VOLKSWAGEN GOLF VARIANT 2007 (06) PDF Document

When doing any repair work, especially in the engine compartment on the VOLKSWAGEN GOLF VARIANT 2007, pay attention to the following due to the cramped conditions:

All wirings (e.g. for fuel, hydraulic system, coolant and refrigerant liquid, brake liquid, vacuum) and electrical wirings must be installed in the original way.

Ensure that there is sufficient clearance to all moving or hot components.

To remove the engine cover on the VOLKSWAGEN GOLF VARIANT 2007:

Pull engine cover upwards abruptly at front -arrows A- and then pull forwards out of rear fastening -arrow B-.

The test prerequisites for checking engine oil level on the VOLKSWAGEN GOLF VARIANT 2007 are:

Engine oil temperature at least 60°C.

Vehicle must be level (horizontal).

Wait a few minutes after switching off the engine to allow the oil to flow back into the sump.

The test procedure for checking engine oil level on the VOLKSWAGEN GOLF VARIANT 2007 is:

Pull out the dipstick, wipe off with a clean cloth and insert it again onto stop.

Pull out the dipstick again and read off the oil level.

The markings on the oil dipstick for the VOLKSWAGEN GOLF VARIANT 2007 are:

1 – Max. mark

2 – Min. mark

a – Area above grooved section up to max. mark: Do not top up with engine oil!

b – Oil level in grooved section: Can be topped up with engine oil.

c – Area from min. mark up to grooved section: Must be topped up, max. 0.5 l of engine oil!

When working on the fuel supply and injection systems of the VOLKSWAGEN GOLF VARIANT 2007, pay careful attention to the following “6 rules” for cleanliness:

Thoroughly clean all unions and adjacent areas before disconnecting.

Place removed parts on a clean surface and cover. Do not use fluffy cloths!

Carefully cover opened components or seal if repairs cannot be carried out immediately.

Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes, etc.).

When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely necessary.

Also ensure that no diesel fuel comes into contact with the coolant hoses. Should this occur, the hoses must be cleaned immediately. Damaged hoses must be renewed.

The WARNING instructions for repair work on the fuel system of the VOLKSWAGEN GOLF VARIANT 2007 are:

All wirings (e.g. for fuel, hydraulic system, coolant and refrigerant liquid, brake liquid, vacuum) and electrical wirings must be installed in the original way.

Ensure that there is sufficient clearance to all moving or hot components.

The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!

The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!

Wear eye and hand protection when performing any type of repair work on the fuel system!

For the installation position of the fuel delivery unit on the VOLKSWAGEN GOLF VARIANT 2007, the tab -2- on the fuel delivery unit must lie between the tongues -1- and -3-. The -arrow- points in direction of travel. The fuel delivery unit can only be installed in this position.

The torque setting for the lock ring when installing the fuel delivery unit on the VOLKSWAGEN GOLF VARIANT 2007 is 110 Nm.

The specification for the measured current draw of the fuel pump on the VOLKSWAGEN GOLF VARIANT 2007 is: max. 7.5 Ampere.

When checking the function and voltage supply of the fuel pump on the VOLKSWAGEN GOLF VARIANT 2007:

At 0.55…0.85 bar the LED must light up briefly.

At 2000 1/min and an oil temperature of 80°C the oil pressure should be min. 2.0 bar.

At higher engine speed, oil pressure must not exceed 7.0 bar.

To check the current consumption of the fuel pump on the VOLKSWAGEN GOLF VARIANT 2007:

Remove seat bench.

Remove cover -1- from fuel delivery unit. The arrow -2- points in direction of travel.

Connect the current clamp -A- of the Vehicle diagnosis, testing and information system -VAS 5051B – to the cable -B- to contact 1 of the 5-pin connector.

Start engine and run at idling speed.

Measure current draw of fuel pump. Specification: max. 7.5 Ampere.

If the values measured lie outside the specifications, renew fuel delivery unit.

To check the function and voltage supply of the fuel pump on the VOLKSWAGEN GOLF VARIANT 2007:

Switch on ignition.

Fuel pump must be heard to run briefly.

If the fuel pump does not run on the VOLKSWAGEN GOLF VARIANT 2007:

Remove seat bench.

Remove cover -1- from fuel delivery unit. The arrow -2- points in direction of travel.

Pull off connector -1-.

Connect voltage tester -V.A.G 1527 B- to outer contacts of connector using auxiliary cables from auxiliary measuring set -V.A.G 1594C- .

Switch ignition on.

The LED must light up briefly.

If LED does not light up briefly: Locate and eliminate open circuit using current flow diagram. If LED lights up briefly (voltage supply OK.): Remove fuel delivery unit. Check that the electrical wires between flange and fuel pump are connected and for continuity. If no open circuit can be found, renew fuel delivery unit.

When working on the turbocharger of the VOLKSWAGEN GOLF VARIANT 2007, pay careful attention to the following rules of cleanliness:

Thoroughly clean all joints and surrounding areas before dismantling.

Place removed parts on a clean surface and cover. Use lint-free cloths only!

Carefully cover opened components or seal if repairs cannot be carried out immediately.

Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes, etc.).

When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely necessary.

The precautions to observe when working on the charge air system of the VOLKSWAGEN GOLF VARIANT 2007 are:

Route all the various lines (e.g. for fuel, hydraulics, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.

Ensure that there is sufficient clearance to all moving or hot components.

Existing transport and protective packaging and sealing caps must only be removed immediately prior to installation.

When making repairs, remove oil from connection and hose ends.

When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely necessary.

To remove the air filter housing with air mass meter and connecting pipe on the VOLKSWAGEN GOLF VARIANT 2007 with engine codes BKC, BXE:

Disconnect connector -2- on air mass meter -G70- .

Pull breather hose -1- and air duct hoses -3- and -5- off.

Unscrew bolt -4- and take off air filter housing.

To remove the air cleaner housing with air mass meter on the VOLKSWAGEN GOLF VARIANT 2007 for engine codes BLS, BRM:

Disconnect connector -2- on air mass meter -G70- .

Pull breather hose -1- off and unhook from bracket -arrow-.

Release spring-type clip -3- with spring-type clip pliers -VAS 5024A- and pull intake hose off air mass meter -G70- .

Pull intake manifold -5- off the air duct.

Unscrew bolt -4- and take off air filter housing.

To remove the engine cover when removing the turbocharger on the VOLKSWAGEN GOLF VARIANT 2007:

Pull engine cover upwards abruptly at front -arrows A- and then pull forwards out of rear fastening -arrow B-.

After tightening the cylinder head on the VOLKSWAGEN GOLF VARIANT 2007, turn the camshaft hub so that the cam lobes -arrows- for cylinder No. 1 point evenly upwards. Turn crankshaft, in engine direction of rotation, to TDC marking before fitting toothed belt.

The cylinder head bolts on the VOLKSWAGEN GOLF VARIANT 2007 must be tightened in four stages in sequence as follows:

1 – Tighten initially with torque wrench:

Stage I = 35 Nm

Stage II = 60 Nm

2 – Turn further with rigid wrench:

Stage III = 1/4 turn (90°)

Stage IV = 1/4 turn (90°)

It is not necessary to retighten cylinder head bolts after repairs.

When installing a new cylinder head gasket on the VOLKSWAGEN GOLF VARIANT 2007:

Observe cylinder head gasket identification.

Piston projection at TDC must be determined when installing new pistons or overhauled engine.

The torque settings for the Engine assembly mounting on the VOLKSWAGEN GOLF VARIANT 2007 are:

A = 20 Nm + 90° (1/4 turn) further. Renew bolts.

B = 40 Nm + 90° (1/4 turn) further. Renew bolts.

C = 60 Nm + 90° (1/4 turn) further. Renew bolts.

The torque settings for the Gearbox assembly mounting on the VOLKSWAGEN GOLF VARIANT 2007 are:

A = 40 Nm + 90° (1/4 turn) further. Renew bolts.

B = 60 Nm + 90° (1/4 turn) further. Renew bolts.

The torque settings for the Pendulum support on the VOLKSWAGEN GOLF VARIANT 2007 are:

A = 40 Nm + 90° (1/4 turn) further. Renew bolts.

B = 100 Nm + 90° (1/4 turn) further. Renew bolts.

For removing: First remove bolt -B- then bolts -A-. For installing: First tighten bolts -A- then bolt -B-.

The axial clearance for the crankshaft on the VOLKSWAGEN GOLF VARIANT 2007 is new: 0.07…0.17 mm, wear limit: 0.37 mm.

The radial clearance check with Plastigage for the crankshaft on the VOLKSWAGEN GOLF VARIANT 2007 has a new value of 0.03…0.08 mm, with a wear limit of 0.17 mm. Do not rotate crankshaft when checking radial clearance.

The dimensions for the VOLKSWAGEN GOLF VARIANT 2007 are:

The letter codes on the lower sealing surface of the cylinder block indicate the thickness of the bearing shell to be fitted at each location on the VOLKSWAGEN GOLF VARIANT 2007:

G = Yellow

B = Blue

W = White

When checking cylinder bores on the VOLKSWAGEN GOLF VARIANT 2007, the difference between actual and nominal diameter must not be more than 0.10 mm.

The piston ring dimensions (New/Wear limit) in mm for the VOLKSWAGEN GOLF VARIANT 2007 are:

The ring-to-groove clearance dimensions (New/Wear limit) in mm for the VOLKSWAGEN GOLF VARIANT 2007 are:

For the piston installation position and allocation to cylinder on the VOLKSWAGEN GOLF VARIANT 2007:

Piston in cylinders 1 and 2: Larger inlet valve recess -arrows- towards flywheel.

Piston in cylinders 3 and 4: Larger inlet valve recess -arrows- towards belt pulley end.

New piston allocation to cylinders is shown by a coloured mark stamped on piston crown.

Piston for cylinders 1 and 2: marked 1/2.

Piston for cylinders 3 and 4: marked 3/4.

The identification hole/notch numbers based on piston projection at TDC measurement for the VOLKSWAGEN GOLF VARIANT 2007 are:

The Piston ∅ and Cylinder bore ∅ dimensions for different honing stages on the VOLKSWAGEN GOLF VARIANT 2007 are:

The dimension “a” (from outer edge of cylinder head to rounded edge of unit injector) specifications for checking the unit injector installation position on the VOLKSWAGEN GOLF VARIANT 2007 are:

When installing the sealing flange with oil seal installed on the VOLKSWAGEN GOLF VARIANT 2007, use guide sleeve -T10053/1-.

After installing the turbocharger on the VOLKSWAGEN GOLF VARIANT 2007 with engine codes BLS, BRM:

Run engine for about 1 minute at idling speed and do not rev up immediately, this ensures that the turbocharger is supplied with oil.

The specified torque for the camshaft toothed belt pulley securing bolts -1- when installing the toothed belt on the VOLKSWAGEN GOLF VARIANT 2007 is 25 Nm.

The tensioning roller securing nut is tightened to 20 Nm and 45° (1/8 turn) further when installing the toothed belt on the VOLKSWAGEN GOLF VARIANT 2007.

The securing bolts for the sealing flange on the VOLKSWAGEN GOLF VARIANT 2007 are tightened to 15 Nm using alternate and diagonal sequence.

When installing the assembly mounting on the VOLKSWAGEN GOLF VARIANT 2007:

Reinstall all cable ties in the same locations when assembling.

Hoses must be locked with clamps.

Renew self-locking nuts and bolts when performing assembly work.

Renew bolts which are tightened to a specified angle as well as oil seals and gaskets.

Insert new dowel sleeves in cylinder block for centring engine and gearbox.

If ceramic glow plugs are fitted before removing, check idling speed smooth running control using Vehicle diagnosis, testing and information system -VAS 5051B- . The compression test is warranted only if one or more cylinders stand out in this idling speed check.

Remove all glow plugs or ceramic glow plugs using jointed extension and socket -3220- .

Screw in adapter -V.A.G 1381/12 – in place of glow plugs or ceramic glow plugs.

Check compression using compression tester -V.A.G 1763- .

Operate starter until tester shows no further pressure increase.

Compression pressures: New: 25…31 bar, wear limit: 19 bar. Maximum permissible difference between all cylinders: 5 bar.

If ceramic glow plugs are fitted, always observe notes on removing and installing ceramic glow plugs.

Remove glow plugs or ceramic glow plugs using jointed extension and socket -3220- . Tightening torque: 15 Nm.

Interrogate engine control unit fault memory.

Disconnecting the central connector for unit injectors causes faults to be stored. Therefore read and clear fault memory.

The test prerequisites for checking the glow plug system on the VOLKSWAGEN GOLF VARIANT 2007 for metal glow plugs are:

Fuse box/battery glow plug strip fuse OK.

Battery charge at least 11.5 V.

Ignition switched off.

The test prerequisites for checking the glow plug system for ceramic glow plugs are:

Engine is cold.

Ignition switched off.

The test procedure for checking metal glow plugs on the VOLKSWAGEN GOLF VARIANT 2007:

Remove engine cover. To do this, pull engine cover upwards abruptly at front -arrows A- and then pull forwards out of rear fastening -arrow B-.

Detach glow plug connectors from glow plugs.

Connect cable of voltage tester -V.A.G 1527 B- with clamps from adapter set -V.A.G 1594 C- to battery positive (+).

Place test probe of voltage tester -V.A.G 1527 B- on each glow plug one after the other. Diode lights up: glow plug OK., diode does not light up: renew glow plug.

Removing: Remove glow plugs with jointed spanner -3220- .

Installing: Install glow plugs with jointed wrench -3220- and tighten to 15 Nm. The rest of the assembly is basically a reverse of the dismantling sequence.

For removing ceramic glow plugs on the VOLKSWAGEN GOLF VARIANT 2007:

Remove engine cover. To do this, pull engine cover upwards abruptly at front -arrows A- and then pull forwards out of rear fastening -arrow B-.

Detach glow plug connectors from glow plugs.

Remove ceramic glow plugs with jointed spanner -3220- .

Do not tilt when removing and installing ceramic glow plugs. Remove components hindering the installation.

For installing ceramic glow plugs on the VOLKSWAGEN GOLF VARIANT 2007:

Before installing, all deposits must be removed completely from cylinder head bore and thread.

The thread of the hole in the cylinder head or the ceramic glow plugs must never be greased or oiled.

Fit the ceramic glow plugs into the cylinder head by hand using the jointed wrench -3220- .

Install glow plugs with jointed wrench -3220- and tighten to 15 Nm.

After installing and before the first engine start on the cold engine, always check resistance of all ceramic glow plugs. Specification: max. 1 Ω. If the specification is exceeded, renew defective ceramic glow plugs. If a defective ceramic glow plug is broken remove all fragments from the engine, otherwise these can cause damage to the engine.

The optical characteristics of the ceramic glow plugs on the VOLKSWAGEN GOLF VARIANT 2007 are:

A – Ceramic glow plug: Step at the point (see magnifying glass), Color code -arrow-: white.

B – Metal glow plug: Color code -arrow-: green.

The recommended mixture proportions for frost protection when filling coolant on the VOLKSWAGEN GOLF VARIANT 2007 are:

The quantity of coolant can vary depending upon vehicle equipment.

The torque settings for installing components on the VOLKSWAGEN GOLF VARIANT 2007 are:

When installing air pipes with plug-in connectors during the installation of the oil filter bracket with oil cooler on the VOLKSWAGEN GOLF VARIANT 2007, ensure that the securing clip -arrow- engages audibly on the retaining lug -A-.

The torque settings for installing the oil filter bracket with oil cooler on the VOLKSWAGEN GOLF VARIANT 2007 are:

The test procedure for checking oil pressure and oil pressure switch on the VOLKSWAGEN GOLF VARIANT 2007 is:

Remove oil pressure switch -F1- and screw into tester.

Screw tester into oil filter bracket in place of the oil pressure switch.

Connect brown wire of tester to earth (-).

Connect voltage tester -V.A.G 1527 B- using adapter cables from adapter set -V.A.G 1594C – to battery positive (+) and oil pressure switch. LED must not light up.

Start engine and increase speed slowly.

At 0.55…0.85 bar the LED must light up, otherwise renew oil pressure switch.

Increase engine speed further. At 2000 1/min and an oil temperature of 80°C the oil pressure should be min. 2.0 bar. At higher engine speed, oil pressure must not exceed 7.0 bar. If necessary renew oil filter bracket.

The torque settings for installing the oil pump on the VOLKSWAGEN GOLF VARIANT 2007 are:

Renew bolt.

When checking the charge air system for leaks on the VOLKSWAGEN GOLF VARIANT 2007, if leaks occur, observe notes for charge air system when doing any repair work.

To check the charge air system for leaks on the VOLKSWAGEN GOLF VARIANT 2007:

Remove intake hose -1- from air filter.

Connect adapter -V.A.G 1687/1- in intake hose -1- and secure with clip.

Prepare charge air system tester -V.A.G 1687- as follows: Unscrew pressure regulating valve -2- complete and close valves -3- and -4-.

Connect charge air system tester -V.A.G 1687- to adapter -V.A.G 1687/1- as shown.

Connect compressed air hose -1- (compressed air source) to charge air system tester -V.A.G 1687- .

If there is water in the sight glass, drain at water drain screw -6-.

Open valve -3-.

Adjust pressure to 0.5 bar with pressure regulating valve -2-.

Caution: The pressure must not exceed 0.5 bar! If the pressure is too high this can cause damage to the engine.

Open valve -4- and wait until the test circuit is filled. If necessary readjust pressure to 0.5 bar.

Check the charge air system for leaks by hearing, touching, with commercially available leak detector spray or using ultrasonic tester -V.A.G 1842- .

Before removing the adapter, depressurise the test circuit by pulling coupling off adapter -V.A.G 1687/1- .

When using quick release couplings on the VOLKSWAGEN GOLF VARIANT 2007 charge air system, the following points must be observed:

Removing: Unlock quick release coupling by pulling on the securing clip -arrow-. Separate hose and pipe without tools.

Installing: When installing, ensure that locking lugs -A- engage securely. If renewed, place seal in groove of charge air hose. Ensure the seal is correctly seated in the groove. Oil sealing surface and seal. Bring securing clip to release position -1-. Push charge air hose into coupling to stop. Set securing clip to locking position -2- and then push charge air hose again. Check if connector coupling seats correctly and is properly engaged by pulling hose.

The seal of the connector coupling on the charge air system of the VOLKSWAGEN GOLF VARIANT 2007 can be damaged if the securing clip is in locking position when installing. Leaks could occur. Observe installation instructions.

To check the pressure relief valve in the filler cap on the VOLKSWAGEN GOLF VARIANT 2007:

Fit coolant system tester -V.A.G 1274- onto sealing cap using adapter -V.A.G 1274/9- .

Use hand pump on cooling system tester -V.A.G 1274- to create a pressure of max. 1.4 bar. The pressure relief valve must not open.

If the pressure relief valve opens prematurely: Renew sealing cap. Increase pressure by 1.4…1.6 bar. Pressure relief valve must open. If pressure relief valve does not open: Renew sealing cap.

The steps for draining the cooling system on the VOLKSWAGEN GOLF VARIANT 2007 are:

Open cap on coolant expansion tank.

Remove noise insulation.

For vehicles with engine codes BKC, BXE: To drain coolant from radiator, open drain plug -arrow-.

For vehicles with engine codes BLS, BRM: Raise retaining clip -arrow- slightly and pull coolant hose from radiator.

For all models: To drain coolant from engine also remove coolant hose at oil cooler -arrow-.

The WARNING when opening the expansion tank during cooling system repair on the VOLKSWAGEN GOLF VARIANT 2007 is that steam may escape. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover cap with cloth and open carefully.

For filling with cooling system charging unit -VAS 6096- on the VOLKSWAGEN GOLF VARIANT 2007:

Screw adapter for cooling system tester -V.A.G 1274/8- onto expansion tank.

Fill coolant circuit using cooling system charging unit -VAS 6096-.

For filling without cooling system charging unit -VAS 6096-:

Fill with coolant slowly up to upper marking of hatched field on expansion tank -arrow-.

Fit expansion tank cap.

Switch off heater and air conditioner.

Start engine and maintain an engine speed of about 2000 rpm for approx. 3 minutes.

Run engine until radiator fan cuts in.

Check coolant level and top-up if necessary.

When the engine is at normal operating temperature the coolant level must lie on the upper marking of the hatched field -arrow-. On cold engine, coolant level should be roughly in middle of hatched area.

The notes for the coolant additive G 12 when filling the cooling system on the VOLKSWAGEN GOLF VARIANT 2007 are:

Only use coolant additive G 12 in accordance with TL VW 774 F. Identification: coloured lilac.

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 “In accordance with 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 tropical climates.

Frost protection is required down to about -25°C (in countries with arctic climates: down to about -35°C).

The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The antifreeze percentage must be at least 40%.

If for climatic reasons greater frost protection is required, the amount of G 12 can be increased, but only up to 60% (frost protection to about -40°C). Otherwise frost protection and cooling effectiveness are reduced again.

The refractometer -T10007- is recommended to determine the freezing temperature of the coolant.

If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.

The instructions for checking the mechanical exhaust gas recirculation valve for engine codes BKC, BXE on the VOLKSWAGEN GOLF VARIANT 2007 are:

Final control diagnosis performed.

Lift engine cover sideways -arrows 1- and pull off forwards -arrow 2-.

Detach vacuum hose at mechanical exhaust gas recirculation valve.

Connect diesel extractor -VAS 5226- or hand-operated vacuum pump -V.A.G 1390- to the valve.

Produce vacuum with the diesel extractor -VAS 5226- or the hand-operated vacuum pump.

Pull diesel extractor -VAS 5226- or hand-operated vacuum pump hose off exhaust gas recirculation valve.

The closing of the valve should be clearly audible. The membrane rod moves in direction of intake manifold.

The following should be observed when installing the assembly mounting on the VOLKSWAGEN GOLF VARIANT 2007:

Before installing the assembly mounting, all engine mounting bolts -arrows- must be tightened to prescribed torque.

Fit engine mounting to engine bracket. To do this put the contact surfaces on the support device -10 – 222A- .

Install centre and lower parts of toothed belt guard.

Install belt pulley vibration damper. Tightening torque: 10 Nm + 90° (1/4 turn) further.

Install poly-V-belt.

Install upper toothed belt guard.

Install connecting pipes between charge air cooler and turbocharger and between charge air cooler and intake connecting flange.

Install front right wheel housing liner.

Install coolant expansion tank.

The torque settings for the intake manifold components when installing the intake manifold on the VOLKSWAGEN GOLF VARIANT 2007 are:

The procedure for checking camshaft axial clearance on the VOLKSWAGEN GOLF VARIANT 2007 is:

Check with bucket tappets removed and with first, third and last bearing caps fitted.

Wear limit: max. 0.15 mm.

The valve dimensions for inlet and exhaust valves on the VOLKSWAGEN GOLF VARIANT 2007 are:

Inlet and exhaust valves must not be machined. Only lapping-in is permitted.

The notes on renewing gaskets, seals and self-locking nuts when installing the exhaust gas recirculation cooler for engine codes BLS, BRM on the VOLKSWAGEN GOLF VARIANT 2007 are:

Renew gaskets, seals and self-locking nuts.

Observe installation position of seal for intake manifold.

Hoses must be locked with clamps.

The WARNING when opening the expansion tank during repair work on the cooling system of the VOLKSWAGEN GOLF VARIANT 2007 is: Steam may escape when expansion tank is opened. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover cap with cloth and open carefully.

The procedure to check the mechanical exhaust gas recirculation valve for engine codes BKC, BXE on the VOLKSWAGEN GOLF VARIANT 2007 involves:

Final control diagnosis performed.

Lift engine cover sideways -arrows 1- and pull off forwards -arrow 2-.

Detach vacuum hose at mechanical exhaust gas recirculation valve.

Connect diesel extractor -VAS 5226- or hand-operated vacuum pump -V.A.G 1390- to the valve.

Produce vacuum with the diesel extractor -VAS 5226- or the hand-operated vacuum pump.

Pull diesel extractor -VAS 5226- or hand-operated vacuum pump hose off exhaust gas recirculation valve.

The closing of the valve should be clearly audible. The membrane rod moves in direction of intake manifold.

The steps to remove the toothed belt on the VOLKSWAGEN GOLF VARIANT 2007 (on vehicles 05.05) are:

Remove engine cover. To do this, pull engine cover upwards abruptly at front -arrows A- and then pull forwards out of rear fastening -arrow B-.

Remove connecting pipe between charge air cooler and intake connecting pipe.

Unscrew coolant expansion tank. Do not disconnect hoses.

Remove poly-V-belt.

Remove locking pin from poly-V-belt tensioning element.

Remove front right wheel housing liner.

Remove charge air pipe between charge air cooler and turbocharger.

Remove flexible charge air pipe between turbocharger and air filter.

Carefully seal openings of charge air duct, e.g. with a clean cloth to prevent particles of dirt from entering.

Remove belt pulley with vibration damper.

Unbolt toothed belt covers (bottom and centre) -arrows-.

Fit support bracket -10 – 222 A- before the gas pressure damper for the front flap using adapter -10 – 222 A/8- , adapter – 10 – 222 A/3- and adapter -10 – 222 A/16- .

Attach trigger snap of spindles to lifting eyes. On the right side use additionally the adapter -10 – 222 A/20-

Take up weight of engine evenly with both spindles (but do not raise engine).

Remove securing bolts -arrows- from the assembly mounting engine and take engine mounting out completely.

Lift the engine slightly using the support device – 10 – 222 A to loosen both engine bracket upper bolts -arrows-.

Lower the engine slightly using the support device – 10 – 222 A- to loosen engine bracket lower bolt -arrow-.

Remove engine bracket downwards.

Turn crankshaft to TDC No. 1 cylinder.

Remove toothed belt.

To check the function and voltage supply for the engine control unit on the VOLKSWAGEN GOLF VARIANT 2007:

Connect vehicle diagnosis, testing and information system -VAS 5051B- as follows:

Fit the connector of the diagnosis cable -2- to the diagnosis connection in the driver footwell.

Start engine and run at idling speed. Only if engine does not start: Switch on ignition.

Select operating mode: Press key on display for “Vehicle self-diagnosis”.

Select vehicle system: Press button “01 – Engine electronics” on display.

The display shows the control unit identification and coding -2- as well as the chassis number and the identification number of the immobilizer (centre part).

Select diagnostic function:

Press key “02 – Read fault memory” on display.

If no fault is stored in engine control unit “0 fault detected” is displayed.

If faults are stored in the engine control unit, these are shown one below the other on the display.

Press the ← button.

Press key “05 – Erase fault memory” on display.

Press function “06-End output”.

To adapt functions and components using the Vehicle diagnosis, testing and information system -VAS 5051B- for the VOLKSWAGEN GOLF VARIANT 2007:

Push diagnosis cable connector onto diagnosis connector in driver footwell.

Switch on ignition.

Select “Guided fault finding” in the Vehicle diagnosis, testing and information system -VAS 5051- .

After all control units have been read:

Press key Go to .

Select “Function/Component selection”.

Select “Drive train”.

Select “Engine code”.

Select “01 – On Board Diagnostic (OBD)”.

Select “Engine management”.

Select “Functions”

Select “Function or component”.

The steps for removing the engine control unit without theft protection on the VOLKSWAGEN GOLF VARIANT 2007 are:

Switch off ignition.

Remove wiper arms and the plenum chamber cover.

Remove bulkhead in plenum chamber.

Release front connector -1- from engine control unit and pull it off.

Lever up catch -2- slightly.

Then push engine control unit out of retainer -arrow-.

Then release rear connector on engine control unit and pull it off.

The steps for installing the engine control unit without theft protection on the VOLKSWAGEN GOLF VARIANT 2007 are:

Fit rear connector to engine control unit and lock it in position.

Push engine control unit onto bracket.

Fit front connector to engine control unit and lock it in position.

Push protective housing onto bracket.

Tighten new shear bolts -1- evenly until heads shear off.

Install bulkhead in plenum chamber.

Install wiper arms and the plenum chamber cover.

The special tools and workshop equipment required for removing and installing the front exhaust pipe with catalytic converter for engine codes BKC, BXE on the VOLKSWAGEN GOLF VARIANT 2007 include a Torque wrench -V.A.G 1331-.

The torque settings for the front exhaust pipe components when installing the front exhaust pipe with catalytic converter for engine codes BKC, BXE on the VOLKSWAGEN GOLF VARIANT 2007 are:

The warning for bending the flexible pipe connection (de-coupling element) on the front exhaust pipe on the VOLKSWAGEN GOLF VARIANT 2007 is that it must not be bent more than 10° – otherwise it can be damaged.

The torque settings for the exhaust system components when installing the diesel particulate filter with engine code BLS on the VOLKSWAGEN GOLF VARIANT 2007 are:

The procedure for stress-free alignment of the exhaust system when cold on the VOLKSWAGEN GOLF VARIANT 2007 is:

Loosen bolts on front retaining clip -1-.

Position clamp-type clip -1- so that the distance -a- to the marking on the pipe -2- is 5 mm and tighten front bolt by hand. The -arrow- points in direction of travel.

Move the exhaust system with silencer forwards until the dimension -a- = 9…11 mm is reached on the outer hand hold straps of the front silencer. The -arrow- points in direction of travel.

In this position, tighten front clamp-type clip evenly to 25 Nm.

Align rear silencer so that dimension -a- between bumper cut out and end pipes on the left and right-hand sides are the same. At the same time the distance -b- from bumper cut-out to end pipes must be parallel. To align tail pipe, loosen rear silencer mountings if necessary.

When working on the exhaust system of the VOLKSWAGEN GOLF VARIANT 2007, renew seals, gaskets and self-locking nuts.

The warning for metal shavings when doing repair work on the exhaust system of the VOLKSWAGEN GOLF VARIANT 2007 is: To avoid injury from metal shavings, wear eye protection and protective clothing.

The torque settings for the exhaust gas recirculation cooler components when installing on the VOLKSWAGEN GOLF VARIANT 2007 are:

To remove the engine lifting eye on the rear of the cylinder head when removing the exhaust gas recirculation cooler and change-over flap on the VOLKSWAGEN GOLF VARIANT 2007: Remove engine lifting eye on rear of cylinder head -arrow-.

The securing bolt -2- of the engine speed sender -G28- -1- is tightened to 5 Nm when installing on the VOLKSWAGEN GOLF VARIANT 2007.

The WARNING regarding ceramic glow plugs on the VOLKSWAGEN GOLF VARIANT 2007 is that they are sensitive against bumps and bending. For this reason dropped down glow plugs must never be used, even if no damage can be seen obviously (and even if the height was about 2 cm). It is absolutely necessary to follow the installation instructions, otherwise there is risk of a pin crack which may result in an engine damage.

After installing and before the first engine start on the cold engine on the VOLKSWAGEN GOLF VARIANT 2007, always check resistance of all ceramic glow plugs. Specification: max. 1 Ω. If the specification is exceeded, renew defective ceramic glow plugs. If a defective ceramic glow plug is broken remove all fragments from the engine, otherwise these can cause damage to the engine.

Glow plugs on the VOLKSWAGEN GOLF VARIANT 2007 are installed with jointed wrench -3220- and tightened to 15 Nm.