4-Cylinder Injection Engine, 2005 BHY

Service
Workshop Manual
Golf - Jetta 2005
4-cylinder injection engine, 2005
Engine ID
BHY
Edition 09.2005
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Service Department. Technical Information
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, Valve gear
17 - Lubrication
19 - Cooling system
20 - Fuel supply system
24 - Mixture preparation, Injection
26 - Exhaust system
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28 - Ignition system
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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.
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright 2010 Volkswagen AG, Wolfsburg
SAR5R025020
Golf - Jetta 2005

4-cylinder injection engine, 2005 - Edition 09.2005
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
1.2
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
1.2
Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
8
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing poly V-belt . . . . . . . . . . . . . .V.ol.ks.w.a. . . . . . . . . . . . . . . . . . . . . . . .
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Dismantling and assembling pistons and conrods
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d
Assembly overview - Pistons and conrods
an
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Checking pistons, piston rings anduthcylinder
bores . . . . . . . . . . . . . . . . . . . . . . .e.or. . . . . . . .
a
a
Piston and cylinder dimensionsss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . .
Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Colour identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
15
18
18
21
23
24
25
25
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1
1.1
1.2
2
2.1
2.2
2.3
3
3.1
3.2
15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
27
28
33
34
39
41
43
46
48
50
51
52
53
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - Oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
1.5
56
56
58
59
60
63
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1
1.1
1.2
1.3
1.4
1.5
1.6
Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly overview - parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - parts of cooling system - body side . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . .
Contents
65
66
68
69
72
74
75
Golf - Jetta 2005

1.7
1.8
Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
78
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . .
Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Removing and installing fuel tank . . . . . .sw. a.g.e.n A
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Repairing fuel supply . . . . . . . . . .ed. b. . . . . . . . . . . . . . . . . . . . . . . . . . .gu. a.ra. . . . . . . . . . . . . .
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Safety precautions when working
tho on the fuel supply system . . . . . . . . . . . . e. o.r . . . . . . . . . .
u
Rules for cleanliness . . . . .ss.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c. . . . . . . . .
Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Active charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - active charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80
80
80
81
82
84
88
88
88
89
91
92
101
101
102
102
104
104
105
105
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1
1.1
1.2
1.3
1.4
1.5
2
2.1
2.2
2.3
2.4
2.5
3
3.1
3.2
3.3
4
4.1
4.2
4.3
24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel rail with intake manifold flaps . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing Teflon seal on injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing anti-theft engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
2
2.1
2.2
107
107
108
108
109
110
111
112
113
113
114
116
118
120
121
121
123
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

1
1.1
1.2
1.3
1.4
Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front exhaust pipe and catalytic converter with attachments . . . . . . . . . . . . . . . . . . . . . . . .
Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separating middle and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aligning exhaust system stress free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
124
125
126
126
127
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

1
1.1
1.2
ii
Contents
Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Golf - Jetta 2005

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Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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1.3
1.4
Contents
iii
Golf - Jetta 2005

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Contents
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Golf - Jetta 2005

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Technical data
Technical data
Engine number page 1 .

Engine data page 1 .
1.1
Engine number
The engine number (engine code and serial number) can be

found at the front on the joint between engine and gearbox.
The engine number consists of up to nine characters (alphanu
meric). The first part (maximum 3 characters) makes up the
engine code, and the second part (6 characters), the serial
number. If more than 999,999 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.
In addition, there is a sticker on the toothed belt guard with engine
code and serial number.
The engine code is also included on the vehicle data sticker.
1.2
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Engine
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cc
kW at rpm
Nm at rpm
mm
mm
BHY
min.
Injection, ignition
Knock control
Self-diagnosis
Lambda regulation
Catalytic converter
Exhaust gas recirculation
Turbocharging/supercharging
Electronic power control
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Output
Torque
Bore
Stroke
Compression ratio
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Engine code
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Displacement
1984
85/5200
175/4000
82.5
92.8
10.5
Coast 95 unleaded
Inland 91 unleaded
Bosch ME 7.5.1
yes
yes
yes
yes
no
no
yes
1. Technical data
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Golf - Jetta 2005

10
Removing and installing engine
Removing and installing engine
Special tools and workshop

equipment required
Torque wrench -V.A.G
1331 Torque wrench -V.A.G
1332 Engine-/gearbox jack V.A.G 1383/A Pliers -VAS 5024/A Step ladder -VAS 5085-
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Installing engine page 8 .

Assembly mountings page 10 .
1.1
Removing engine
Securing engine to assembly stand page 7 .
Rep. Gr.10 - Removing and installing engine
AG.
Securing engine to assembly stand page 7 .
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Removing engine page 2 .
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Golf - Jetta 2005

Note
Before carrying out further work, disconnect battery earth
strap. First check whether a coded radio is fitted. Obtain radio

code first if necessary.
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.
Caution
When doing any repair work, especially in the engine compart

ment, pay attention to the following due to the cramped condi
tions:
Route all types of lines (e.g. for fuel, hydraulics, active
charcoal filter system, coolant, refrigerant, brake fluid and
vacuum) and electrical wiring in their original positions.
To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
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Remove engine cover.
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Remove air filter housing with connecting hoses.
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Disconnect earth strap at battery
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Electrical system; Rep. Gr. 27
ut; Disconnecting and connecting
ra
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battery.
1. Removing and installing engine
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Golf - Jetta 2005

Remove battery and battery tray -arrows-.
Remove top part of intake manifold.
Remove plenum chamber bulkhead General body repairs,
exterior; Rep. Gr. 50 ; Body front; Plenum chamber bulkhead.
Detach connectors from the following components:
Ignition transformer -N152 Injector for cylinder 1 -N30 Injector for cylinder 2 -N31 Injector for cylinder 3 -N32 Injector for cylinder 4 -N33 Coolant temperature sender -G62 Engine speed sender -G28 Knock sensor 1 -G61 Knock sensor 2 -G66 Secondary air pump motor -V101 Oil pressure switch -F1 Throttle valve control module -J338 If necessary A/C system shutoff thermal switch -F163 Pull engine wiring harness connector off engine control unit.
Separate all connectors betweenenengine
harness
and
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body and lay engine wiringolkharness
on engine.
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Remove noise insulation tray General body repairs, exteri

or; Rep. Gr. 50 ; Body front; Noise insulation.
Bring lock carrier into service position General body repairs;
Rep. Gr. 50 ; Body front; Lock carrier service position .
Drain coolant page 69 .
Remove left wheel housing liner.
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Disconnect breather line -1-and fuel supply line -2-.
rrectness of i
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spec
at
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The fuel supply line is under pressure! Wear protective glasses

and clothing to avoid injuries and skin contact. Before loosen
ing hose connections, wrap a cloth around the connection.
Then release pressure by carefully pulling hose off connection.
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WARNING
ut
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Golf - Jetta 2005

Unbolt heat shield for right-hand drive shaft -arrows-.
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Remove right drive shaft and then left drive shaft at gearbox
Running gear, axles, steering; Rep. Gr. 40 ; Removing and
installing drive shaft .
Remove bolts -1, 2 and 3- and remove pendulum support.
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Separate all connection, coolant, vacuum and intake hoses

from engine.
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Pull off or disconnect all other electrical connections from en

gine and gearbox as necessary and lay to side.
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Remove securing nuts -arrows- for front exhaust pipe/exhaust

manifold and pull front exhaust pipe off exhaust manifold.
Note
To prevent damage to condenser or to refrigerant pipes and ho

ses, ensure that pipes and hoses are not stretched, kinked or
bent.
To facilitate removing and installing engine without opening re
frigerant circuit:
Remove poly V-belt page 16 .
Separate air conditioner compressor from compact bracket
Heating, air conditioning; Rep. Gr. 87 ; Removing and instal
ling compressor bracket .
Secure air conditioner compressor to lock carrier so that re
frigerant lines are free of stress.
Vehicles with manual gearbox
Remove selector mechanism from gearbox Manual gear
box; Rep. Gr. 34 ; Repairing selector mechanism .
Golf - Jetta 2005

Remove strut -1-.
Remove slave cylinder -arrows- and lay to side. Do not open
hydraulic system.
Caution
Do not operate clutch pedal after slave cylinder has been re

moved. This can damage the slave cylinder.
Vehicles with automatic gearbox
Disconnect selector lever cable from gearbox Automatic
gearbox 09G; Rep. Gr. 37 ; Repairing selector mechanism .
All vehicles (continued):
Insert engine bracket -T10012- in engine-/gearbox jack -V.A.G
1383/A- .
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Fit engine bracket -T10012- to front of cylinder block with
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Tighten securing nut exhaust side by hand. s au
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From above, unbolt engine side of assembly mounting from

engine bracket -arrows-.
Note
Note
Engine and gearbox must be guided carefully when lowering to

prevent damage to the bodywork, hoses and lines.
AG.
Carefully lower engine with gearbox.
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From above, unbolt gearbox side of assembly mounting from

gearbox bracket -arrows-.
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To remove securing bolts, use stepladder -VAS 5085- .
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Lift engine and gearbox slightly using engine-/gearbox jack V.A.G 1383/A- .
Golf - Jetta 2005

1.1.1
Securing engine to assembly stand

equipment required
Lifting appliance -VAS
2024A Workshop crane -VAS
6100 Engine and gearbox sup
port -VAS 6095-
rrectness of i
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Secure engine on engine and gearbox support -VAS 6095- to

carry out repairs.
Remove gearbox.
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Golf - Jetta 2005

Attach lifting appliance -VAS 2024A- as follows and lift from
engine-/gearbox jack -V.A.G 1383/A- using workshop crane VAS 6100- .
Pulley end: 3rd hole in hook at position 2.
Flywheel end: 3rd hole in hook at position 8.
Caution
Use securing pins on hooks and locking pins to avoid damage

to engine and vehicle.
The positions marked 1...4 on the bar must be towards the
pulley end.
The holes in the hooks are counted up from the hook.
Secure engine to engine and gearbox support -VAS 6095- .
1.2
Installing engine
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Assembly mountings page 10 .
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Installation is carried out in the

note the following:
Caution
rrectness of i
t to the co
nform
spec
at
i
h re
o
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wit
in t
his

tions:
Route all types of lines (e.g. for fuel, hydraulics, active
Insert new dowel sleeves in cylinder block for centering engine
and gearbox.
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Golf - Jetta 2005

Hook intermediate plate onto sealing flange and slide onto
dowel sleeves -arrows-.
Lightly grease input shaft splines with grease -G 000 100- .
Check clutch and clutch control and install Manual gearbox;
Rep. Gr. 30 ; Repairing clutch control .
Continuation for all vehicles
When installing engine and gearbox assembly, ensure suffi
cient clearance to subframe and radiator.
Align engine mountings tension free by shaking. If necessary,
loosen engine mounting on body.
Install pendulum support.
Note
Torque settings for engine and gearbox mountings
page 10 .
Electrical connections and routing Electrical system; Rep.
Gr. 97 .
Install right-hand drive shaft and bolt or slot left-hand drive

shaft onto gearbox Running gear; Rep. Gr. 40 ; Removing
and installing drive shaft .
Install selector mechanism and adjust mechanism if necessa
ry Manual gearbox; Rep. Gr. 34 ; Repairing selector
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mechanism .
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Install selector lever cable and adjust if necessary Auto

matic gearbox 09G; Rep. Gr. 37 ; Repairing selector mecha
nism .
All vehicles (continued):
Install air conditioner compressor Heating, air conditioning;

Rep. Gr. 87 ; Removing and installing compressor bracket .
Install poly V-belt page 16 .
Install sound insulation tray General body repairs, exterior;

Rep. Gr. 50 ; Body front; Assembly overview .
Install plenum chamber bulkhead General body repairs,
exterior; Rep. Gr. 50 ; Body front; Plenum chamber bulkhead .
Fill coolant system with coolant page 71 .
Adapt engine control unit Vehicle diagnosis, testing and in

formation system VAS 5051; Guided functions .
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Carry out road test and then read fault memory.
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spec
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Vehicles with automatic gearbox
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Install slave cylinder for hydraulic clutch Manual gearbox;
ris
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Rep. Gr. 30 ; Repairing clutch mechanism; Assembly
over
au
view - hydraulics .
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Golf - Jetta 2005

Torque settings
Threaded connection
Torque setting
Bolts, nuts
1.2.1
M6
10 Nm
M7
15 Nm
M8
25 Nm
M 10
40 Nm
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Assembly
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A1) = 20 Nm + 1/4 turn (90 ) further

B1) = 40 Nm + 1/4 turn (90 ) further
C1) = 60 Nm + 1/4 turn (90 ) further
1) Renew
Gearbox assembly mounting

A2) = 40 Nm + 1/4 turn (90 ) further
B2) = 60 Nm + 1/4 turn (90 ) further
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B3) = 100 Nm + 1/4 turn (90 ) further

3) Renew
10
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A3) = 40 Nm + 1/4 turn (90 ) further
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Pendulum support
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2) Renew
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Engine assembly mounting
Golf - Jetta 2005

13
Crankshaft group
Dismantling and assembling engine

Note
Finding metal shavings or a large quantity of small metal par

agenthe
ticles during engine repair could
indicate
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the
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after
repairs:
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Thoroughly clean
au oil channels.
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Renew oil spray jets.

Renew oil cooler.
rrectness of i
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spec
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wit
Renew oil filter.

Assembly overview page 12 .
Removing and installing poly V-belt page 15 .
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1. Dismantling and assembling engine
11
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Golf - Jetta 2005

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Rep. Gr.13 - Crankshaft group
AG.
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Part II page 14
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Part I page 13
rrectness of i
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spec
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Assembly overview
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Golf - Jetta 2005

1.1.1
Part I
1 - Bolt
45 Nm
2 - Engine bracket
3 - Poly V-belt tensioner
Swivel with open jaw
spanner to slacken poly
V-belt page 15
4 - Toothed belt guard - centre
part
5 - Toothed belt guard - upper
part
6 - Nut
20 Nm
7 - Washer
8 - Tensioning roller
Checking semi-auto
matic toothed belt ten
sioning roller
page 33
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9 - Toothed belt
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Check for wear
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Do not kink
s
Removing, installing
and tensioning
page 28
rrectness of i
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spec
a
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10 - Bolt
20 Nm
11 - Rear toothed belt guard
12 - O-ring
Renew
13 - Coolant pump
Check for ease of movement
If damaged or leaking, renew complete
Removing and installing page 72
15 - Crankshaft belt pulley

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16 - Bolt
90 Nm + 1/4 turn (90 ) further
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14 - Bolt
15 Nm
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Renew
Threads and shoulder must be free of oil and grease
Use counterhold tool -3415- to loosen and tighten
13
AG.
Prote
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Golf - Jetta 2005

17 - Toothed belt guard - lower part
18 - Bolts
10 Nm
Renew
19 - Pulley
For aircon
20 - Poly V-belt
Mark direction of rotation before removing
Check for wear
Do not kink
21 - Pulley and vibration damper
Can only be installed in one position, holes are offset
Note position when installing toothed belt page 28
22 - Bolt
25 Nm
7 - Bracket
For ignition coil
8 - Bracket
9 - Oil filter bracket
Dismantling and assem
bling page 59
14
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AG.
6 - Bolt
10 Nm
do
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5 - Oil dipstick
The oil level must not be
above the max. mark!
Markings page 57
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4 - Coolant pipe
Prote
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by
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rig
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3 - Bolt
20 Nm
The torque setting influ
ences the function of the
knock sensor
rrectness of i
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spec
a
t
i
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thi
s
2 - Connector
Knock sensor 1 -G61 Gold-plated contacts
Do not interchange
Current flow dia
grams, Electrical fault
finding and Fitting loca
tions
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1 - Knock sensor 1 -G61 Gold-plated contacts
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Part II
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Co
t.
1.1.2
Golf - Jetta 2005

10 - Bolt
Renew
11 - O-ring
Renew
12 - Oil cooler
Coat contact surface to oil filter bracket outside the seal with sealing paste -AMV 188 100 02 Ensure clearance to adjacent components
13 - Nut
25 Nm
14 - Oil filter
Loosen with strap wrench
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Tighten by hand
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Observe installation instructions on oil filter
r
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hole
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16 - Bolt
15 Nm
th
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s
s
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
17 - Thermostat
Checking: heat thermostat in water
Opening begins at approx. 86 C
Opening lift min. 7 mm
18 - Bolt
45 Nm
or
ac
ility
ab
y li
an
pt
ce
15 - Connection
19 - Compact bracket
For poly V-belt tensioner, alternator and air conditioner compressor
Prote
cted
by
1.2
AG.
23 - Gasket
Renew
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22 - Engine speed sender
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21 - O-ring
Renew if damaged
do
c
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en
20 - Cylinder block
Removing and installing sealing flange and flywheel/drive plate
Removing and installing crankshaft page 24
Dismantling and assembling pistons and conrods
Removing and installing poly V-belt
Special tools and workshop equipment required
15
Golf - Jetta 2005

Mandrel -T10060A-
1.2.1
Removing poly V-belt
Remove right-hand insulation tray: Rep. Gr. 50 .

Mark direction of rotation of poly V-belt.
Swing tensioning device in direction of -arrow- to relieve ten
sion on poly V-belt.
Lock tensioning element using locking pin -T10060A- .

AG. Volkswagen AG d
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spec
a
t
i
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wit
thi
s
1.2.2
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hole
ercia
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Remove poly V-belt.
Installing poly V-belt
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Prote
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16
do
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Installation is carried out in the reverse sequence of removal.
Golf - Jetta 2005

Note
Before installing poly V-belt, ensure that all ancillary assem
blies (alternator, air conditioner compressor) are secured tight

ly.
When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
For vehicles without air conditioning, fit poly V-belt on alterna
tor last.
For vehicles with air conditioning, fit poly V-belt on air condi
tioner compressor last.
After completing repairs always:

Start engine and check belt running.
Belt drive without air conditioner compressor.
Belt drive with air conditioner compressor.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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erm
or
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a
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iv
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du
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nl
f
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AG. Volkswagen AG d
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17
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Prote
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by c
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Golf - Jetta 2005

Dismantling and assembling pistons

and conrods
Gradual introduction of industrially cracked conrods.

Identification:
-A- conventional conrods (smooth joining surface)
-B- industrially cracked conrods (rough joining surface)
Assembly overview - Pistons and conventional conrods
page 19 .
Assembly overview - Pistons and industrially cracked conrods
page 20 .
2.1
Assembly overview - Pistons and con

rods
Conventional conrods page 19 .

Industrially cracked conrods page 20 .
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Prote
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18
rrectness of i
t to the co
nf
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m
spec
atio
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n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
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or
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f
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AG. Volkswagen AG d
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Golf - Jetta 2005

2.1.1
Conventional conrods
1 - Piston rings
Offset gaps by 120
Remove and install us
ing piston ring pliers
TOP faces towards
piston crown
Checking ring gap
page 21
2 - Piston
Checking page 22
Mark installation posi
tion and cylinder num
ber
Arrow on piston crown
points to pulley end
Oil scraper ring, 2 part
Checking ring-to-groove
clearance page 21
Install using piston ring
clamp
es
wage
ks
Vol
not
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5 - Nuts
Renew
Oil threads and contact surface
To measure radial clearance, tighten to 30 Nm but not further
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
4 - Conrod bearing cap

Mark cylinder number
-B Installation position:
marking -A- faces to
wards pulley end
thi
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3 - Conrod
db
ise
r
Renew as set
thoonly
au
s
s
Mark cylinder
number
wards pulley end
6 - Bearing shell
Note installation position
Do not interchange used bearing shells
Ensure retaining lug fits tightly in recess
Upper bearing shell with oil drilling for piston pin lubrication
Axial clearance new: 0.05...0.31 mm, wear limit: 0.37 mm
Check radial clearance with Plastigage: new: 0.01...0.06 mm, wear limit: 0.12 mm. Do not rotate crank
shaft when checking radial clearance
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7 - Cylinder block
Checking cylinder bores page 23
Piston and cylinder dimensions page 23
2. Dismantling and assembling pistons and conrods
19
Golf - Jetta 2005

8 - Conrod bolt
9 - Circlip
10 - Piston pin
If difficult to remove, heat piston to 60 C
Remove and install with drift -VW 222A-
2.1.2
AG. Volkswagen AG d
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Industrially cracked conrods
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un
le
3 - Piston pin
If difficult to remove,
heat piston to 60 C
Remove and install with
drift -VW 222A-
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py
Co
t.
r
fo
ng
2 - Piston
Checking page 22
Mark installation posi
tion and cylinder num
ber
Arrow on piston crown
points to pulley end
Install using piston ring
clamp
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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p
ility
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1 - Piston rings
Offset gaps by 120
Remove and install us
ing piston ring pliers
TOP faces towards
piston crown
Checking ring gap
page 21
Checking ring-to-groove
clearance page 21
4 - Circlip
5 - Conrod
With industrially
cracked bearing caps
Renew as set only
Mark cylinder number
wards pulley end
6 - Bearing shell
Note installation position page 22
Insert bearing shells centrally
Do not interchange used bearing shells
Check for secure seating
Axial clearance new: 0.10...0.35 mm, wear limit: 0.4 mm
Check radial clearance with Plastigage: new: 0.01...00.05 mm, wear limit: 0.12 mm. Do not rotate crank
shaft when checking radial clearance
20
Golf - Jetta 2005

7 - Cylinder block
Checking cylinder bores page 23
Piston and cylinder dimensions page 23
8 - Conrod bearing cap
The caps only fit in one position and only on the appropriate conrod due to the breaking procedure
(cracking) separating the cap from the conrod
. Volkswagen AG
AG
9 - Bolt
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ed ) further
es, in part or in w
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f
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rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
2.2
is
or
th
Torx T10
au
s
s
Renew
Oil threads and contact surface
To measure radial clearance, tighten to 30 Nm but not further
ility
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does
not
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Checking pistons, piston rings and cyl

inder bores
Checking piston ring gap
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Test sequence:
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Feeler gauges
thi
sd
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Push ring squarely from above down to approx. 15 mm from

bottom end of cylinder.
AG.
Prote
cted
by
Piston ring
Compression rings (top)
Compression rings (bottom)
Oil scraper ring
Gap
mm
mm
mm
New
0.150.35
0.40...0.40
0.200.70
Wear limit
0.8
0.8
0.9
Checking ring-to-groove clearance

21
Golf - Jetta 2005

Feeler gauges
Clean groove before check.
Piston ring
Top compression rings
Middle compresion rings
Oil scraper ring
Ring-to-groove clearance
New
Wear limit
0.040.075
0.15
0.02...0.055
0.15
0.050.13
0.20
mm
mm
mm
Checking piston
Special tools
Measure pistons approx. 10 mm from the lower edge of skirt, at

90 to the piston pin axis.
Bearing shells - installation position
Bearing shell -1- with oil hole -arrow- for conrod.
Bearing shell -2- without oil hole for conrod bearing cap.
Fit bearing shells in centre of conrod and conrod cap.
Dimension -a- must be the same on the left and right, max. devi
ation: 0.2 mm.
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22
rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
Deviation from nominal dimension max. 0.04 mm.
thi
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es, in part or in w
l purpos
hole
ercia
, is n
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External micrometer 75...100 mm
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and workshop
equipment required
a
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Golf - Jetta 2005

Checking cylinder bores

Cylinder gauge 50...100
AG. Volkswagen AG d
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wa
olks
oes
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V
Measure at 3 dpositions
both across -A- and in-line
by
ara
nte
ise
-Br
o
e
h
ut
or
ac
Note
Cylinder bores must not be measured when cylinder block is

mounted on a repair stand with engine and gearbox support -VW
540- , as measurements may then be incorrect.
2.3
Piston and cylinder dimensions
Honing dimension
Basic dimension
1st oversize
Piston
mm
mm
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
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a
Deviation
from nominal dimension max. 0.08 mm
ss
Cylinder bore
82.465 ( 0.009)
82.9654)
82.50 (+0.015 +0.005)

83.01
4)
thi
sd
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cu
m
en
4) Dimension without graphite coating (thickness 0.02 mm). The graphite coating
wears away.
23
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Golf - Jetta 2005

AG. Volkswagen AG d
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Note
d
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is
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ut
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a
Before removing crankshaft,
ensure
that
a
suitable
surface
for
storing
crankshaft
is prepared so that sender
c
s
s
ility
ab
y li
an
pt
ce
wheel ( Item 8 (page 24) ) does not contact anything and cannot be damaged.
es, in part or in w
l purpos
hole
ercia
, is n
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om
c
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erm
o
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t
a
itte
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nl
f
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n
Removing and installing crankshaft
When working on engine, secure to repair stand using engine and gearbox support -VW 540- and supple
mentary kit -VW 540/1B- .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
1 - Oil pump
With 12 bar pressure re
lief valve
Before installing, check
that both dowel sleeves
for centring oil pump on
cylinder block are fitted
Removing and installing
page 56
2 - Bolt
15 Nm
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4 - Bearing shells 1, 2, 3, 4 and

5
Classification for order
ing spare parts
page 25
For bearing cap without
oil groove
For cylinder block with
oil groove
Do not interchange
used bearing shells
(mark)
do
c
um
en
3 - Sprocket
For oil pump drive
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
5 - Bolts
65 Nm +90 (1/4turn)
further
Renew
Threaded along com
plete length
Tighten crankshaft to
65 Nm when measuring
radial clearance
6 - Bearing cap
Bearing cap 1: Pulley end
Bearing cap 3 with recesses for thrust washers
Bearing shell retaining lugs in cylinder block and bearing caps must be on the same side
7 - Bearing shell 3
Item 4 (page 24)
Do not interchange used bearing shells (mark)
8 - Sender wheel
Renew
24
Golf - Jetta 2005

Engine speed sender -G28 Can only be installed in one position, holes are offset
9 - Bolt
Renew
10 - Thrust washer
For bearing cap, bearing 3
Note fixing arrangement
Lettering faces bearing pedestal
es, in part or in w
l purpos
hole
ercia
, is n
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11 - Crankshaft
AG. Volkswagen AG d
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Axial clearance new: 0.07...0.23bymm,
wear limit: 0.30 mm
V
gu
ara
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nte 0.15 mm
is
Check radial clearance withorPlastigage,
new: 0.01...0.04 mm, wear limit:
eo
h
ut
ra
a
Do not rotate crankshaft
when
checking
radial
clearance
c
s
s
Crankshaft dimensions page 25
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
12 - Thrust washer
For cylinder block, bearing 3
Lettering faces bearing pedestal
Identification for upper main bearing shell (gradual introduction)
Upper main bearing shells of the proper thickness are allocated
to the cylinder block in the factory. Coloured spots serve to identify
the thickness of the bearing shells.
Which bearing thickness is to be used at each place is marked by
letters on the lower sealing surface of the cylinder block.
Black
Red
Yellow
AG.
=
=
=
Bearing colour
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cted
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Letter on cylinder block
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Co
t.
Colour identification
do
c
um
en
3.1
Note
Arrow points in direction of travel.
If the colour marks are not yet stamped in or are no longer
legible, use medium (red) bearing shells.
As a replacement part only colour code yellow is supplied for
lower main bearing shells.
3.2
Crankshaft dimensions
(dimensions in mm)
3. Removing and installing crankshaft
25
Golf - Jetta 2005

un
le
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iva
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fo
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AG.
Prote
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by
c
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C
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do
c
um
en
26
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
3rd oversize
-0.022
47.80
es n
wage
s
k
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-0.042
o
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ran
e
s
i
-0.022
tee
r
o
h
or
ut
ac
a
47.55
ss
-0.042
-0.022
47.30
-0.042
-0.022
47.05
-0.042
ility
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2nd oversize
Conrod journal
pe
rm
itte
d
1st oversize
-0.017
54.00
-0.037
-0.017
53.75
-0.037
-0.017
53.50
-0.037
-0.017
53.25
-0.037
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Basic dimension
Main journal
ht
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Co
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Honing dimension
Golf - Jetta 2005

15
Cylinder head, Valve gear
Removing and installing cylinder

head
Checking compression page 39 .

Note
When installing an exchange cylinder head with fitted cam
shaft, the contact surfaces between the bucket tappets and

the cam must be oiled before installing the cylinder head cov
er.
olkswagen AG
en AG. V
ag
lksw
does
not
gu
ara
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nte
not be removed until immediately
ris before fitting cylinder head.
o
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a
If the cylinder head is renewed,
the entire coolant must also
c
ss
Vo the open valves must

The plastic packing pieces for protecting
by
un
le
ility
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ce
be renewed.
Removing and installing intake manifold page 113 .

1 - Cap
2 - Nut
10 Nm
3 - Gasket
4 - Cylinder head cover
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by
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.
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7 - Seal
Renew
ht
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py
Co
t.
6 - Plug
15 Nm
Renew
r
fo
ng
5 - Cylinder head cover gasket

Renew if damaged
Before fitting coat tran
sition points between
bearing cap and cylin
der head with sealant -D
454 300 A2-
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
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erm
or
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a
itte
v
i
r
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p
8 - Connection
9 - Bolt
10 Nm
10 - Lifting eye
11 - Bolt
20 Nm
12 - Cylinder head gasket
Renew
After renewing, renew
entire coolant
13 - Bolt
15 Nm
1. Removing and installing cylinder head
27
Golf - Jetta 2005

14 - Bolt
20 Nm
16 - Cylinder head
Check for distortion page 28
Reworking sealing surface page 42
After renewing, renew entire coolant
17 - Cylinder head bolt
Renew
Remove and install polydrive cylinder head bolt using special wrench, long reach -T10070 Sequence when loosening and tightening page 34
18 - Oil deflector
Checking cylinder head for distortion
Max. permissible distortion: 0.1 mm.
Removing, installing and tensioning
es n
wage
s
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o
yV
ua
toothed belt
b
ra
ed
nte
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ris
tho
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fo
ng
AG.
Prote
cted
by
Rep. Gr.15 - Cylinder head, Valve gear
agen
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28
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
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o
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erm
or
e
t
a
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v
i
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p
ility
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(Adjusting valve timing)
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equipment required
rrectness of i
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spec
at
i
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in t
his
Engine support bracket V.A.G 10-222A- with frame

-V.A.G 10-222A/1 Pin wrench -T10020 Torque wrench -V.A.G
1331- (5..50 Nm)
1332- (40...200 Nm)
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1.1.1
Golf - Jetta 2005

2005 - Edition 09.2005
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4-cylinder injection engine,
s
Removing

Remove right-hand insulation tray: Rep. Gr. 50 .
Remove poly V-belt tensioner.
Remove coolant expansion tank (coolant hoses remain con
nected).
Remove toothed belt guard - upper part.
29
Golf - Jetta 2005

Set camshaft belt pulley to TDC no. 1 cylinder by turning
crankshaft. Marking on camshaft belt pulley must align with
arrow on toothed belt guard.
AG. Volkswagen AG d
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Fit engine support bracket -V.A.G 10-222A- with frame -V.A.G

10-222A/1- as shown.
rrectness of i
t to the co
nform
spec
a
t
i
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wit
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Remove securing bolts from assembly mounting/engine

bracket, assembly mounting/body and assembly mounting/
body bracket -arrows- and remove assembly mounting com
plete.
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30
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Remove belt pulley with vibration damper.
Golf - Jetta 2005

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oand
Unbolt engine bracket from cylinder block-1-, -2yV
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Note
b
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When loosening the front engine bracket bolt the engine must be
raised slightly with the support bracket.
rrectness of i
t to the co
nf
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m
spec
atio
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wit
Remove centre and lower parts of toothed belt guard.

Mark direction of rotation of toothed belt.
Loosen tensioning roller and remove toothed belt.
Turn crankshaft back slightly.
1.1.2
Installing
The pistons must not be positioned at TDC.
Place toothed belt on crankshaft belt pulley and coolant pump

(observe direction of rotation).
bration damper/belt pulley in advance.
Danger of damage to valves and piston crowns.
AG.
Adjusting valve timing
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When camshaft is turned, crankshaft must not be at TDC.
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With engine removed: install lower toothed belt guard and vi
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Note
Align mark on camshaft belt pulley with mark on toothed belt

guard.
Engine installed:
Turn crankshaft to TDC No.1 cylinder (vehicles with manual

gearbox).
31
Golf - Jetta 2005

Turn crankshaft to TDC No.1 cylinder (vehicles with automatic
gearbox).
Engine removed:
Set vibration damper to TDC No. 1 cylinder -arrows-.

Fit toothed belt to tensioning roller and camshaft belt pulley.
Tensioning toothed belt
The engine must be no more than warm to touch.
Camshaft belt pulley is at TDC no. 1 cylinder.
Before tensioning toothed belt, turn tensioning roller on ec

centric to stop five times in both directions using pin wrench T10020- .
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32
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rrectness of i
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spec
a
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Procedure:
Golf - Jetta 2005

Tension toothed belt. To do this, turn pin wrench -T10020- on
eccentric to left -in direction of arrow- onto stop.
Then reduce tension on toothed belt until notch -1- and indi
cator -2- align (use mirror).
Tighten securing nut to 20 Nm.
Turn crankshaft two full revolutions in direction of engine ro
tation until engine is again at TDC No. 1 cylinder. It is important
that the last 45 of rotation (1/8 turn) is performed without in
terruption.
Check belt tension again.
Specification: indicator and notch align.
Continuation, fully installing toothed belt:
Install centre and lower toothed belt guard.
Install vibration damper/belt pulley.
Torque: 25 Nm
Fit engine mounting bracket to cylinder block.
Torque: 45 Nm
Before installing engine mounting insert bolts into mounting.

Remove frame -V.A.G 10-222A/1- .
Install upper toothed belt guard.
Install poly V-belt tensioning element.

Torque: 25 Nm
Install coolant expansion tank.
Install right-hand insulation tray: Rep. Gr. 50 .
Checking semi-automatic toothed belt

tensioning roller
r
fo
ng
1.2
The retainer -arrow- must locate in notch in cylinder head.
Prote
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Condition
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Installation position
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Fit engine cover.
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form
spec
atio
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Note
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Install engine mounting complete.
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Test procedure
Position crankshaft at TDC for cylinder No. 1.
33
Golf - Jetta 2005

Press toothed belt forcefully with thumb. The indicator -2- must
move.
Release toothed belt and turn crankshaft two full revolutions
in direction of engine rotation until engine is again at TDC No.
1 cylinder. It is important that the last 45 of rotation (1/8 turn)
is performed without interruption.
The tensioning roller must return to its initial position. (Notch
-1- and indicator -2- align again.)
Note
Check using a mirror.
1.3
Removing and installing cylinder head

equipment required
Drip tray -V.A.G 1306- or
drip tray for workshop hoist
-VAS 6208 Torque wrench -V.A.G
1332- (40...200 Nm)
Pliers -VAS 5024/ Guide pins -3450/2A Removal tool -3450/3-
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spec
atio
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wit
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Polydrive key -3452- or

special wrench, long-reach
-T10070-
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34
thi
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Golf - Jetta 2005

Assembly tool -T10029-
1.3.1
Removing

WARNING

tions:
Route all types of line (e.g. for fuel, hydraulics, activated
Ensure that there is sufficient clearance to all moving or
. Volkswagen AG
hot components.
gen AG
does
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spec
atio
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wit
Before carrying out further work, disconnect battery earth strap.

First check whether a coded radio is fitted. Obtain radio code first
if necessary.
With the ignition switched off, disconnect battery earth strap.
All cable ties which are opened or cut open when engine is
removed must be replaced in the same position when engine
is installed.
Remove upper part of intake manifold page 110 .

Note
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Fuel system is under pressure! Before opening the system

place a cloth around the connection. Then release pressure by
carefully loosening the connection.
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WARNING
thi
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Seal intake ports in the lower part of intake manifold using a clean
cloth.
35
Golf - Jetta 2005

Pull the fuel supply line (white mark) off the fuel rail and place
the wiring harness down forwards.
Seal lines so that fuel system is not contaminated by dirt.
Remove the connections with coolant hoses.
Remove secondary air pump intake and pressure lines.
Remove bracket of pressure line.
Unbolt secondary air pump motor -V101- and bracket and re
move.
Pull off the following connectors:
For secondary air pump motor -V101 For injectors (unclip cable guide)
For spark plugs (with assembly tool -T10029- )
Unbolt front exhaust pipe with catalytic converter and manifold
support.
Turn crankshaft to set camshaft belt pulley to TDC of cylinder
no. 1. Marking on camshaft belt pulley must align with arrow
on toothed belt guard.
Release tensioning roller and remove toothed belt from cam
shaft belt pulley.
Remove cylinder head cover.
Remove rear toothed belt guard upper bolt.
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AG. Volkswagen AG d
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ut head bolts in specified sequence and then re
Loosen socket
ra
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s
s
move completely.
Use special wrench, long reach -T10070- for polydrive cylinder

head bolts.
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36
do
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Carefully lift cylinder head off.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
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l purpos
hole
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com
Note
Golf - Jetta 2005

09.2005
ility
ab
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an
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ce
Note
Installing
es, in part or in w
l purpos
hole
ercia
, is n
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m
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1.3.2
AG. Volkswagen AG d
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not 2005 - Edition
l
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There must be no oil or coolant in the cylinder head bolt pock
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
ets in the cylinder head.
Do not remove new cylinder head gasket from its packing until
immediately before installing.
Handle new gasket with extreme care. Damage will cause
leakage.
Place clean cloths in cylinders so that no dirt or emery cloth

particles can get in between cylinder wall and piston.
Also prevent dirt and emery cloth particles from getting into
coolant.
To centralize, screw guide pins -3450/2A- into front outer cyl

inder head bolt threaded holes.
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If crankshaft has been turned in the meantime, position No. 1

cylinder piston to TDC and then turn crankshaft back slightly.
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Carefully remove metal particles, emery residue and cloths.
thi
sd
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m
en
Now carefully clean sealing surfaces of cylinder head and cyl

inder block. Ensure thereby that surfaces are not scored or
scratched (if abrasive paper is used, grade must not be less
than 100).
AG.
Note
The tolerance of the centring holes is reduced in the upper sec

tion. Therefore, before positioning cylinder head, check that guide
pins can be removed upwards. If necessary, knurled part of guide
pins may be ground off slightly.
Fit new cylinder head gasket.
Fit cylinder head, screw in 8 remaining cylinder head bolts and
tighten by hand.
Remove guide pins with removal tool through bolt holes. To
do this, turn removal tool anti-clockwise until pins are free.
Now insert last two cylinder head bolts and tighten them handtight also.
37
Golf - Jetta 2005

Tighten cylinder head bolts in tightening sequence as follows:
Pre-tighten all bolts to 40 Nm.
Then tighten all bolts 1/4 turn (90 ) further using a rigid span
ner.
Finally tighten all bolts again 1/4 turn (90 ) further.
Further assembly is basically the reverse of the dismantling pro
cedure.
Note
When camshaft is turned, crankshaft must not be at TDC. Danger

of damage to valves and piston crowns.
Installing toothed belt and adjusting valve timing page 28 .
Torque setting: 25 Nm
AG. Volkswagen AG d
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ht
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38
do
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rrectness of i
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nform
spec
a
t
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wit
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hole
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Filling with new coolant page 71 .
Golf - Jetta 2005

1.4
Checking compression

equipment required
Plug spanner -VAS 3122B Assembly tool -T10029-
un
le
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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Compression tester -V.A.G

1763-
AG. Volkswagen AG d
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1331- (5..50 Nm)
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Test prerequisite
Engine oil temperature must be at least 30 C.
Voltage supply OK.
Procedure
Remove upper part of intake manifold.
39
Golf - Jetta 2005

Pull 4 pin connector -1- off output stage for ignition coils -2-.
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
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or
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t
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Remove fuse 28 for fuel pump.
Pull off spark plug connectors using assembly tool -T10029- .

Remove spark plugs using plug spanner -VAS 3122B- .
Have a second mechanic fully depress the accelerator pedal.
Check compression using compression tester -V.A.G 1763- .
Note
How to use test instrument operating instructions .
Prote
cted
by
40
AG.
Maximum permissible difference between all cylinders: 3 bar.
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New: 10...13 bar pressure, wear limit: 7.5 bar pressure.
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Compression pressures
thi
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Operate starter until tester shows no further pressure in

crease.
Golf - Jetta 2005

Repairing valve gear

Note
Cylinder heads which have cracks between the valve seats or
between a valve seat insert and the spark plug thread can be
used further without reducing service life, provided the cracks
do not exceed a maximum of 0.3 mm in width, or when no more
es n
wage
than the first 4 turns of the spark plug thread are cracked.
o
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ed engine must
When new bucket tappets have been installedristhe
6 - Bearing cap
Installation position
page 43
Installation sequence
page 48 , removing
and installing camshaft
Lightly coat contact sur
face of bearing cap 1
with sealant -AMV 174
004 01-
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5 - Nut
20 Nm
AG.
4 - Woodruff key
Check for secure seat
ing
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3 - Seal
Renew page 46
Prote
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by c
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2 - Camshaft toothed belt pul

ley
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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en
1 - Bolt
100 Nm
Use counterhold tool
-3415- to loosen and
tighten
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not be started for about 30 minutes. (Otherwise
valves will
au
s
contact pistons.) Then turn crankshaft two
full revolutions.
s
7 - Camshaft
Checking axial clear
ance page 42
page 48
Check radial clearance
with plastigage, wear
limit: 0.1 mm
Runout: max. 0.05 mm
8 - Bucket tappet
Do not interchange
With hydraulic valve clearance compensation
Checking page 50
Store with cam contact surface downwards
Before installing check camshaft axial clearance page 42
2. Repairing valve gear
41
Golf - Jetta 2005

Oil contact surface
9 - Cotters
10 - Upper valve spring plate
11 - Valve spring
Removing and installing: with cylinder head removed, use valve spring compressor -2037- ; with cylinder
head installed page 53
12 - Valve stem seal
Renew page 53
un
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nform
spec
a
t
i
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wit
thi
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14 - Cylinder head
Reworking sealing surface page 42
Reworking valve seats page 43
ility
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13 - Valve guide
Checking page 51
Renew page 52
Service version with collar
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15 - Valves
Do not rework, only lapping-in is permitted
Valve dimensions page 43
Reworking cylinder head sealing surface
Cylinder head reworking dimension: a = at least 132.6 mm.
If sealing surface is reworked, valves must be set deeper by the

same distance.
Prote
cted
by
AG.
42
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Checking camshaft axial clearance
do
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Note
Golf - Jetta 2005

Universal dial gauge bracket -VW 387-
Dial gauge
Check with bucket tappets removed and first and last bearing
caps fitted.
Wear limit: max. 0.15 mm.
Fitting position of camshaft bearing caps
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Note that bearing caps are not symmetrical. Before installing

camshaft, fit bearing caps and determine installation positions.
Note
Valves must not be reworked. Only lapping-in is permitted.

Dimension
a
b
c
2.1
mm
mm
mm
Inlet valve
Exhaust valve
39.5 0.15
6.98 0.007
91.85
44.66
32.9 0.15
6.96 0.007
91.15
44.66
Reworking valve seats
Depth gauge
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Valve seat refacing tool
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spec
a
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l purpos
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Valve dimensions
43
agen
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.
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Golf - Jetta 2005

4-cylinder injection engine, 2005 - Edition 09.2005en AG. Volkswagen AG
es, in part or in w
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or
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f
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Note
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When repairing engines with leaking valves, it is not sufficient
rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
to reface or renew valve seats and valves. There is also a re

quirement to check the valve guides for wear. This particularly
important on high mileage engines.
Valve seats should be reworked only enough to produce a
perfect seating pattern. Before beginning to rework valve

seats, calculate the maximum permissible reworking dimen
sion. If the reworking dimension is exceeded, hydraulic valve
compensation can no longer be guaranteed and the cylinder
head should be renewed.
The max. permissible reworking dimension is calculated as fol

lows:
Insert valve and press firmly against seat.
Note
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Calculate maximum permissible reworking dimension from

measured distance -a- and minimum dimension.
ht
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Co
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Measure distance -a- between end of valve stem and upper

edge of cylinder head.
Prote
cted
by
AG.
Minimum dimension: inlet valve 33.8 mm, exhaust valve 34.1 mm

Measured distance -a- minus minimum dimension = maximum
permissible reworking dimension.
Example:
Measured distance -aMinimum dimension

Max. perm. rework dimension 5)
35.1
34.1
1.0
5) The max. permissible reworking dimension is shown on illustrations for rework

ing valve seats as dimension b.
Reworking inlet valve seat
Dimension
a
44
mm
Inlet valve seat

39.2
mm
mm
mm
thi
sd
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cu
m
en
If the valve is to be renewed as part of a repair, use a new valve

for the calculation.
Golf - Jetta 2005

Dimension
AG.
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32.4
Max. permissible rework dimension
2.22.6
Lower edge of cylinder head
Valve seat angle
Upper correction angle
agen
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mm
mm
mm
Exhaust valve seat
do
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Dimension
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Reworking exhaust valve
Max. permissible rework dimension

1.82.2
AG. Volkswagen AG d
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Valve
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Upper
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Inlet valve seat
45
Golf - Jetta 2005

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Renewing camshaft oil seal
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1332- (40...200 Nm)
c
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Removing

shaft belt pulley.
46
do
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um
en
2.2.1
Prote
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by

1331- (5..50 Nm)
rrectness of i
t to the co
nform
spec
at
i
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his
Fitting tool -T10071-
AG.
Counterhold tool -3415-
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Oil seal extractor -2085-
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equipment required
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Co
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2.2
Golf - Jetta 2005

Remove camshaft belt pulley. When loosening camshaft
sprocket, hold with counterhold tool -3415- .
Remove woodruff key from camshaft.
Screw securing bolt of camshaft belt pulley into camshaft to
stop.
Screw inner part of oil seal extractor -2085- two turns (approx.
3 mm) out of outer part and lock with knurled screw.
es, in part or in w
l purpos
hole
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Loosen knurled screw and turn inner part against camshaft

until the oil seal is pulled out.
2.2.2
Installing
Condition
Gradual introduction of PTFE seals (poly-tetra-fluoro-ethylene).

Identification: has no circular spring, sealing lip is wider. The seal
ing lip of this oil seal must not be additionally oiled or greased. A
radial shaft seal of the old type (with circular spring) can be re
placed with a PTFE seal - but not the other way around.
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Clamp flats of oil seal extractor -2085- in vice. Remove oil seal
with pliers.
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Lubricate threaded head of oil seal extractor -2085, place it
ut
ra
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c
s
s
in position and forcefully screw it as far as possible
into oil seal.
AG.
Prote
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by
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.
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Position seal using assembly tool -T10071- and press in onto

stop using press sleeve -T10071/1- and bolt -T10071/2- .
Insert woodruff key in camshaft.
47
Golf - Jetta 2005

Install camshaft belt pulley. When tightening bolt of camshaft
belt pulley, hold with counterhold -3415- .
Note
When camshaft is turned, crankshaft must not be at TDC. Danger

of damage to valves and piston crowns.
cedure.
2.3
Removing and installing camshaft

equipment required
Counterhold tool -3415 Torque wrench -V.A.G
1331- (5..50 Nm)
AG. Volkswagen AG d
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48
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Removing
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Sealant -AMV 174 004 01-
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Not illustrated:
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1332- (40...200 Nm)
Golf - Jetta 2005

Note
cloth.
shaft belt pulley.
Remove camshaft belt pulley. When loosening camshaft

sprocket, hold with counterhold tool -3415- .
Remove woodruff key from camshaft.
First remove bearing caps 5, 1 and 3. Loosen bearing caps 2
and 4 alternately and diagonally.
Installing
un
le
r
fo
ng
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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n
wit
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Prerequisite
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2.3.2
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49
Golf - Jetta 2005

Note
When camshaft is installed, No. 1 cylinder cams must point
upwards.
When installing bearing caps, note that caps are not symmet
rical; before installing bearing cap, set in place and determine

fitting position.
Procedure
Oil camshaft running surfaces.
Insert camshaft.
Tighten bearing caps 2 and 4 alternately and diagonally to 20
Nm.
Lightly coat contact surface of bearing cap 1 with sealant -AMV
174 004 01- .
Install bearing caps 3, 1, and 5 and tighten to 20 Nm.
Insert woodruff key in camshaft.
Caution
When camshaft is turned, crankshaft must not be at TDC.

Danger of damage to valves and piston crowns.
. Volkswagen AG
Install camshaft belt pulley. When tightening bolt
of camshaft
gen AG
does
not
belt pulley, hold with counterhold -3415- V. olkswa
by
ed
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au

Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. Hydraulic compensation el
ements must settle (otherwise valves will strike pistons).
2.4
Checking hydraulic bucket tappets

Feeler gauges
Renew defective bucket tappets complete (cannot be adjusted

Irregular valve noises when starting engine are normal.
Start engine and run until radiator fan has switched on once.
50
AG.
Test procedure
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or repaired).
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Note
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Wood or plastic wedge
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
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s
Further assembly is basically the sreverse
of the dismantling pro
cedure.
gu
ara
nte
eo
ra
c
Golf - Jetta 2005

Increase engine speed to about 2500 rpm for approx. 2 mi
nutes.
If hydraulic tappets are still noisy, locate defective tappets as fol
lows:
Note
cloth.
olkswagen AG
en AG. V
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Rotate crankshaft clockwise until cam of tappet
to be checked
sa
s
is pointing upwards.
If play exceeds 0.2 mm, renew bucket tappet. If play is less

than 0.1 mm or there is no play, continue with check as follows:
Push bucket tappet down lightly with a wooden or plastic
wedge. If when bucket tappet is pushed down, a 0.2 mm feeler
gauge can be pushed between camshaft and bucket tappet,
bucket tappet must be renewed.
Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. Hydraulic compensation el
ements must settle (otherwise valves will strike pistons).
r
fo
ng
Checking valve guides
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Universal dial gauge bracket -VW 387-
ht
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Co
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2.5
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s
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form
spec
atio
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n
wit
i
n
thi
sd
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p
Determine play between cam and bucket tappet.
Dial gauge
51
Golf - Jetta 2005

Test procedure
Insert new valve in guide. End of valve stem must be flush with
guide. Due to differences in stem diameters, use only an inlet
valve in inlet guide and an exhaust valve in exhaust guide.
Determine rock. Wear limit: inlet valve guide = 1.0 mm; ex
haust valve guide = 1.3 mm.
2.6
Renewing valve guides

Drift -3121-
7 mm reamer -3120- and cutting fluid
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Removing
Clean and check cylinder head. Cylinder heads in which the

valve seats can no longer be reworked (observe minimum di
mension page 43 ), or cylinder heads which have already
been machined to the minimum dimension ( page 42 ),
should not have the valve guides renewed.
Press out worn valve guides with drift -3121- from camshaft
side (repair version with shoulder - from combustion chamber
side).
Installing
Using drift -3121- , press in new, oil coated guides from cam
shaft side to shoulder in cold cylinder head.
agen
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by
AG.
Prote
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by
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rig
ht
.
C
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ht
rig
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Co
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52
do
c
um
en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
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t
a
itte
riv
du
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nl
f
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n
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ab
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AG. Volkswagen AG d
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Golf - Jetta 2005

Note
When the shoulder on guide makes contact, the pressure must

not exceed 10 kN (approx. 1.0 t) otherwise shoulder may break
off.
Ream valve guide with 7 mm reamer -3120- . Use plenty of
cutting fluid.
Reworking valve seats page 43 .
2.7
Renewing valve stem seals
(With cylinder head installed)

equipment required
Puller -VAS 3047A Plug spanner -VAS 3122B-
do
c
um
en
pe
rm
itte
d
r
te o
iva
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fo
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n
rrectness of i
t to the co
nform
spec
a
t
i
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o
n in
wit
thi
s
es, in part or in w
l purpos
hole
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, is n
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com

1331- (5..50 Nm)
ility
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Assembly tool -T10029-
un
le
Fitting tool -3129-
AG. Volkswagen AG d
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Co
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Valve assembly device

-2036-
53
agen
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AG.
Prote
cted
by
c
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p
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C
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Golf - Jetta 2005

Valve lever -VW 541/1A Thrust piece for VW 541/1A
and 2037 -VW 541/5-
AG. Volkswagen AG d
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by
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rig
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.
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Remove camshaft page 48 .
Remove bucket tappets and place bucket tappets with the

contact surface downwards. When doing this, ensure that tap
pets are not interchanged.
AG.
Pull off spark plug connectors using assembly tool -T10029- .

Remove spark plugs using plug spanner -VAS 3122B- .
Set piston of respective cylinder to bottom dead centre.
54
ht
rig
py
Co
t.
Removing
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
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o
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erm
or
e
t
a
itte
v
i
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p
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an
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ce
un
le
Pressure hose -VW 653/3-
Golf - Jetta 2005

Fit valve assembly tool -2036- and adjust mountings to height
of studs.
Screw pressure hose -VW 653/3- into spark plug thread.
Connect pressure hose to compressed air source of at least 6
bar.
Remove valve springs using valve lever -VW 541/1A- and
thrust piece for VW 541/1A and 2037 -VW 541/5- .
Note
Tight cotters can be loosened by tapping lightly on lever.

Pull off valve stem seals using puller -VAS 3047A- .
Installing
pe
rm
itte
d
un
le
Place
stem. This will prevent the new valve stem seal -B- being
damaged.
do
c
um
en
ht
rig
py
Co
t.
r
te o
iva
r
rp
fo
g
n
Oil valve stem seal sealing lip and press carefully onto the
valve guide.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Place new valve stem seal in fitting tool -3129- .
ility
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ce
AG. Volkswagen AG d
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a
c
s
the
s plastic sleeve -A- supplied on the respective valve
55
agen
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by
AG.
Prote
cted
by
c
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rig
ht
.
C
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yi
Golf - Jetta 2005

17
Lubrication
Removing and installing parts of the

lubrication system
Note
Finding metal shavings or a large quantity of small metal par
ticles during engine repair could indicate that the crankshaft

bearings or conrod bearings are damaged. To prevent sub
sequent damage, perform the following after repairs:
Thoroughly clean oil channels.

Renew oil spray jets.
Renew oil cooler.
Renew oil filter.
The oil level must not be above the max. mark - danger of
damage to catalytic converter! Markings page 57 .
Engine oil page 56 .

Assembly overview - Oil filter bracket page 59 .
Assembly overview - Oil pump page 58 .
Checking oil pressure and oil pressure switch page 63 .
1.1
Engine oil
Oil capacities:
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
Engine oil specification: vehicles 05.99 with LongLife service

Use engine oils conforming to VW standard 503 00.
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Prote
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Rep. Gr.17 - Lubrication
ht
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Co
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56
thi
sd
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en
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l purpos
hole
ercia
, is n
m
m
ot p
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c
erm
or
e
t
a
itte
iv
r
du
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o
nl
f
e
ng
Engine oil conforming to VW standard 500 00, 501 01 or 502 00

can be used. In exceptional cases only: multi-grade/single-grade
oil conforming to ACEA A2/A3.
ility
ab
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. Volkswagen AG
gen AG
does
swa
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not
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With oil filter 4.0 l.
V
gu
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db
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nte
is
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Latest figures Exhaust
emissions
test
binder
.
o
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h
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c
s
s
Engine oil specification:
Vehicles 05.99
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
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iv
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o
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f
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Note
AG. Volkswagen AG d
agen
s no 2005
Golf -oeJetta
ksw
l
o
t gu
yV
b
ara
d injection engine, 2005 - Edition 09.2005
4-cylinder
e
nte
is
r
o
eo
h
ut
ra
a
c
s
s
The engine is filled at the factory with engine oil conforming to
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
VW standard 503 00. This engine oil is designed for long serv
ice intervals.
Engine oils conforming to VW standard 500 00, 501 01 or
502 00 can continued to be used. These oils must be changed

every 12 months or 15,000 kilometres. The service interval
display must be programmed accordingly. Procedure: Main
tenance ; Booklet 37 .
Markings on oil dipstick

1 - max. mark
2 - min. mark
b - Oil level within hatched field: can be topped up with engine oil
ht
rig
py
Co
t.
c - Area from min. mark up to hatched zone: must be topped up,

max. 0.5 l of engine oil!
thi
sd
o
cu
m
en
a - Area above hatched zone up to max. mark: do not top up with

engine oil!
agen
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AG.
Prote
cted
by
c
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py
rig
ht
.
C
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1. Removing and installing parts of the lubrication system
57
Golf - Jetta 2005

1.2
Assembly overview - Parts of lubrication system
1 - Oil dipstick
The oil level must not be
above the max. mark!
Markings page 57
2 - Dipstick guide
Secured to intake mani
fold
Pull out to extract oil
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
6 - Bolt
15 Nm
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
5 - O-ring
Renew
pe
rm
itte
d
4 - Dowel sleeves
ility
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un
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3 - Guide tube
AG. Volkswagen AG d
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Prote
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11 - Sump AAAA
Clean sealing surface
before fitting
Install with silicone seal
ant -D 176 404 A2 page 60
page 60
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10 - Bolt
15 Nm
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9 - Bolt
15 Nm
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8 - Baffle plate
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7 - Suction line
Clean strainer if soiled
12 - Seal
Renew
13 - Oil drain plug
30 Nm
Renew plug with attached seal
14 - Oil pump
With 12 bar pressure relief valve
Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted
Renew if running surfaces and gears are scored
15 - Sprocket
16 - Bolt
20 Nm
Use counterhold tool -T10051- to loosen and tighten
58
Golf - Jetta 2005

17 - Chain
18 - Bolt
15 Nm
19 - Sealing flange
Must seat on dowel sleeves
Install with silicone sealant -D 176 404 A2 Removing and installing
Renewing crankshaft oil seal - pulley end
20 - Chain tensioner with tensioning rail
15 Nm
When installing, pre-tension spring and fit
21 - Pressure relief valve
27 Nm
22 - Oil spray jet
For piston cooling
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6 - Non-return valve
8 Nm
Different versions: bol
ted or pressed in
Pressed in valves are
not available as replace
ment parts
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5 - Gasket
Renew
AG.
4 - Piston
For pressure relief
valve, approx. 4 bar
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3 - Spring
For pressure relief
valve, approx. 4 bar
Prote
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2 - Seal
Permanently attached
to Item 1 (page 59)
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1 - Plug
40 Nm
Renew
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Assembly overview - Oil filter bracket
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1.3
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7 - Seal
Push on up to shoulder
of sealing cap
Item 8 (page 59)
8 - Cap
9 - Securing clip
10 - Plug
15 Nm
59
Golf - Jetta 2005

11 - Seal
If seal is leaking, nip open and renew
12 - 1.4 bar oil pressure switch -F1 25 Nm
Black
Checking page 63
13 - Seal
If seal is leaking, nip open and renew
14 - Oil filter bracket
15 - Bolt
Renew
16 - Gasket
Renew
Fit into lugs on oil cooler
17 - Oil cooler
Coat contact surface to oil filter bracket outside the seal with sealing paste -AMV 188 100 02 Ensure clearance to adjacent components
18 - Nut
25 Nm
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1.4
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19 - Oil filter
Loosen with strap wrench or
Tighten by hand
Observe installation instructions on oil filter
Removing and installing sump

Jointed wrench 10 mm -3185-
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60
Golf - Jetta 2005

AG. Volkswagen AG d
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Not illustrated:
Hand drill with plastic brush attachment
Silicone sealant -D 176 404 A2-
1.4.1
Removing
Remove centre and right-hand insulation tray: Rep. Gr. 50 .
Note
ht
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Co
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Observe environmental regulations for disposal.
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Drain engine oil.
rrectness of i
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spec
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Special wrench, long reach -T10058-
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Pull 3-pin connector off oil level and oil temperature sender G266- .
AG.
Loosen and tighten sump bolts using 10 mm jointed wrench

-3185- . Loosen or tighten flywheel-end bolts only with allen
key, long reach -T10058- .
Remove sump. If necessary, loosen sump using light blows
with rubber-headed hammer.
Remove sealant residue on cylinder block with a flat scraper.
Remove sealant residue on sump using a rotating brush, e.g.
a hand drill with a plastic brush attachment (wear protective
glasses).
Clean sealing surfaces. They must be free of oil and grease.
1.4.2
Installing
Note
Note use-by date of silicone sealant -D 176 404 A2- .
Install oil sump within 5 minutes of applying silicone sealant -
D 176 404 A2- .
61
Golf - Jetta 2005

Cut off tube nozzle at forward marking (approx. 3 mm nozzle
).
Apply silicone sealing compound, as shown, to clean sealing
surface on oil sump. Sealant bead must be:
2...3 mm thick
Run bead along inner side of bolt holes -arrows-.
Note
The sealing compound bead must not be thicker. Otherwise ex

cess sealing compound will enter the sump and can block the oil
suction line strainer.
Apply silicon sealant, as shown in diagram, with great care
(particularly in area of -arrows-) to clean contact surface of oil
sump.
Fit sump immediately and tighten bolts as follows:
1-
Tighten all bolts between sump and cylinder block only very
lightly and in diagonal sequence.
2-
Tighten bolts between sump and gearbox lightly.
3-
Further tighten all bolts between sump and cylinder block

lightly and in diagonal sequence.
4-
Tighten bolts between sump and gearbox to 45 Nm.
5-
Tighten all bolts between sump and cylinder block diago n AG. Volkswagen A
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that sump is flush with cylinder block at flywheel end.
Let sealing compound dry for approx. 30 minutes after instal
ling sump. Only then fill with engine oil.
AG.
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62
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cedure.
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When installing sump with engine out of the vehicle, ensure

equipment required
Oil pressure tester -V.A.G
1342 Voltmeter -V.A.G 1527/B-
r
fo
ng
Auxiliary measuring set V.A.G 1594/A- or auxiliary

measuring set -V.A.G
1594/C-
rrectne
s
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spec
atio
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Checking oil pressure and oil pressure switch
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1.5
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Golf - Jetta 2005
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Test prerequisites
Engine oil level OK, checking page 57
Engine oil temperature at least 80 C (radiator fan must have

run once)
Note
Functional check and repair of the visual and acoustic oil pressure
warning Current flow diagrams, Electrical fault finding and Fit
ting locations.
63
Golf - Jetta 2005

Test procedure
Remove oil pressure switch -F1- and screw it into tester.
Screw tester into oil filter bracket in place of oil pressure
switch.
Connect brown wire of tester to earth (-).
Connect voltmeter -V.A.G 1527/B- to battery positive (+) and
oil pressure switch using cables from auxiliary measuring set
-V.A.G 1594/A- or auxiliary measuring set -V.A.G 1594/C- .
LED must not light up.
If the LED lights up, renew 1.4 bar oil pressure switch -F1- .
If LED does not light up:
Start engine and run at idling speed. At 1.2...1.6 bar, the LED
must light up. Otherwise replace oil pressure switch.
Increase engine speed further. At 2000 rpm and at an oil tem
perature of 80 C, the oil pressure should be between 2.7...4.5
bar.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.
If the specifications are not obtained:
Check strainer in suction line for dirt Item 7 (page 58) .
Note
Mechanical damage, e.g. to bearings, could also be the cause

behind the oil pressure being too low.
If necessary, renew oil filter bracket with pressure relief valve
Item 14 (page 60) or oil pump.
AG. Volkswagen AG d
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Check oil channels.
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If necessary, replace oil filter bracket with pressuressrelief valve
If the specification is exceeded:
AG.
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64
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Item 14 (page 60) .
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Golf - Jetta 2005

19
Cooling system
Removing and installing parts of cool

ing system
WARNING
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Note
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. Volkswagen AG
Steam may escape when expansion tank is opened.
Wear
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protective glasses and clothing to avoid eye injuries
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When the engine is warm, the cooling system is under pres
rrectness of i
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spec
a
t
i
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wit
thi
s
sure. If necessary, release pressure before beginning repair

work.
Secure all hose connections with hose clamps comparable to
production standard.
Hose clip pliers -V.A.G 1921- or pliers -VAS 5024/- are rec
ommended for installation of spring-type clips.
Replace gaskets and seals.

The arrows on the coolant pipes and on the ends of the hoses
must be aligned with each other.
Assembly overview - parts of cooling system - body side

page 68 .
Removing and installing radiator fan -V7- and radiator fan 2 V177- page 75 .
AG.
Removing and installing thermostat page 74 .
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Removing and installing coolant pump page 72 .
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Draining and filling coolant page 69 .
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Assembly overview - parts of cooling system - engine side

page 66 .
Removing and installing radiator page 76 .

Checking cooling system for leaks page 78 .
1. Removing and installing parts of cooling system
65
Golf - Jetta 2005

1.1
Assembly overview - parts of cooling system - engine side
1 - To top of expansion tank

2 - To heat exchanger
3 - Connector
4-pin
Wire of chamber 1 or C
and wire of chamber 3 or
D for coolant tempera
ture sender -G62 Contacts for coolant
temperature sender G62- , gold-plated
4 - Sender for coolant temper
ature sender -G62 For engine control unit
With sender for coolant
temperature gauge
sender -G2 Contacts for coolant
temperature sender G62- , gold-plated
If necessary, release
pressure in cooling sys
tem before removing
5 - Securing clip
ing
6 - From heat exchanger
ility
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8 - Bolt
10 Nm
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7 - Coolant pipe
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9 - To bottom of expansion
tank
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atio
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10 - To top of radiator
11 - To bottom of radiator
12 - Oil cooler
Ensure clearance to adjacent components
13 - Bolt
10 Nm
14 - Connection
AG.
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Rep. Gr.19 - Cooling system
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17 - O-ring
Renew
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16 - Thermostat
Checking: heat thermostat in water
Opening begins at approx. 86 C
Opening lift min. 7 mm
ht
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15 - O-ring
Renew
Golf - Jetta 2005

un
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20 - Bolt
15 Nm
22 - Bolt
20 Nm
23 - Throttle valve control module
Heated by coolant
25 - Connection
26 - O-ring
Renew if damaged
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24 - O-ring
Renew if damaged
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a
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19 - Coolant pump
Check for ease of movement
If damaged or leaking, renew complete
ility
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18 - Toothed belt
. Volkswagen AG
AG
Mark D.O.R. before
removing
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Check for
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67
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Golf - Jetta 2005

1.2
Assembly overview - parts of cooling system - body side
1 - Upper coolant hose

To connection on cylin
der head
9 - Bracket
For radiator
10 - Screw
5 Nm
11 - Support
12 - Nut
10 Nm
13 - Cowling
14 - Screw
5 Nm
15 - Radiator fan 2 -V177 Removing and installing page 75
16 - Connector
17 - Radiator fan -V7 Removing and installing page 75
With radiator fan control unit -J29318 - Lower coolant hose
To connection for thermostat
68
un
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8 - Expansion tank
Test for leaks in cooling
system using cooling
system tester -V.A.G
1274- and adapter for
expansion tank -V.A.G
1274/8-
AG.
7 - Screw
5 Nm
agen
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6 - Connector
rrectness of i
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spec
a
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i
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wit
thi
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5 - Cap
Check using cooling
system tester -V.A.G
1274- and adapter for
cooling system tester V.A.G 1274/9 The pressure relief
valve must open at a
pressure of 1.4...1.6 bar
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4 - Seal
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3 - Radiator
page 76
After renewing, renew
entire coolant
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2 - O-ring
Renew if damaged
Golf - Jetta 2005

19 - Securing clip
20 - Radiator outlet coolant temperature sender -G8321 - O-ring
Renew
1.3
Draining and filling coolant

equipment required
Cooling system tester
adapter -V.A.G 1274/8 Drip tray -V.A.G 1306 Pliers -VAS 5024/ Cooling system charge unit
-VAS 6096 Refractometer -T10007-
rrectness of i
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nf
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m
spec
atio
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wit
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hole
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AG. Volkswagen AG d
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Draining coolant
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1.3.1
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Filling with coolant page 71 .
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Draining coolant page 69 .
Note
Catch drained-off coolant in a clean container for re-use or
disposal.
Observe waste disposal regulations.
69
Golf - Jetta 2005

WARNING
Steam may escape when expansion tank is opened. Wear

protective glasses and clothing to avoid eye injuries and scald
Open cap on coolant expansion tank.
Remove noise insulation tray General body repairs, exteri
or; Rep. Gr. 50 ; Body front; Noise insulation .
Open drain plug -arrow- on radiator. If necessary fit drain hose
to connection.
Note
AG. Volkswagen AG d
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Co
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70
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s
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atio
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thi
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If there is no drain plug, release quick-release coupling -arrowand pull coolant hose off radiator.
Golf - Jetta 2005

1.3.2
Filling with coolant
Note
Use only coolant additive G 12 in accordance with
TL VW 774 F. Identification: purple colour.
G 12 purple (in accordance with TL VW 774 F) can be mixed
with the previous coolant additive G 12 red!
G 12 and coolant additives marked Conforming to
TL VW 774 F prevent frost and corrosion damage, scaling

and also raise boiling point of coolant. Therefore, the cooling
system must be filled all year round with frost and corrosion
protection additives.
Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop

ical climates.
Frost protection is required down to about -25 GC

(in countries
. Volkswage
If for climatic reasons greater frost protection is required, the
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
amount of G 12 can be increased, but only up to 60% (frost

protection to about -40C). Otherwise frost protection and
cooling effectiveness are reduced again.
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The coolant concentration must
not
be
reduced
by
adding
wa
e
nte
is
r
eo
ter even in warmer seasonsutand
ho in warmer countries. The frost
ra
a
protection additive must sbe
c
s at least 40% of mixture.
If radiator, heat exchanger, cylinder head or cylinder head
gasket is replaced, do not reuse old coolant.
Recommended mixture proportions:

Frost
protection to
-25 C
-35 C
Anti-freeze
proportion
40 %
50 %
G 126)
Water6)
3.2 l
4.0 l
4.8 l
4.0 l
6) The quantity of coolant can vary depending upon vehicle equipment.
Close drain plug -arrow-.
Install noise insulation tray General body repairs, exterior;

Rep. Gr. 50 ; Body front; Noise insulation .
With cooling system filler unit -VAS 6096Prote
cted
by c
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Fill coolant circuit using cooling system charge unit VAS 6096- Operating instructions for cooling system charge
unit 6096 .
ht
rig
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Co
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Screw adapter for cooling system tester -V.A.G 1274/8- onto

expansion tank.
do
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es, in part or in w
l purpos
hole
ercia
, is n
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erm
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A
agen
with arctic climates: down to about -35
C).
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Without cooling system filler unit -VAS 6096-
71
es, in part or in w
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hole
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Golf - Jetta 2005
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2005 - Edition 09.2005
c
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Slowly fill coolant to upper marking of shaded field on expan

sion tank.
rrectness of i
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nf
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spec
atio
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wit
Fit expansion tank cap.
Start engine and maintain an engine speed of about 2000 rpm

for about 3 minutes.
Run engine until radiator fan cuts in.
WARNING


1331- (5..50 Nm)
Assembly tool for springtype clips -VAS 5024- or
spring-type clip pliers -VAS
5024/A-
AG.
Refractometer -T10007-
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equipment required
72
Prote
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Removing and installing coolant pump
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1.4
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Check coolant level and top-up if necessary. When the engine

is at normal operating temperature, the coolant level must be
at the upper mark; when the engine is cold, in the middle of
the shaded field.
un
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Note
Always renew seals and gaskets.
rrectness of i
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spec
a
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wit
thi
s
The lower part of the toothed belt guard need not be removed.
The toothed belt remains on the crankshaft belt pulley.
Cover toothed belt with a cloth to protect it from coolant before
removing coolant pump.

Remove toothed belt guard upper and centre parts.
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Take toothed belt off coolant pump belt pulley page 28 .
do
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Remove securing bolt -1- from rear toothed belt guard -2-.
Unscrew coolant pump securing bolts -5- and remove coolant

pump -4-.
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Installing
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Golf - Jetta 2005

injection engine, 2005 - Edition 09.2005
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Removing
c
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Installation is carried out in the reverse order. When installing,

note the following:
AG.
Moisten new O ring -3- with coolant.

Fit coolant pump -4-. Installation position: drain plug in housing
faces downwards.
Tighten securing bolts -5-.
Torque: 15 Nm
Tighten rear toothed belt guard -2- securing bolt -1- to cylinder
head.
Torque: 20 Nm
Torque: 25 Nm
Fill with coolant page 71 .
73
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Golf - Jetta 2005

1.5
Removing and installing thermostat
rrectness of i
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spec
at
i
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wit
in t
his

equipment required

1331- (5..50 Nm)
Assembly tool for springtype clips -VAS 5024- or

spring-type clip pliers -VAS
5024/A-
74
AG.
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Always renew seals and gaskets.
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Note
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Removing
Golf - Jetta 2005

Pull coolant hose off connection -3-.
Remove connecting flange -3- securing bolts -4- and remove
connecting flange -3- with thermostat -1-.
Installing
note the following:
es
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Moisten new O ring -2- with coolant.
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Note
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Fit connection -3- with thermostat -1- into
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Tighten securing bolts -4-.

1.6
rrectness of i
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spec
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wit
The brace on the thermostat must be almost vertical.
Removing and installing radiator fan V7- and radiator fan 2 -V177-
Removing radiator fan:

Remove cowl securing bolts -arrows-.
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Unclip lower coolant hose on radiator.
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Remove air cowling on lock carrier.
Separate electrical connector -1- and unbolt lower cowling se

curing bolts -arrows-.
Remove cowl downwards.
75
Golf - Jetta 2005

Disconnect electrical connection -1- and free wiring.
Remove nuts -arrows- and remove fans.
Installing radiator fan:
Installation is carried out in the reverse order; note the following:
Install cowling from below.
Torque settings
Component
Nm
Radiator fan to cowling

Cowling to radiator
10
5
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Bring lock carrier into service position General body repairs;
Rep. Gr. 50 ; Body front; Lock carrier service position .
Pull coolant hoses off radiator.
76
thi
sd
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en
Removing radiator:
Prote
cted
by
Cooling system charge unit

-VAS 6096-
rrectness of i
t to the co
nf
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m
spec
atio
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n in
wit
Spring-type clip pliers -VAS

5024/A-
AG.
Drip tray -V.A.G 1306-
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adapter -V.A.G 1274/8-
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equipment required
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Removing and installing radiator
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1.7
Golf - Jetta 2005

Remove cowling with radiator fans page 75 .
To prevent damage to
ses, ensure that pipes
bent.
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Note
Remove bolts -1- from radiator mounting.

Swing radiator slightly to back.
Remove radiator upwards.
Installing radiator:
rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit
Remove condenser securing bolts -2-.

note the following:
If a new radiator is installed, the old coolant may not be reused.
5
5
5
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AG.
Prote
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Radiator mounting to lock carrier

Condenser to radiator
Cowling to radiator
Nm
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Torque settings
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77
Golf - Jetta 2005

Checking cooling system for leaks

equipment required
Test sequence
WARNING

Open cap on coolant expansion tank.
78
AG.
Engine at operating temperature.
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Checking pressure relief valve in filler cap page 79
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Cooling system tester V.A.G 1274-
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1.8
Golf - Jetta 2005

Set cooling system tester -V.A.G 1274- with adapter V.A.G 1274/8- on coolant reservoir.
Use hand pump on tester to create a pressure of about 1.0 bar.
If pressure drops find leaks and rectify.
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Testing pressure relief valve in filler cap
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1.8.1
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Set cooling system tester -V.A.G 1274- with adapter V.A.G 1274/9- on cap.
Operate hand pump.
Pressure relief valve should open at between 1.4 and 1.6 bar.
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79
Golf - Jetta 2005

20
Fuel supply system
Fuel tank
Safety precautions when working on fuel supply system

page 80 .
Rules for cleanliness page 80 .
Assembly overview - fuel tank page 81 .
Emptying fuel tank page 82 .
Removing and installing fuel tank page 84 .
1.1
Safety precautions when working on the

fuel supply system
Caution

tions:
Route all the various lines (e.g. for fuel, hydraulics, acti
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po
sitions.
When removing and installing fuel gauge sender or fuel pump
(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
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Prevent skin contact with fuel! Wear fuel-resistant gloves.

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Rules for cleanliness
When working on the fuel supply and injection system, pay careful
attention to the following 5 rules:
Thoroughly clean all unions and the adjacent areas before
disconnecting.
Place parts that have been removed on a clean surface and
cover them over. Do not use fluffy cloths!
Carefully cover or seal open components if repairs cannot be
carried out immediately.
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Only install clean components: replacement parts should only

be unpacked immediately prior to installation. Do not use parts
that have been stored loose (e.g. in tool boxes etc.).
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Rep. Gr.20 - Fuel supply system
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80
do
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When the system is open: Do not work with compressed air if

this can be avoided. Do not move vehicle unless absolutely
necessary.
rrectness of i
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spec
a
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1.2
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Before commencing work,n switch

extraction sys
wagexhaust
en AG
AG. Volkson
doesender
wage hose close to the
tem and place an extraction
opening
s no
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in the fuel tankdto
by extract escaping petrol fumes. Ifgno
araexhaust
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extraction system
is available, a radial fan with a displacement
eo
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3
u
ra
of at least
c
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s
of the air stream).
Golf - Jetta 2005

1.3
Assembly overview - fuel tank
1 - Cap
Renew if damaged
2 - Securing bolt
3 - Earth connection
ing
4 - Bolt
10 Nm
5 - Cable guide
6 - Fuel tank
When removing, sup
port using engine-/gear
box jack -V.A.G 1383/A Removing and installing
page 84
7 - Bolts
25 Nm
Renew
8-
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10 - Heat shield
11 - Fuel filter
Fitting position: arrow
indicates direction of
flow
12 - Supply line
To fuel rail
ing
13 - Breather line
Clipped onto side of fuel tank
thi
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14 - Seal
Renew if damaged
When installing, insert seal dry into fuel tank opening
Moisten with fuel only when installing flange
rrectness of i
t to the co
nf
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m
spec
atio
h re
n in
wit
es, in part or in w
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9-
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Clamping
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Securing
strap
c
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15 - Fuel delivery unit

If fuel delivery unit was replaced, adapt the engine control unit to the fuel pump Vehicle diagnosis,
testing and information system VAS 5051; Guided functions
Checking fuel pump page 92
Note installation position on fuel tank page 82
With fuel gauge sender -G Removing and installing fuel sender page 91
Clean strainer if soiled
1. Fuel tank
81
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Golf - Jetta 2005

16 - Locking ring
110 Nm
Remove and install using wrench -T1020217 - Supply line
Black
18 - Return line
Blue
19 - Tank flap unit
With rubber cup
Removing and installing General body repairs, exterior; Rep. Gr. 55 ; Tank flap unit; Removing and
installing fuel tank flap unit
Fitting position of fuel delivery unit flange
Marking -3- on sender points opposite direction of travel.
Return line (blue or with blue mark) -1-.
Supply line (black) -2-.
Emptying fuel tank

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Fuel extractor -VAS 5190-
rrectness of i
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spec
atio
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wit
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82
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1.4
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Golf - Jetta 2005

Wrench -T10202-
Torque wrench (40...200 Nm) -V.A.G 1332 Note safety precautions before beginning work page 80 .
Emptying fuel tank if it is more than 3/4 full page 83
Emptying fuel tank if it is less than 3/4 full page 84
1.4.1
Emptying fuel tank if it is more than 3/4

AG. Volkswagen AG d
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Detach tapered adapter -2- from shaft end -1- of fuel extractor
-VAS 5190- .
Use insulating tape to mark the extraction hose -arrow- at a
distance of -a- = 1.180 mm from the end of the hose.
Fit shaft end -1- of fuel extractor -VAS 5190- onto fuel filler
neck.
do
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Remove filler cap from fuel filler neck.
rrectness of i
t to the co
nform
spec
a
t
i
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wit
thi
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Secure earth wire of fuel extractor -VAS 5190- to a bare metal

part on the body.
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Push extraction hose into fuel tank until marking on hose

-arrow- coincides with shaft end.
1. Fuel tank
83
agen
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AG.
Golf - Jetta 2005

Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank -1-; it must not be damaged by the extraction hose -3-.
Therefore, only push the hose in as far as the tape marking
-arrow-.
Drain fuel tank as much as possible through fuel filler neck.
Carefully remove extraction hose.
Note
When no more fuel is extracted, the tank is emptied just
enough for the sender flange to be opened without danger.

The tank may be removed while containing remaining fuel.
Emptying the fuel tank completely page 84 . AG. Volkswagen

AG do
agen
1.4.2
Emptying fuel tank if it is less than 3/4 full
Remove cover from fuel delivery unit.

WARNING
Fuel supply line is pressurized. Wear eye protection and pro

tective clothing to avoid injuries and skin contact. Before loos
ening hose connections, wrap a cloth around the connection.
Pull connector and fuel lines off flange.
Note
Press buttons on hose couplings to do this.
Prote
cted
by
1.5
Removing and installing fuel tank
84
AG.
If fuel tank needed only to be emptied, reinstall sender flange

page 89 .
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Insert suction hose of fuel extractor -VAS 5190- as far as pos

sible into fuel tank and extract fuel.
ht
rig
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Co
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Lift sender flange.
r
fo
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Open locking ring using wrench -T10202- .
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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wit
i
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Remove seat bench General body repairs, interior; Rep.

Gr. 72 ; Rear seat; Removing and installing seat bench .
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Torque wrench (5...50 Nm) -V.A.G 1331-
Golf
n AG. Volkswagen A
G do - Jetta 2005
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wage
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o
4-cylinder
injection
engine,
2005
- Edition
V
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Engine-/gearbox jack -V.A.G 1383/A-
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Removing fuel tank

Note safety precautions before beginning work page 80 .
First check whether a coded radio is fitted. If so, obtain antitheft coding.
Note
Before disconnecting battery, open fuel filler flap and, if applica

ble, take wheel lock adapter out of luggage compartment.
Disconnect earth strap at battery with ignition switched off
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
If necessary, empty fuel tank using fuel extractor -VAS 5190 page 82 .
Remove cover -1- from fuel delivery unit.
1. Fuel tank
85
Golf - Jetta 2005

Pull 5-pin connector -1- off flange.
Remove right rear wheel.
Remove rear right wheel housing liner General body re
pairs, exterior; Rep. Gr. 66 ; Removing and installing wheel
housing liner; Rear wheel housing liner .
Unscrew tank flap unit securing bolt and remove tank flap unit
General body repairs, exterior; Rep. Gr. 55 ; Tank flap unit .
Unbolt filler pipe from body -arrows-.

Unclip electrical wiring from filler pipe.
Remove middle and rear silencers.
Remove heat shields from middle and rear silencers.
WARNING

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Press in safety ring to release
Disconnect breather hose -1- (white) and fuel line -2- (black)
at connecting point.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
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fuels alines.
ac
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Golf - Jetta 2005

Remove securing strap bolt and securing strap. When doing
this, support fuel tank with engine-/gearbox jack -V.A.G 1383/
A- .
Lower fuel tank.
Installing fuel tank
Installation is performed in the reverse sequence. In the process,
note the following:
Install breather and fuel lines free of kinks.
Do not interchange supply and return hose (return hose blue
or with blue markings, supply hose black).
Ensure that fuel line connections are tight.
rrectness of i
t to the co
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spec
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wit
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Check earth connection between tank and body of filler
by neck.
ara
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If fuel delivery unit was renewed, adapt engine ucontrol
unit
to
h
t
ra
a
fuel pump Vehicle diagnosis, testing and information
system
c
s
s
1. Fuel tank
87
Golf - Jetta 2005

Repairing fuel supply

Note
Fuel hoses on engine must be secured only with spring-type
clips which conform to production standard.
Spring-type clip pliers -VAS 5024/A- or hose clip pliers -V.A.G
1921- are recommended for installation of spring-type clips.
If fuel delivery unit was renewed, adapt engine control unit to
fuel pump Vehicle diagnosis, testing and information system

Safety precautions when working on fuel supply system

page 88 .
Removing and installing fuel delivery unit pagen89
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Checking fuel pump page 92 .
rrectness of i
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spec
a
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Caution
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Safety precautions when working on the

ss
fuel supply system
un
le
2.1
G do
es n
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ua
ran
tee
or
ac

tions:
Route all the various lines (e.g. for fuel, hydraulics, acti
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po
sitions.
AG.
2.2
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Prevent skin contact with fuel! Wear fuel-resistant gloves.
disconnecting.
88
ht
rig
py
Co
t.
Before commencing work, switch on exhaust extraction sys

tem and place an extraction hose close to the sender opening
in the fuel tank to extract escaping petrol fumes. If no exhaust
extraction system is available, a radial fan with a displacement
of at least 15 m3/h can be used (the fan motor must be clear
of the air stream).
do
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When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
Golf - Jetta 2005

necessary.
2.3
Removing and installing fuel delivery

unit
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Wrench -T10202-
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Fuel tank should be no more than1/2full.
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2.3.1
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Installing page 90 .
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Removing page 89 .
rrectness of i
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a
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wit
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s
Torque wrench (40...200 Nm) -V.A.G 1332-
Note
If necessary, empty fuel tank using fuel extractor -VAS 5190- .
Note safety precautions before beginning work page 88 .
Observe rules for cleanliness page 88 .
First check whether a coded radio is fitted. If so, obtain antitheft coding.
Disconnect earth strap at battery with ignition switched off
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
2. Repairing fuel supply
89
Golf - Jetta 2005

es n
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Remove cover -1y Vfrom fuel delivery unit.

Pull connector as well as supply and return lines -1 and 2- off

flange.
Note
Press in safety ring to release fuel lines.
do
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Open locking ring using wrench -T10202- and raise flange

slightly.
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Pull fuel delivery unit and seal out of the opening in fuel tank.
Note
If delivery unit is to be renewed, drain old delivery unit before dis

posal.
2.3.2
Installing
Installation of fuel delivery unit is carried out in reverse order. In

the process, note the following:
When inserting fuel delivery unit, ensure that fuel gauge send
er is not bent.
Insert seal for fuel delivery unit dry into opening of fuel tank.
Moisten seal with fuel only when installing fuel delivery unit.
Observe fitting position of fuel delivery unit flange page 82
Do not interchange supply and return hose (return hose blue
or with blue markings, supply hose black).
Ensure that fuel line connections are tight.
If fuel delivery unit was renewed, adapt engine control unit to
fuel pump Vehicle diagnosis, testing and information system
Observe required procedures after connecting battery Elec
trical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
90
rrectness of i
t to the co
nform
spec
at
i
h re
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es, in part or in w
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WARNING
ss
Golf - Jetta 2005

2.4
Removing and installing fuel gauge

sender -G-
Removing
Remove fuel delivery unit page 89 .
ility
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Installing
un
le
Insert fuel sender -G- into guides on fuel delivery unit and
press upwards until it engages.
Reconnect connector and check that it has engaged correctly.
ht
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fo
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Install fuel delivery unit page 90 .
rrectne
s
s
o
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i
t to the co
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form
spec
atio
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wit
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Release connectors for lines -1- and
-2and
pull
off.
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Raise retaining tabs -3- and -4using
a
screwdriver
and
pull
t
u
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c
fuel gauge sender off downwards
-arrows-.
s
s
91
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Golf - Jetta 2005

2.5
Checking fuel pump

equipment required
Pressure tester -V.A.G
1318 Adapter -V.A.G 1318/1 Adapter -V.A.G 1318/11 Hose adapter -V.A.G
1318/16 Adapter -V.A.G 1318/17 Connector -V.A.G 1318/23-en AG. Volkswagen AG
does
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92
rrectness of i
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at
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Golf - Jetta 2005

Wrench -T10202-
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Remote control -V.A.G
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Auxiliary measuring
set au
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s
V.A.G 1594/C-
Multimeter -V.A.G 1715-
rrectness of i
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spec
at
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Torque wrench (40..0.200

Nm) -V.A.G 1332 Measuring container
Voltmeter -V.A.G 1527/B-
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2.5.1
Checking function and voltage supply
Battery charge at least 11.5 V.
Fuse SC27 on fuse holder OK.
Fuel pump control unit -J538- is OK.
Fuel pressure sender for low pressure -G410- is OK.
Switch on ignition. Fuel pump must run briefly.
93
Golf - Jetta 2005

Note
The fuel pump runs very quietly.

Switch off ignition.
If fuel pump does not run
Pull connector off fuel pump control unit -J538- .
Check voltage supply between contacts -1- and -6- using volt
meter -V.A.G 1527/B- . The LED must light up.
If LED does not light up.
Locate and eliminate open circuit using current flow diagram
Current flow diagrams, Electrical fault finding and Fitting lo
cations.
agen
If LED lights up (voltage supply
OK).
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Pull 5-pin connector off fuel delivery unit flange.
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94
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Remove cover -1- with fuel pump control unit -J538- -2- from
fuel delivery unit.
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Golf - Jetta 2005

Open locking ring using wrench -T10202- .
Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found.
Fuel pump is defective. Renew fuel delivery unit page 89 .
2.5.2
Checking fuel pressure

WARNING
ole,
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is n
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p
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The fuel supply line
y V is under pressure! Wear protective
ua glasses
b
d
r
and clothing rto
ise avoid injuries and skin contact. Beforeanloosen
tee
ing hose uconnections,
wrap a cloth around the connection.
tho
or
ac
a
Then release
pressure by carefully pulling hose off connection.
ss
Remove supply line -2- and collect escaping fuel with a cloth.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
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um
en
Connect pressure tester -V.A.G 1318- , replacing fuel supply

line with adapter -V.A.G 1318/1- and adapter set -V.A.G
1318/17- .
r
fo
ng
Close cut-off tap of pressure tester. The lever then points in

position -A-.
Switch on ignition repeatedly until fuel pressure does not rise

any more on pressure gauge.
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Read fuel pressure on pressure gauge. Specification: 3.5 to

5.0 bar.
AG.
Prote
cted
by
If fuel pressure is OK., check residual pressure page 96 .

If the specification is exceeded:
Check return line between fuel filter and fuel pump for kinking
and blockages.
If no fault is found.
Pressure limiting valve in fuel filter defective. Replace fuel fil
ter.
If specification is not reached:
95
Golf - Jetta 2005

Check fuel delivery rate upstream of fuel filter. Connect pres
sure tester -V.A.G 1318- with adapter set -V.A.G 1318/17between fuel filter and supply pipe.
Open the pressure tester shut-off tap. The handle points in
direction of flow.
Start engine and run at idling speed.
Caution
Close the cut-off tap only slowly. At a fuel pressure of 8 bar,

reopen the cut-off tap immediately to prevent damage to the
pressure tester.
Slowly close cut-off tap of pressure tester. The pressure must
rise to 6.0 bar. When 6 bar have been reached, immediately
reopen cut-off tap.
If pressure has risen:
Fuel pump is OK. Pressure limiting valve in fuel filter is defec
tive. Renew fuel filter.
If pressure does not rise:
2.5.3
Checking residual pressure
Fuel pressure is OK and pressure tester -V.A.G 1318- is con

nected. Checking fuel pressure page 95 .
Switch on ignition repeatedly until fuel pressure does not

rise
AG. Volkswagen AG d
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e
Read fuel pressure on pressure gauge. Specification:
3.5 to
ris
tho
u
5.0 bar.
a
ss
es, in part or in w
l purpos
hole
ercia
, is n
m
m
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t
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f
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Watch pressure drop on pressure gauge. After 10 minutes,

pressure must not drop below 3.0 bar.
If the pressure continues to drop:
thi
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rrectness of i
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spec
atio
h re
n in
wit

96
or
ac
Golf - Jetta 2005

Immediately close pressure tester cut-off tap. The lever then
points in direction -B-.
If the pressure drops again:
Check fuel pipe to high-pressure pump for leaks.
Renew high-pressure pump.
If pressure does not drop any further:
Check fuel line to fuel filter for leaks.
If no fault in the fuel line is detected:
Check the check valve in the fuel delivery unit. Connect pres
sure tester -V.A.G 1318- with adapter set -V.A.G 1318/17between fuel filter and supply pipe.
Open the pressure tester shut-off tap. The handle points in
direction of flow.
Volkswagen AG
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AG.
Read fuel pressure on pressure gauge. Specification:sw3.5
agento
olk
V
5.0 bar.
by
Watch pressure drop on pressure gauge. After 10 minutes,

pressure must not drop below 3.0 bar.
If pressure drops.
Fuel pump non-return valve is defective, renew fuel delivery

unit page 89 .
If the pressure does not drop:
Pressure limiting valve in fuel filter defective. Replace fuel fil

ter.
2.5.4
Checking delivery rate
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Co
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rrectne
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After pressure has built up, immediately close pressure tester

cut-off tap.
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97
AG.
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Golf - Jetta 2005

fuel delivery unit.
Pull 5-pin connector off fuel delivery unit flange.
G. Volkswagen
G d(+)gen A to contactA-1
oes of
Connect remote control -V.A.Glk1348/3Aswa
not
o
Vof connector using adapter ca
gu
fuel pump and contact -1 (+)y
b
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bles.
ise
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ut
un
le
Pull off supply line -2- and catch escaping fuel with a cloth.
Note
AG.
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98
ht
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Press in safety ring to release fuel lines.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
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is n
mer
m
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itte
v
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Remove filler cap from fuel tank filler neck.
eo
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ab
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ce
a
Connect contacts -6
ss (-)- of connector and -5 (-)- of fuel pump
using an adapter cable from auxiliary measuring set -V.A.G
1594/C- .
Golf - Jetta 2005

Connect pressure tester -V.A.G 1318- with connector -V.A.G
1318/23- and adapter set -V.A.G 1318/17- .
Push hose adapter -V.A.G 1318/16- onto adapter -V.A.G
1318/11- of pressure tester and hold it in measuring container.
WARNING
Danger of spray when shut-off tap is opened. Wear protective

glasses and clothing to avoid injuries and skin contact. Hold
container over free connection of pressure tester.
Close cut-off tap of pressure tester. The lever then points in
direction of flow -A-.
Operate remote control -V.A.G 1348/3A- . Then slowly close
cut-off tap until a pressure of 4 bar is displayed on pressure
gauge. From this point on do not move position of cut-off tap.
Empty measuring container.
The quantity delivered by the fuel pump depends on the bat
tery voltage. Therefore connect multimeter -V.A.G 1715- with
adapter cables from auxiliary measuring set -V.A.G 1594/Cto vehicle battery.
Operate remote control for 30 seconds while measuring bat
tery voltage.
Compare quantity of fuel delivered with specification.
*) Minimum delivery rate cm3/30 seconds.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
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erm
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**) Voltage at fuel pump with engine not running
b
ara
d
nte
ise
ning (approx. 2 volts less than battery voltage).
r
o
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t
u
ra
a
c
s
Example
s
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
During the test a voltage of 12.5 volts is measured at the battery.

As the voltage at the pump is approx. 2 volts less than the battery
voltage, this will equate to a minimum delivery rate of approx.
580cm3/30 seconds.
If the minimum delivery rate is not attained.
Check fuel lines for possible restrictions (kinks) or blockages.
WARNING

do
c
um
en
ht
rig
py
Co
t.
99
agen
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Golf - Jetta 2005

Pull supply hose -1- off fuel filter inlet.
Connect pressure tester -V.A.G 1318- with adapter set -V.A.G
1318/17- to hose.
Repeat delivery rate check.
If the minimum delivery rate is now attained.
Renew fuel filter.
If the minimum delivery rate is again not attained.
Remove fuel delivery unit and check for dirt in filter strainer.
Only if still no fault has been detected.
Renew fuel delivery unit.
If delivery rate has been attained, but nevertheless you suspect
a fuel supply system fault (e.g. intermittent failure of fuel supply
system):
Measure current consumption of fuel pump page 100 .
2.5.5
Checking current consumption

fuel delivery unit.
pe
rm
itte
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AG. Volkswagen AG d
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Connect multimeter -V.A.G 1715- to contact 1 -arrow- ofor5-pin
is
eo
h
connector using pick-up clamp.
ut
ra
a
c
s
s
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Note
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Measure current consumption of fuel pump. Specification:

max. 9 amps.
If the fuel system malfunction is intermittent, you can perform the

check during a road test, but a 2nd person is necessary.
If the current consumption is exceeded.
agen
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100
do
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Golf - Jetta 2005

Checking electronic power control

(EPC)
Function of EPC system page 101 .

Assembly overview - accelerator pedal module page 102 .
Removing and installing accelerator module page 102 .
3.1
Function of EPC system

AG. Volkswagen
en
With the E-Gas system, the throttle valve islknot
by a AG does n
wagoperated
ot g
o s
V
cable. There is no mechanical connection
y between the acceler
ua
db
ran
e
ator and the throttle valve.
is
te
or
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ra
c
h
ut
The position of the accelerator pedal (driver's requirement) is a

main input value for the engine control unit.
The throttle valve is operated over the complete engine speed
and load range by an electric motor (throttle valve positioner) in
the throttle valve module.
The throttle valve is operated by the throttle valve positioner which
is controlled by the engine control unit.
When the engine is not running and the ignition is switched on,
the engine control unit moves the throttle valve exactly as pre
scribed by the accelerator pedal position sender. That is, when
the accelerator is depressed halfway, the throttle valve positioner
opens the throttle valve by the same amount. The throttle is then
approximately half open.
Prote
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.
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After evaluating the torque requirements of various components

(e.g. air conditioning system, automatic gearbox, ABS/ESP and
so on), the engine control unit calculates the optimal throttle valve
opening angle for the respective situation.
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This means that the throttle valve can already be completely open
even though the accelerator pedal is depressed half way. This
has the advantage of preventing throttling losses at the throttle
valve.
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When the engine is running (under load), the engine control unit
can open or close the throttle valve independently of the accel
erator pedal position sender.
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
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The position of the accelerator spedal

is transmitted to the engine
sa
control unit by two accelerator pedal position senders (variable
resistors together in one housing) connected to the accelerator
pedal.
AG.
This also results in significantly improved consumption and ex

haust emission values under certain load conditions.
EPC is a system comprising all components which contribute to
determining, controlling or monitoring the position of the throttle
valve, e.g. accelerator pedal position sender, the throttle valve
control part, the EPC warning lamp and the engine control unit.
3. Checking electronic power control (EPC)
101
Golf - Jetta 2005

3.2
Assembly overview - accelerator pedal module
1 - Connector
Black, 6-pin
3 - Bolt
10 Nm
es, in part or in w
l purpos
hole
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Release tool -T10240-
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102
rrectness of i
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nform
spec
at
i
h re
o
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wit
in t
his
Removing and installing accelerator

module
do
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3.3
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4 - Cap
AG. Volkswagen AG d
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2 - Accelerator pedal position G79- with sender 2 for accel

erator pedal position -G185 Cannot be adjusted
The accelerator position
sender passes the posi
tion of the accelerator
on to the engine control
unit
-A- openings for release
tool
page 102
Golf - Jetta 2005

Remove steering column cover -arrows-.
ility
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rrectness of i
t to the co
nform
spec
at
i
h re
o
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hole
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Lever out cap Item 4 (page 102) using a screwdriver.
d
ran
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tee
o
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t
or
Remove securing bolt Item 3 (page 102)
u.
ac
a
ss
Push release tool -T10240- into intended holes as shown to

stop and remove accelerator pedal module.
Separate electrical connection and pull wire guide off accel
erator pedal.
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Push wiring guide -1- and electrical connector -2- onto accel
erator pedal.
do
c
um
en
Installing
Prote
cted
by
Press accelerator pedal module onto securing pins -6-.

Insert centring pin -7- into hole in floor of vehicle.
Secure accelerator pedal with bolt -3-, torque setting 10 Nm
and install cap -4-.
Install steering column trim.
3. Checking electronic power control (EPC)
103
Golf - Jetta 2005

Active charcoal filter system
Function page 104 .

Assembly overview - active charcoal filter system page 105 .
Checking fuel tank breather page 105 .
4.1
Function
Depending upon the air pressure and ambient temperature, fuel

vapour will form above the level of fuel in the tank.
The active charcoal filter system prevents these HC emissions
escaping to the atmosphere.
In limited quantities, fuel vapours pass through a gravity valve
(which closes at an angle of 45) located at the highest point in
the tank and through a pressure retention valve into the activated
charcoal filter.
The activated charcoal stores these vapours like a sponge.
When the car is being driven and the lambda control is active
(engine warm), the active charcoal filter solenoid valve 1 -N80- ,
also known as regeneration valve, is activated (pulsed) by the
olkswage
engine control unit depending upon load
and
engine
speed.
n AG d The
AG. V
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opening period depends on the input
kswsignals.
not
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spec
a
t
i
h re
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wit
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The pressure retention valve prevents fuel vapours from being

drawn from the tank when the solenoid valve is open and intake
manifold vacuum is present. It thus ensures that the evacuation
of the activated charcoal filter has priority.
ility
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During the purging procedure

ise (regeneration of the activated char
or
hvacuum
t
coal), the intake manifold
draws in fresh air through the
au
ss
vent opening on the underside
of the activated charcoal filter. The
fuel vapours stored in the activated charcoal and fresh air are fed
to combustion in metered quantities.
When not energised (e.g. open circuit), the solenoid valve is

closed. The activated charcoal filter will not be purged.
Note
Hose connections are secured with either spring-type or
clamp-type clips.
Always replace clamp-type clips with spring-type clips.

Spring-type clip pliers -VAS 5024 A- are recommended for in
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Prote
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104
do
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stallation of spring-type clips.
Golf - Jetta 2005

4.2
Assembly overview - active charcoal filter system
1 - Activated charcoal filter

Location: in engine
compartment on right
2 - Pressure retention valve
with connecting hose
3 - Connecting hose
ing
From fuel tank
4 - Bolt and nut
10 Nm
. Volkswagen AG
gen AG
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a
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wit
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s
6 - Connecting hose
To intake manifold
ing
7 - Bracket
For activated charcoal
filter
8 - Breather hose
Checking fuel tank breather
c
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4.3
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Hand vacuum pump -VAS 6213-
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9 - Sealing grommet
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a
ksw filter sol
5 - Activated charcoal
Vol
y
b
enoid valvee1
d -N80ris
ho
Valve
closed with igni
t
au
ss tion switched off
When engine is warm,
valve will be actuated
(pulsed) by engine con
trol unit
4. Active charcoal filter system
105
Golf - Jetta 2005

Adapter set -V.A.G 1318/17-
Test procedure
un
le
Ignition must be switched off.
pe
rm
itte
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Test prerequisite
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t
or
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ac
a
ss
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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com
Pull off breather line -1-. To do this, press release button.

Then connect hand vacuum pump -VAS 6213- using adapter
set -V.A.G 1318/17- to the activated charcoal filter line.
Operate hand vacuum pump -VAS 6213- several times. Vac
uum must not build up.
If vacuum builds up.
Check breather hose Item 8 (page 105) on activated char

coal filter for soiling and clean if necessary.
If vacuum does not build up.
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106
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Renew activated charcoal filter.
do
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If vacuum does not build up.
r
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fo
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n
Hold breather connection Item 8 (page 105) shut and oper

ate vacuum pump again several times. A vacuum must build
up.
Golf - Jetta 2005

24
Mixture preparation, Injection
Repairing injection system
1.1
General notes on injection
Fuel hoses in engine compartment must be secured only with

spring-type clips which conform to production standard. The
use of clamp or screw-type clips is not permissible.
The battery must be disconnected only with ignition switched
off. If a coded radio is installed, ascertain code before discon
necting battery.
Observe required procedures after connecting battery Elec
trical system; Rep. Gr. 27 ; Disconnecting and connecting
battery .
For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam
age the Lambda probe.
During some checks, it is possible that the control unit will de
tect and store a fault. Therefore, after completing all checks
and repairs, read the fault memory and erase if necessary
page 123 .
Volkswa
AG.
agen
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do
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Vehicles with an airbag are
with a crash fuel shut-off.
ot g It
olkfitted
yV
b
da fire in a crash as the fuel pump is uara
reduces the danger of
e
nte
ris
switched off via the
eo
thofuel pump relay.
au
es, in part or in w
l purpos
hole
ercia
, is n
m
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erm
or
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f
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Safety precautions page 108 .
ra
c
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ce
ss is opened, the fuel pump is activated for 2

When driver door
seconds to develop pressure in the fuel system. This improves
the quality of the start behavior.
rrectness of i
t to the co
nf
o
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m
spec
atio
h re
n in
wit

Technical data page 109 .
thi
sd
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1. Repairing injection system
107
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.
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Golf - Jetta 2005

1.2
Safety precautions
WARNING
AG. Volkswagen system

Fuel system is under pressure! Before
does
agen opening theAG
ksw Then release pressure
not
l
o
place a cloth around the connection.
by
V
gu
y
ara
db
carefully loosening the connection.
e
nt
ris
tho
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le
pe
rm
itte
d
Do not touch or disconnect ignition wiring when the engine

is running or being turned at starter speed.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
The ignition must be switched off before connecting or

disconnecting injection or ignition system wiring or tester
cables.
ee
or
ac
ility
ab
y li
an
pt
ce
To prevent injuries to
aupersons and/or damage to the fuel in
ss
jection and ignition system,
the following must be noted:
Observe following if test and measuring instruments are re

quired during a test drive:
Test and measuring instruments must be secured to rear
seat and operated by a 2nd person from this location.
If test and measuring instruments are operated from front
passenger's seat and the vehicle is involved in an acci
dent, there is a possibility that the person sitting in this seat
may receive serious injuries when the airbag is triggered.
Pull 4 pin connector -1- off output stage for ignition coils -2-.
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Note
Removing fuse 32 interrupts the voltage supply to the injectors.
1.3
disconnecting.
108
Rep. Gr.24 - Mixture preparation, Injection
ht
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Remove fuse 32.
do
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If the engine is to be turned at starter speed, without starting:
Golf - Jetta 2005

necessary.
1.4
Technical data
Engine codes
rpm
620...800
bar
bar
approx. 4.0...6.0
about 40...110
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
7) If voltage supply to engine control unit drops below 12 Volt, idling speed will
be raised incrementally up to 990 rpm. The idling speed cannot be adjusted.
8) Renew engine control unit Vehicle diagnosis, testing and information system
ht
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or
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swagen AGBosch ME 7.5.1

AG. VolkMotronic
does
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not catalogue
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Electronic parts
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is
rpm
approx.
6800
r
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Idling check
Idling speed7)
Engine control unit8)
System designation
Part number
Engine speed governor
Fuel pressure
Low pressure
High pressure
BHY
109
Prote
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by
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rig
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.
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Golf - Jetta 2005

1.5
Dismantling and assembling intake manifold - upper part
1 - Bolt
8 Nm
2 - Throttle valve module J338- *
If replaced match en
gine control unit
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or
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3 - Seal
Vol
by
d
Renew if damaged
ise
or
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ility
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4 - Rubber bush ss a
For engine cover
5 - Intake manifold - upper part
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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com
6 - 8 Nm
For securing intake
manifold - upper part
7 - 5 Nm
For engine cover
8 - To intake manifold - lower
part
10 - Intake manifold pressure

sensor -G71- with intake air
temperature sender -G72-
110
AG.
13 - To brake servo
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12 - Warm air deflector plate

with intake manifold support
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11 - Rubber bush
do
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fo
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9 - From activated charcoal fil

ter system solenoid valve I
(pulsed) -N80 Activated charcoal filter
system page 104
Dismantling and assembling intake manifold - lower part
ility
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an
pt
ce
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
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t
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itte
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1.6
Golf - Jetta 2005

AG. Volkswagen AG d
agen
oes
ksw
not
l
4-cylinder
injection
engine,
2005
- Edition 09.2005
o
gu
yV
ara
db
e
n
s
tee
ri
ho
or
ut
ac
a
ss
1 - Fuel rail with injectors
3 - Cable strip
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
2 - Bolt
8 Nm
4 - To intake manifold - upper

part
Item 8 (page 110)
5 - Sealing
Renew if damaged
6 - Bolt
25 Nm
7 - Seal ring
Renew if damaged
do
c
um
en
ht
rig
py
Co
t.
8 - Intake manifold - lower part

For air shrouded injec
tors
111
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AG.
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by
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Golf - Jetta 2005

1.7
Fuel rail
1 - Supply line
Secure with spring type
clips
ing
From fuel filter
2 - Fuel rail
3 - Securing clip
Ensure seated correctly
at injector and fuel rail
4 - Injectors -N30, N31, N32,
N33 When renewing erase
fault memory
5 - Sealing ring
Renew
Before installing mois
ten with clean engine oil
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Prote
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by
c
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rig
ht
.
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thi
sd
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m
en
112
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
o
c
erm
or
e
t
a
itte
iv
r
du
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o
nl
f
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ility
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AG. Volkswagen AG d
agen
oes
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not
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is
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ra
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c
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ht
rig
py
Co
t.
6 - Bolt
8 Nm
Golf - Jetta 2005

1.8
Dismantling and assembling air cleaner
1 - Screw
5 Nm
2 - Air duct
To bumper
3 - Air duct
11 - Screw
3 Nm
12 - Air cleaner upper part
13 - Filter element
14 - Air cleaner housing
15 - Resonator
16 - Nut
20 Nm
AG.
10 - Screw
8 Nm
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9 - Screw
2 Nm
Prote
cted
by
c
o
py
rig
ht
.
C
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yi
8 - Air duct
r
fo
ng
7 - Connection for crankcase

breather
With resistance heater
for cold climates
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
ility
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pt
ce
6 - Intake hose
With crankcase breath
er valve
un
le
5 - Screw
2 Nm
AG. Volkswagen AG d
agen
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not
l
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ht
rig
py
Co
t.
4 - Slider
17 - Spring type clip

18 - Intake air duct
19 - Screw
2 Nm
20 - Speed nut
1.9
Removing and installing intake manifold

Note
Always follow safety precautions page 108 .

Observe rules for cleanliness page 108 .
Pull hoses off vacuum reservoir and remove it.
113
Golf - Jetta 2005

AG. Volkswagen AG d
agen
oes
ksw 09.2005
not
l
4-cylinder injection engine, 2005 - Edition
o
V
g
Pull coolant hoses off throttle
y
db
ise
r
valveuhousing.
tho
a
s
s
ua
ran
tee
un
le
ility
ab
y li
an
pt
ce
Separate all electrical connections on intake manifold.
or
ac
Remove intake manifold upwards.

Installation is carried out in the reverse sequence of removal.
Removing and installing fuel rail with in

take manifold flaps
r
fo
ng
If the fuel rail is replaced, the intake manifold flap potentiometer

-G336- must be adapted to the engine control unit, Vehicle di
agnosis, testing and information system VAS 5051; Guided func
tions .
Prote
cted
by
Removing
Remove intake manifold page 113 .

WARNING

Pull off fuel supply line -2-.
Separate all electrical connections on fuel rail.
WARNING
The fuel pressure in the high-pressure pump can reach

120 bar! Wear protective glasses and clothing to avoid injuries
and skin contact. Before loosening fuel pipes, wrap a cloth
around the connection. Then release pressure by carefully
loosening banjo bolt.
Remove fuel lines.
114
AG.
1.10.1
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Removing page 114 .
ht
rig
py
Co
t.
1.10
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
Remove intake manifold securing nuts -arrows-.
Golf - Jetta 2005

Loosen fuel rail securing bolts -arrows-.
Pull fuel rail with intake manifold flaps off injectors.
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
r
erm
o
e
t
a
itte
riv
du
p
or
nl
f
e
g
n
Installing
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
1.10.2
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d
nte
ise
r
o
eo
h
t
u
ra
a
c
s
s

note the following:
Before installation, connectors must be pushed onto injectors.
If an injector was pulled out of the cylinder head when the fuel
rail was removed, Teflon seal must be renewed
page 118 .
Renew O-rings between injector and fuel rail and moisten
slightly with clean engine oil.
do
c
um
en
If the fuel rail was replaced, the intake manifold flap potenti
ometer -G336- must be adapted to the engine control unit,
Vehicle diagnosis, testing and information system VAS
5051; Guided functions .
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Set fuel rail on cylinder head and evenly press onto injectors.
115
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Prote
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by
Golf - Jetta 2005

1.11
Removing and installing injectors
Special tools and work

shop equipment re
quired
Puller -T10133-
Combustion cham
ber seal (Teflon
seal), renew. When
installed, ring must
not be greased or
treated with any
other lubricant.
3-
Groove in injector.
4-
Support washer
(renew).
5-
O-ring (renew; to
install, lightly lubri
cate with clean en
gine oil.)
6-
Support ring.
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2-
Removing page 116 .

1.11.1
Removing
Remove intake manifold page 113 .

Remove fuel rail with intake manifold flaps page 114 .
AG.
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116
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Using a screwdriver, bend locking lugs to side and pull support

ring off injector valve.
rrectne
s
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t to the co
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form
spec
atio
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thi
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Radial compensa
tion, renew if dam
aged.
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1-
un
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Injector components
Golf - Jetta 2005

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Note
Installing
eo
ra
c
The Teflon injector seal must not be oiled or lubricated.

It is possible that an open inlet valve hinders cleaning. In this
case, turn engine by hand using spanner.
Thoroughly clean holes in cylinder head for high-pressure in

jectors using nylon brush -T10133/4- .
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Co
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Renew O-ring and Teflon seal for injector page 118 .
rrectne
s
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f
i
t to the co
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form
spec
atio
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wit
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1.11.2
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Screw slide hammer -T10133/3- to puller -T10133/2- . Then

guide puller -T10133/2- into groove in injector and carefully . Volkswage
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hammer injector out. This may destroy radial compensation
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jector is installed.
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Insert injector in hole in cylinder head to stop using drift T10133/9- .
117
Golf - Jetta 2005

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Renewing Teflon seal on injector
r
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Carefully cut open seal with a knife.

Clean groove for seal.
Push new seal onto assembly cone -T10133/5- . Push seal as

far as possible onto assembly cone -T10133/5- using assem
bly sleeve -T10133/6- .
118
Prote
cted
by
Carefully clean injector in area of seal -arrow-. Remove coking

deposits using a wire brush.
AG.
The seal must not be oiled.
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Note
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Puller -T10133-
rrectne
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spec
atio
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1.12
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Insure correct position of injectors in cylinder
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Golf - Jetta 2005

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Fit assembly cone -T10133/5- on injector and push seal onto

injector using assembly sleeve -T10133/6- .
es, in part or in w
l purpos
hole
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Remove assembly cone -T10133/5- and push seal into groove

using assembly sleeve -T10133/6- .
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Turn assembly sleeve -T10133/6- around and push seal to

end of assembly cone -T10133/5- .
Press calibration sleeve -T10133/7- onto injector to stop by

turning gently (approx. 180).
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Pull off calibrating sleeve -T10133/7- by turning in opposite

direction.
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Now press calibration sleeve -T10133/8- onto injector to stop

by turning gently (approx. 180).
Pull off calibrating sleeve -T10133/8- by turning in opposite
direction.
Renew O-ring on injector and on support washer.
119
Golf - Jetta 2005

Attach support ring -1- to injector and clip radial compensation
-2- into support ring.
1.13
Cleaning throttle valve module -J338Note
When cleaning the throttle valve housing it must not be
scratched.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Undo the air filter housing and pull the intake hose off the
throttle valve housing.
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If a new engine control
unit is installed the throttleotvalve
mod
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ule must be adapted.
Adaption
must
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be
performed
is
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r
ee a
ho
or
new or cleaned
throttle valve module, because soiling/coking
ut
a
a
in closedss throttle valve can lead to incorrect adaption values.c
Remove throttle valve module.

Open the throttle valve by hand and, with a suitable object,
block the throttle valve in its open position -arrow-.
WARNING
Acetone is highly inflammable. Please observe the accidental

regulations and safety notes when handling with highly inflam
mable fluids. Do not use compressed air when cleaning the
throttle valve. Wear protective glasses and clothing to avoid
injuries and skin contact.
do
c
um
en
ht
rig
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Co
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Thoroughly clean throttle valve housing, especially around the

closed throttle valve using commercially available acetone ac
cording to DIN 53247 and a cleaning brush.
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Wipe off throttle valve housing using a lint-free cloth.

AG.
Wait until the acetone is fully evaporated and reinstall the

cleaned throttle valve module.
Adapt the engine control unit to throttle valve module Vehicle
diagnosis, testing and information system VAS 5051; Guided
functions .
120
Golf - Jetta 2005

Engine control unit
Removing and installing anti-theft engine control unit

page 121 .
Reading and erasing engine control unit fault memory
page 123 .
2.1
Removing and installing anti-theft en

gine control unit

Electric cutter -V.A.G 1561/A Saw set -V.A.G 1561/14 Pliers
Note
If the engine control unit is to be replaced, connect diagnostic
operation center -VAS 5051/- and perform Renewing engine

control unit in Guided functions.
. Volkswagen AG
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If engine control unit is renewed, throttle valve module
Vol
2.1.1
Removing
Remove wiper arms, plenum chamber cover and plenum bulk

head Electrical system; Rep. Gr. 92 ; Windscreen wiper
system; Removing and installing windscreen wiper system .
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Remove bolts with pliers .
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Cut into heads of shear bolts so that two parallel surfaces are
created -arrows-.
rrectne
s
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i
t to the co
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form
spec
atio
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wit
i
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thi
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Switch off ignition.
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Removing page 121 .
un
le
be cleaned page 120 .
2. Engine control unit
121
Golf - Jetta 2005

Insert a screwdriver between protective housing -A- and re
taining plate -arrow-.
Lever up protective housing using screwdriver -A- and pull to

side off retaining plate -arrow-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Lever up catch -2- slightly.

Then push engine control unit out of retainer -arrow-.
Now release rear connector on engine control unit and pull it
off.
2.1.2
Installing
Fit rear connector to engine control unit and lock it in position.

Push engine control unit onto bracket.
c
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Push protective housing onto bracket.

Tighten new shear bolts -1- evenly until heads shear off.
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cted
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Install plenum chamber bulkhead, plenum chamber cover and

wiper arms Electrical system; Rep. Gr. 92 ; Windscreen
wiper system; Removing and installing windscreen wiper sys
tem .
AG.
122
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Fit front connector to engine control unit and lock it in position.
do
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hole
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Release front connector -1- from engine control unit and pull
it off.
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Golf - Jetta 2005

2.2
Reading and erasing engine control unit

fault memory

Diagnostic operation center -VAS 5051/-
Connect diagnostic operation center -VAS 5051/- as follows:

Push diagnosis lead connector onto diagnosis connector in
driver footwell.
Only when engine does not start:
Switch on ignition.
Select operating mode:
ility
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Press button 01 - Engine electronics on display.

The control unit identification with code -2- as well as chassis
number and immobilizer identification number will be indicated in
the middle section of the display.
Note
A print-out can be made if needed. Press the Print key.

Select diagnostic function:
Press button 02 - Interrogate fault memory on display.

If no fault is stored in engine control unit 0 fault(s) detected
is displayed.
Prote
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by c
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Press button 05 - Erase fault memory on display.

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Press function 06 - End output.
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Press the key.
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If faults are stored in the engine control unit, these are shown
one below the other on the display.
rrectne
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form
spec
atio
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thi
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Select vehicle system:
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Press button on display for
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Vehicle
self-diagnosis.
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AG.
Note
Regenerate readiness code after erasing fault memory Vehicle

diagnosis, testing and information system VAS 5051; Guided
functions.
2. Engine control unit
123
Golf - Jetta 2005

olkswag-enEdition
09.2005
AG
en AG. V2005
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itte
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Note
After working on the exhaust system, ensure that the system
is not under stress and that there is sufficient clearance to the

bodywork. If necessary, loosen clamp and align silencers and
exhaust pipe so that sufficient clearance is maintained to the
bodywork at all points and the mountings are evenly loaded.
Always renew seals, gaskets and self-locking nuts.

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Front exhaust pipe and catalytic converter with attachments

page 125 .
Silencer with mountings page 126 .
Separating middle and rear silencers page 126 .
Aligning exhaust system stress free page 127 .
124
Rep. Gr.26 - Exhaust system
do
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fo
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Lambda probe open ring spanner set -3337-
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
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ot
com
Removing and installing parts of ex

haust system
ility
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does
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Exhaust system
un
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26
ag
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Vol
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b
ed
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Golf - Jetta 2005

engine, 2005 - Edition 09.2005
Front exhaust pipe and catalytic converter with attachments

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1 - Gasket
Renew
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1.1
AG. Volkswagen A4-cylinder

injection
G do
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spec
a
t
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wit
thi
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es, in part or in w
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hole
ercia
, is n
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com
2 - Lambda probe -G39 50 Nm

Grease thread only with
hot bolt paste -G 052
112 A3- ; hot bolt paste
-G 052 112 A3- must not
get into the slots of the
probe body
lambda probe open ring
spanner set -3337- .
3 - Warm air collector plate
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6 - Nut
25 Nm
Renew
ht
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5 - Bolt
25 Nm
do
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4 - Bolt
10 Nm
7 - Exhaust manifold
8 - Nut
40 Nm
Renew
9 - Lambda probe after catalyt
ic converter -G130 50 Nm
Grease thread only with
hot bolt paste -G 052
112 A3- ; hot bolt paste
-G 052 112 A3- must not get into the slots of the probe body
Remove and install with lambda probe open ring spanner set -3337- .
10 - Front clamp
Align exhaust system free of stress before tightening clamp page 127
Installation position page 127
Tighten bolted connections evenly
11 - To middle silencer
12 - Nut
25 Nm
13 - Tunnel bridge
14 - Nuts
20 Nm
15 - Bolts
25 Nm
16 - Mounting
Renew if damaged
1. Removing and installing parts of exhaust system
125
Golf - Jetta 2005

17 - Front pipe
18 - Gasket
Renew
1.2
Silencer with mountings
1 - From catalytic converter

2 - Mounting
3 - Bolts
25 Nm
4 - Middle silencer
In initial equipment,
component with rear si
lencer. Can be renewed
separately for repairs
Aligning exhaust sys
tem free of stress
page 127
Separate exhaust sys
tem page 126
8 - Nuts
20 Nm
9 - Tunnel bridge
Separating middle and rear silencers
Only front-wheel drive vehicles.
126
AG.
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The cutting point is marked with an indentation on the outside

of the exhaust pipe.
ht
rig
py
Co
t.
The connecting pipe can be cut through at the point marked

in order to renew the middle and rear silencers separately.
thi
sd
o
cu
m
en
1.3
rrectness of i
t to the co
nf
o
r
m
spec
atio
h re
n in
wit
7 - Mounting
Renew if damaged
ility
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6 - Rear silencer
In initial equipment,
component with middle
silencer. Can be re
newed separately for re
pairs
Aligning exhaust sys
tem free of stress
page 127
Separate exhaust sys
tem page 126
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f
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ng
5 - Retainers
Renew if damaged
Golf - Jetta 2005

Body saw -V.A.G 1523/A-
or
Chain-type pipe cutter -VAS 6254 Protective glasses
WARNING
To avoid injury from metal shavings, wear eye protection and

protective clothing.
Cut through exhaust pipe at right angles using e.g. body saw
-V.A.G 1523/A- at separating point -arrow 2-.
When installing, position clamp -4- at side markings
-arrow 1- and -arrow 3-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
Install clamp so that end of bolt does not extend beyond lower
edge of clamp.
Bolted connection faces rear.
Align exhaust system free of tension page 127 .
1.4
The exhaust system must be aligned when cold.

Prote
cted
by c
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Loosen bolted connections of front clamp.
ht
rig
py
Co
t.
Aligning exhaust system stress free
do
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en
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
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erm
o
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1. Removing and installing parts of exhaust system
127
AG.
Installation position of front clamp

edge of clamp.
Bolted connection faces right.
do
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by
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rig
ht
.
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Installation position of rear clamp

edge of clamp.
Bolted connection faces rear.
Tighten bolted connections of clamp evenly to 25 Nm.
128
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
es, in part or in w
l purpos
hole
ercia
, is n
m
ot p
om
c
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erm
o
e
t
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Push exhaust system forward until preload on rear silencer

retainer is -dimension a- 5...11 mm.
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AG. Volkswagen AG d
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Golf - Jetta
2005
nte
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h
4-cylinder
injection engine, 2005 - Edition 09.2005or a
ut
a
c
s
s
Golf - Jetta 2005

28
Ignition system
Repairing ignition system
General notes on ignition system page 129 .

Safety precautions page 129 .
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Assembly overview - ignition system page
d 130 .
ran
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tee
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or
Test data, spark plugs page 130 . au
ac
ss
General notes on ignition system

pe
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1.1
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
For trouble-free operation of electrical components, a voltage

of at least 11.5 V is necessary.
During some checks, it is possible that the control unit will de
tect and store a fault. Therefore, after completing all checks
and repairs, read the fault memory and erase if necessary
page 123 .
If, after fault finding, repairs or component tests, the engine
starts, runs for a short period and then stops, then the fault
may be that the immobilizer is blocking the engine control unit.
In this case, the control unit must be adapted Vehicle diag
nosis, testing and information system VAS 5051; Guided
functions .
1.2
Safety precautions
AG.
Observe following if test and measuring instruments are required

during a test drive:
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.
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Switch off ignition before connecting or disconnecting injection

and ignition system wiring as well as test instrument cables.
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Co
t.
Do not touch or pull off ignition coils with output stage when
engine is running or turning at starter speed.
do
c
um
en
r
te o
iva
r
rp
fo
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n
To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:
Prote
cted
by
Test and measuring instruments must be secured to rear seat

and operated by a second person from this location.
If test and measuring instruments are operated from front pas
senger's seat and the vehicle is involved in an accident, there is
a possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
1. Repairing ignition system
129
un
le
Assembly overview - ignition system
1 - H.T. cable
4...8 kw
With suppression con
nector and spark plug
connector
2 - Spark plug
25 Nm
Type and electrode gap
page 130
plug spanner -VAS
3122B-
r
fo
ng
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t
.
C
op
yi
4 - Knock sensor 1 -G61 Contacts gold plated
ht
rig
py
Co
t.
3 - Bolt
20 Nm
The torque setting influ
ences the function of the
knock sensor
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
erm
or
e
t
a
itte
v
i
r
d
p
1.3
ility
ab
y li
an
pt
ce
es n
wage
s
k
l
ot g
o
yV
ua
b
ran
ed
s
i
tee
r
Golf - Jetta 2005ho
t
or
u
ac
a
4-cylinder injection
engine,
2005
Edition
09.2005
ss
5 - 3pin connector
Contacts gold plated
Black
6 - Hall sensor -G407 - 3pin connector
Black
For hall sensor -G408 - 4pin connector
Black
9 - Ignition coil with output
stage -(N70, N127, N291,
N292) With output stage -N12210 - Bolt
10 Nm
1.4
Spark plugs
Engine codes
Firing order
Spark plugs
VW/Audi
Manufacturer's designation
Electrode gap
Torque setting
130
Rep. Gr.28 - Ignition system
BHY
1-3-4-2
101 905 620
PZFR5N-11TG
1.0...1.1 mm
25 Nm

4-Cylinder Injection Engine, 2005 BHY

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4-Cylinder Injection Engine, 2005 BHY

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Service

4-cylinder injection engine, 2005

Service Department. Technical Information

All rights reserved.

Golf - Jetta 2005

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

Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 - Cylinder head, Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Golf - Jetta 2005

Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Golf - Jetta 2005

Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Golf - Jetta 2005

Golf - Jetta 2005

Engine number page 1 .

The engine number (engine code and serial number) can be

Golf - Jetta 2005

Removing and installing engine

Removing and installing engine

Special tools and workshop

Installing engine page 8 .

Securing engine to assembly stand page 7 .

Rep. Gr.10 - Removing and installing engine

Securing engine to assembly stand page 7 .

Removing engine page 2 .

Golf - Jetta 2005

strap. First check whether a coded radio is fitted. Obtain radio

The engine is removed downwards together with the gearbox.

removed must be replaced in the same position when engine

When doing any repair work, especially in the engine compart

Remove engine cover.

Remove air filter housing with connecting hoses.

1. Removing and installing engine

Golf - Jetta 2005

Remove noise insulation tray General body repairs, exteri

Rep. Gr.10 - Removing and installing engine

Disconnect breather line -1-and fuel supply line -2-.

The fuel supply line is under pressure! Wear protective glasses

Golf - Jetta 2005

Remove bolts -1, 2 and 3- and remove pendulum support.

Vehicles with air conditioning

Separate all connection, coolant, vacuum and intake hoses

Pull off or disconnect all other electrical connections from en

Remove securing nuts -arrows- for front exhaust pipe/exhaust

To prevent damage to condenser or to refrigerant pipes and ho

1. Removing and installing engine

Golf - Jetta 2005

Do not operate clutch pedal after slave cylinder has been re

From above, unbolt engine side of assembly mounting from

Engine and gearbox must be guided carefully when lowering to

Rep. Gr.10 - Removing and installing engine

Carefully lower engine with gearbox.

From above, unbolt gearbox side of assembly mounting from

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

Golf - Jetta 2005