VOLKSWAGEN GOLF 2004 (09) PDF Document

The engine number, which consists of code letters and a serial number, can be found at the joint between the engine and the gearbox. Additionally, there is a sticker on the toothed belt guard that contains the engine code and the serial number. The engine code is also included on the vehicle data sticker.

For a one-piece engine cover, pull the cover abruptly upwards at the front and right, then pull forwards out of the rear fastening. For a two-piece engine cover, first pull the outer engine cover abruptly upwards, then pull the inner engine cover abruptly upwards.

The fuel and fuel lines can become very hot, presenting a danger of scalding. The system is also under pressure. Before opening the system, place cloths around the connections and carefully loosen the connection to release the pressure. Always wear eye and hand protection when working on the fuel system.

Remove the noise insulation and the lower part of the front right wheel housing liner. Swing the tensioning element in the direction indicated to remove tension from the poly V-belt. The 16 mm open-end spanner T10241 is suitable for this purpose. Once the tension is relieved, lock the tensioning element using the locking pin T10060 A and remove the belt.

The cylinder head bolts should be tightened in four stages as follows:

Stage I: 35 Nm

Stage II: 60 Nm

Stage III: + 90 degrees turn further

Stage IV: + 90 degrees turn further

Ensure the engine is at operating temperature. Open the expansion tank cap carefully, as hot steam may escape. Attach the cooling system tester V.A.G 1274 with the appropriate adapter to the expansion tank and use the hand pump to create a pressure of about 1.0 bar. If the pressure drops, investigate and rectify any leaks.

Close the coolant drain plug and connect all coolant hoses. Install the noise insulation and screw the V.A.G 1274/8 adapter onto the expansion tank. Fill the coolant circuit using the cooling system charge unit VAS 6096, following the instructions enclosed with the unit. The recommended mixture for -35 degrees Celsius frost protection is 50 percent anti-freeze and 50 percent water.

Check the oil level using the dipstick. If the oil level is in the area of the min. mark, top up with a maximum of 0.5 liters of engine oil. If the level is in the middle range (hatched field), it can be topped up with engine oil. If the level is in the area of the max. mark, do not add engine oil.

Ensure the engine oil temperature is at least 30 degrees Celsius. Disconnect the central connector for the unit injectors. Remove the glow plugs using the jointed extension and socket 3220. Screw the adapter V.A.G 1381/12 into the glow plug hole and connect the compression tester V.A.G 1763. Operate the starter until the tester shows no further pressure increase. The compression pressure for a new engine is 25 to 31 bar, with a wear limit of 19 bar and a maximum permissible difference between all cylinders of 5 bar.

Ceramic glow plugs are sensitive to jolts and bending; do not use a glow plug that has been dropped. Ensure the engine is cold and the ignition is switched off. Pull the connectors off the glow plugs and remove them using the jointed extension and socket 3220. When installing, clean the drilling in the cylinder head and threads of all deposits. Do not oil or grease the threads. Tighten to 15 Nm and perform a resistance test when cold; the specification is a maximum of 1 ohm.