Support - AST Tool # 20362345
     • Drive Belts, Mounts, Brackets and Accessories4 pages

       • Ribbed Belt <--> [Drive Belt] › Component Information › Diagrams › With Power Steering Pump and A/C Compressor2
       • Engine Mount › Component Information › Service and Repair2
     • Engine Lubrication92 pages

       • Engine Oil Pressure › Component Information › Specifications23
       • Engine Oil Drain Plug › Component Information › Technical Service Bulletins › Engine - Oil Drain Plug Thread Cleaning2
       • Engine Oil › Component Information24 pages

         • Technical Service Bulletins › Engine - Measurement Of Oil Consumption2345678910111213141516171819
         • Specifications › Capacity Specifications2
         • Service and Repair › Checking / Adding Engine Oil23
       • Oil Cooler, Engine › Component Information › Service and Repair2
       • Oil Filter, Engine › Component Information › Locations23
       • Oil Filter Housing › Component Information › Locations › Lubrication System Components23456
       • Oil Pan, Engine › Component Information › Technical Service Bulletins › Engine - Hybrid Oil Pan Information2
       • Oil Pressure Sender › Component Information12 pages

         • Locations
         • Diagrams › Diagram Information and Instructions234567891011
       • Oil Pressure Warning Lamp/Indicator › Component Information › Diagrams › Diagram Information and Instructions234567891011
       • Oil Pick Up/Strainer › Component Information14 pages

         • Locations › Crankshaft, Assembly Overview234567
         • Service and Repair › Crankshaft, Assembly Overview234567
       • Oil Pump, Engine › Engine Oil Pressure › Component Information › Specifications23
       • Oil Spray Jet › Component Information › Locations2345678
       • Oil Temperature Sensor/Switch, Engine › Component Information › Service and Repair2
     • Intake Manifold › Component Information › Specifications › Intake Manifold Torque2
     • Lamps and Indicators - Engine › Oil Pressure Warning Lamp/Indicator › Component Information › Diagrams › Diagram Information and Instructions234567891011
     • Seals and Gaskets, Engine30 pages

       • Camshaft Housing Gasket › Component Information › Technical Service Bulletins6 pages

         • All Technical Service Bulletins for Camshaft Housing Gasket: › 1505-01 › Nov › 05 › Engine - Upper Engine Oil Leak Diagnostic Guidelines23
         • Customer Interest for Camshaft Housing Gasket: › 1505-01 › Nov › 05 › Engine - Upper Engine Oil Leak Diagnostic Guidelines23
       • Camshaft Oil Seal › Component Information › Technical Service Bulletins6 pages

         • All Technical Service Bulletins for Camshaft Oil Seal: › 1505-01 › Nov › 05 › Engine - Upper Engine Oil Leak Diagnostic Guidelines23
         • Customer Interest for Camshaft Oil Seal: › 1505-01 › Nov › 05 › Engine - Upper Engine Oil Leak Diagnostic Guidelines23
       • Crankshaft Main Bearing Seal › Component Information › Locations234
       • Front Crankshaft Seal › Component Information › Service and Repair23
       • Valve Cover Gasket › Component Information › Technical Service Bulletins6 pages

         • Customer Interest for Valve Cover Gasket: › 1505-01 › Nov › 05 › Engine - Upper Engine Oil Leak Diagnostic Guidelines23
         • All Technical Service Bulletins for Valve Cover Gasket: › 1505-01 › Nov › 05 › Engine - Upper Engine Oil Leak Diagnostic Guidelines23
       • Valve Guide Seal › Component Information5 pages

         • Service and Repair23
         • Tools and Equipment › Valve Seal Remover - AST Tool # 33642
     • Sensors and Switches - Engine25 pages

       • Oil Pressure Sender › Component Information12 pages

         • Locations
         • Diagrams › Diagram Information and Instructions234567891011
       • Oil Temperature Sensor/Switch, Engine › Component Information › Service and Repair2
       • Variable Valve Timing Actuator Position Sensor › Component Information › Diagrams › Diagram Information and Instructions234567891011
     • Timing Components50 pages

       • Camshaft Gear/Sprocket › Component Information › Specifications2
       • Crankshaft Gear/Sprocket › Component Information › Specifications
       • Timing Belt › Component Information › Service and Repair › Procedures234567
       • Timing Belt Tensioner › Component Information5 pages

         • Specifications
         • Tools and Equipment › 1.8T Tensioner Holder Set - AST Tool # 6700234
       • Timing Chain › Component Information › Service Precautions234
       • Timing Chain Tensioner › Component Information › Technical Service Bulletins › Engine - Rattling Noise On Start Up (Normal Condition)
       • Timing Component Alignment Marks › Component Information › Locations › Timing Chain Alignment Marks
       • Timing Cover › Component Information › Specifications
       • Variable Valve Timing28 pages

         • Camshaft Adjuster/Chain Tensioner <--> [Variable Valve Timing Actuator] › Component Information17 pages

           • Technical Service Bulletins › Engine - Rattling Noise On Start Up (Normal Condition)
           • Diagrams › Diagram Information and Instructions23456789101112
           • Testing and Inspection › With Generic Scan Tool234
         • Variable Valve Timing Actuator Position Sensor › Component Information › Diagrams › Diagram Information and Instructions234567891011
     • Tune-up and Engine Performance Checks22 pages

       • Fuel Pressure › System Information › Specifications › System Pressure2
       • Idle Speed › System Information › Specifications2345
       • Air Cleaner Housing › Component Information › Locations23
       • Fuel Filter › Fuel Pressure Release › System Information › Service Precautions
       • Ignition Timing › Number One Cylinder › Component Information › Locations
       • Spark Plug › Component Information6 pages

         • Specifications234
         • Tools and Equipment › Spark Plug Pliers - AST Tool # H 18492
       • Compression Check › System Information › Specifications23
       • Valve Clearance › System Information › Specifications
     • Water Pump › Component Information › Specifications234567
   • Cooling System94 pages

     • Coolant › Component Information5 pages

       • Technical Service Bulletins › Cooling System - Coolant Identification/Mixing23
       • Specifications › Capacity Specifications2
     • Coolant Level Sensor › Component Information › Locations
     • Radiator Cooling Fan25 pages

       • A/C Pressure Sensor/Switch - Cooling Fan › Component Information7 pages

         • Locations › A/C Pressure Switch F1292
         • Description and Operation › A/C Pressure Switch F1292
         • Testing and Inspection › A/C Pressure Switch F12923
       • Radiator Cooling Fan Control Module › Component Information14 pages

         • Locations
         • Diagrams › Diagram Information and Instructions2345678910111213
       • Radiator Cooling Fan Motor › Component Information › Diagrams
       • Radiator Cooling Fan Motor Relay › Component Information › Locations
       • Radiator Cooling Fan Temperature Sensor / Switch › Component Information › Locations
       • Fan Clutch › Component Information › Tools and Equipment
     • Engine - Coolant Temperature Sensor/Switch9 pages

       • Coolant Temperature Sensor/Switch (For Computer) › Component Information › Technical Service Bulletins › Engine Coolant Temperature (ECT) Sensor - Checking2345678
       • Radiator Cooling Fan Temperature Sensor / Switch › Component Information › Locations
     • Heater Core › Component Information › Service and Repair2
     • Radiator › Component Information › Service and Repair23
     • Relays and Modules - Cooling System15 pages

       • Radiator Cooling Fan Control Module › Component Information14 pages

         • Locations
         • Diagrams › Diagram Information and Instructions2345678910111213
       • Radiator Cooling Fan Motor Relay › Component Information › Locations
     • Sensors and Switches - Cooling System17 pages

       • A/C Pressure Sensor/Switch - Cooling Fan › Component Information7 pages

         • Locations › A/C Pressure Switch F1292
         • Description and Operation › A/C Pressure Switch F1292
         • Testing and Inspection › A/C Pressure Switch F12923
       • Coolant Level Sensor › Component Information › Locations
       • Engine - Coolant Temperature Sensor/Switch9 pages

         • Coolant Temperature Sensor/Switch (For Computer) › Component Information › Technical Service Bulletins › Engine Coolant Temperature (ECT) Sensor - Checking2345678
         • Radiator Cooling Fan Temperature Sensor / Switch › Component Information › Locations
     • Thermostat, Engine Cooling › Component Information10 pages

       • Specifications
       • Service and Repair › Procedures23456789
     • Water Pump › Component Information › Specifications234567
   • Exhaust System11 pages

     • Catalytic Converter › Component Information › Technical Service Bulletins8 pages

       • Customer Interest for Catalytic Converter: › 2607-06 › Sep › 07 › Emissions - Possible MIL ON/Cat Converter DTC's Set234
       • All Technical Service Bulletins for Catalytic Converter: › 2607-06 › Sep › 07 › Emissions - Possible MIL ON/Cat Converter DTC's Set234
     • Exhaust Manifold › Component Information › Specifications
     • Heat Shield, Exhaust › Component Information › Technical Service Bulletins › Exhaust System - Heat Shield Replacement Guidelines2
5. 05Powertrain ManagementPowertrain Management: Sections
6. 06Transmission and DrivetrainTransmission and Drivetrain: Sections
7. 07Brakes and Traction ControlBrakes and Traction Control: Sections
8. 08Starting and ChargingStarting and Charging: Sections
9. 09Power and Ground DistributionPower and Ground Distribution: Sections
10. 10Steering and SuspensionSteering and Suspension: Sections
11. 11Heating and Air ConditioningHeating and Air Conditioning: Sections
12. 12Restraint SystemsRestraint Systems: Sections
13. 13Accessories and Optional EquipmentAccessories and Optional Equipment: Sections
14. 14Body and FrameBody and Frame: Sections
15. 15Cruise ControlCruise Control: Sections
16. 16Instrument Panel, Gauges and Warning IndicatorsInstrument Panel, Gauges and Warning Indicators: Sections
17. 17Lighting and HornsLighting and Horns: Sections
18. 18Windows and GlassWindows and Glass: Sections
19. 19Wiper and Washer SystemsWiper and Washer Systems: Sections