VOLKSWAGEN GOLF 2004 (11) PDF Document

The engine number, which includes the engine code and serial number, is located next to the vibration damper on the cylinder block of the VOLKSWAGEN GOLF 2004. Additionally, a sticker containing this information is attached to the camshaft cover.

The fuel system is pressurized. You must wear eye protection and protective clothing to avoid injury and skin contact. Before loosening any hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling the hose off the connection.

If the battery is not disconnected, the fuse for the fuel pump must be removed before opening the fuel system to prevent the fuel pump from activating via the driver door contact switch.

Additionally, when removing a fuel gauge sender or fuel pump from a full or partly full tank, an activated fume extraction system must be used in the vicinity of the assembly opening.

To drain the coolant, first ensure the engine is cool, then open the cap on the coolant expansion tank to release pressure. Next, remove the noise insulation. Locate the lower coolant hose on the radiator, release the quick-release coupling, and remove the hose to drain the coolant. For remaining coolant, remove the additional bottom coolant hose connected to the continued coolant circulation pump (V51).

The engine oil temperature must be at least 30 degrees Celsius and the battery voltage must be at least 11.5 V.

1. Use assembly tool T10118 to release the connectors and pull them off ignition coils 1 through 6.

2. Remove fuse SC 27 from the fuse holder to interrupt power to the fuel pump relay.

3. Remove the spark plugs using spark plug socket 3122 B.

4. Check compression using compression tester V.A.G 1763 by operating the starter until no further pressure increase is shown.

The compression pressure for the CBRA engine should be between 10.0 and 13.0 bar, with a wear limit of 7.5 bar and a maximum difference of 3.0 bar between cylinders.

This check only applies to vehicles equipped for cold climate zones. Remove the air filter upper part and filter element. Spray the thermal element with chilling spray.

At temperatures above 14 degrees Celsius, the regulating flap must have completely closed the hot air connection. At temperatures below 0 degrees Celsius, the regulating flap must have completely opened the hot air connection.

This test should only be performed if engine elasticity or pulling power is inadequate. With the engine at idling speed, have a second person abruptly increase the engine speed (throttle burst) and observe the vacuum unit; the actuator must switch.

If it does not switch, connect a hand vacuum pump to the vacuum unit. Move the slide ring on the pump to the vacuum position and operate it; the operating rod must move. When the pump is pulled off, the rod must return to its original position. If it does not move, the vacuum unit must be renewed.

Remove the intake manifold and pull the connectors off the injectors. Remove the complete fuel rail while keeping fuel lines connected. Pull fuse SB6 from socket F6 and connect the terminal to the battery positive using auxiliary cables so the fuel pump runs. Perform a visual check; no more than 1 to 2 drops per minute must escape from each valve while the fuel pump is running.

The system must be bled after working on fuel pipes or the fuel filter to prevent damage to the catalytic converter. Unscrew the protective cap from the bleeder valve. Attach adapter V.A.G 1318/20 and connect the hose of the diesel extractor VAS 5226. Screw the valve clockwise into the bleed valve.

Use the vehicle diagnosis tester to actuate the fuel pump relay until fuel flows out of the breather valve without bubbles. Once finished, switch off the ignition, clamp off the hose from the diesel extractor, remove the adapter, and reinstall the protective cap.