Volkswagen Golf Plus 2005 - User Manual

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Workshop Manual
Golf 2004 ➤
Golf Plus 2005 ➤
Passat 2006 ➤
Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 4 valve)
Engine ID
AZV BKD BMN BKP BMA BVE BMR BUZ BWV
Edition 02.2011
Service
Service Department. Technical Information

Summary

00 - Technical data

1 Technical data

Details about engine number and general engine data.

1.1 Engine number

Location and format of the engine number.

1.2 Engine data

Technical specifications for various engine codes.

10 - Removing and installing engine

1 Removing and installing engine

Procedure for removing and installing the engine, including necessary tools.

1.1 Removing engine

Step-by-step guide for engine removal, including warnings.

1.1.1 Procedures for Golf, Golf Plus, Touran

Specific steps for engine removal on Golf, Golf Plus, and Touran.

13 - Crankshaft group

1 Dismantling and assembling engine

Overview of engine dismantling and assembly, including belt drives.

1.1 Assembly overview - poly V-belt drive

Diagram and components of the poly V-belt drive system.

1.2 Removing and installing poly V-belt

Procedure for removing and installing the poly V-belt.

1.3 Assembly overview - toothed belt drive

Diagram and components of the toothed belt drive system.

1.4 Assembly overview - crankcase

Diagram and components of the crankcase.

2 Removing and installing sealing flange and flywheel

Steps for removing and installing the crankshaft sealing flange and flywheel.

2.1 Renewing crankshaft sealing flange - flywheel end

Procedure for renewing the crankshaft sealing flange at the flywheel end.

2.1.1 Pressing out sealing flange with sender wheel

Steps for pressing out the sealing flange with the sender wheel.

3 Pistons and conrods

Details on pistons, conrods, and their installation.

3.1 Assembly overview - pistons and conrods

Diagram and components of pistons and conrods.

3.2 Piston and cylinder dimensions

Technical specifications for piston and cylinder dimensions.

3.3 Checking piston projection at TDC

Procedure for checking piston projection at Top Dead Center.

3.4 Piston rings, cylinder bore and piston installation position

Details on piston rings, cylinder bores, and piston installation.

4 Crankshaft

Assembly overview and dimensions of the crankshaft.

4.1 Assembly overview - crankshaft

Diagram and components of the crankshaft assembly.

4.2 Crankshaft dimensions

Technical specifications for crankshaft dimensions.

4.3 Pulling needle bearing out of and driving into crankshaft

Procedure for removing and installing the needle bearing in the crankshaft.

15 - Cylinder head, valve gear

1 Cylinder head

Overview and procedures for cylinder head removal and installation.

1.1 Assembly overview - cylinder head

Diagram and components of the cylinder head assembly.

1.2 Removing and installing cylinder head cover

Procedure for removing and installing the cylinder head cover.

1.3 Removing, installing and tensioning toothed belt

Steps for removing, installing, and tensioning the toothed belt.

1.4 Removing and installing cylinder head

Procedure for removing and installing the cylinder head.

1.5 Checking compression

Procedure for checking engine compression.

2 Valve gear

Assembly overview and procedures for valve gear components.

2.1 Assembly overview - valve gear

Diagram and components of the valve gear.

2.2 Removing and installing roller rocker finger

Procedure for removing and installing roller rocker fingers.

2.3 Valves

Information on valves, including dimensions.

2.4 Removing and installing camshafts

Procedure for removing and installing camshafts.

2.5 Removing and installing camshaft oil seal

Procedure for removing and installing camshaft oil seals.

17 - Lubrication

1 Engine oil

Information on engine oil specifications, capacities, and level checking.

1.1 Oil capacities - Golf, Golf Plus, Touran

Engine oil capacities for Golf, Golf Plus, and Touran models.

1.2 Oil capacities - Passat

Engine oil capacities for Passat models.

1.3 Checking engine oil level

Procedure for checking the engine oil level.

19 - Cooling

1 Parts of cooling system

Overview of cooling system components on the body and engine sides.

1.1 Parts of cooling system, body side

Components of the cooling system located on the vehicle body.

1.2 Assembly overview - parts of cooling system, engine side (Golf, Golf Plus, Touran)

Diagram of cooling system parts on the engine side for specific models.

1.3 Assembly overview - parts of cooling system, engine side (Passat)

Diagram of cooling system parts on the engine side for Passat.

1.4 Coolant hose schematic diagram

Schematic diagram illustrating coolant hose routing.

1.5 Draining and filling coolant

Procedure for draining and refilling the coolant.

1.6 Removing and installing fan support with fans

Steps for removing and installing the fan support and fans.

1.7 Removing and installing radiator

Procedure for removing and installing the radiator.

1.8 Removing and installing coolant pump

Procedure for removing and installing the coolant pump.

1.9 Removing and installing thermostat

Procedure for removing and installing the thermostat.

1.10 Checking cooling system for leaks

Procedure for checking the cooling system for leaks.

1.11 Checking oil cooler for leaks

Procedure for checking the oil cooler for leaks.

20 - Fuel supply system

1 Safety precautions

General safety precautions for working on the fuel supply system.

1.1 Safety precautions when working on fuel supply system

Specific safety precautions for fuel system repairs.

2 Rules for cleanliness

Essential rules for maintaining cleanliness in the fuel system.

2.1 Rules for cleanliness when working on fuel supply system

Specific cleanliness rules for fuel supply system work.

3 Parts of fuel supply system (Golf, Golf Plus)

Detailed overview of fuel tank and related components for Golf/Golf Plus.

3.1 Fuel tank, vehicles with front-wheel drive

Assembly overview of the fuel tank for front-wheel drive vehicles.

3.1.1 Assembly overview - fuel tank

Diagram and components of the fuel tank assembly.

3.1.2 Removing and installing fuel tank

Procedure for removing and installing the fuel tank.

3.2 Fuel tank, vehicles with four-wheel drive

Assembly overview of the fuel tank for four-wheel drive vehicles.

3.2.1 Assembly overview - fuel tank

Diagram and components of the fuel tank assembly for 4WD.

3.2.2 Removing and installing fuel tank

Procedure for removing and installing the fuel tank for 4WD.

3.2.3 Removing and installing fuel gauge sender 2 -G169-

Procedure for removing and installing the fuel gauge sender.

3.2.4 Removing and installing suction-jet pump

Procedure for removing and installing the suction-jet pump.

3.3 Emptying fuel tank

Procedures for emptying the fuel tank.

3.3.1 Emptying fuel tank if it is more than 3;4 full

Steps for emptying the fuel tank when more than 3/4 full.

3.3.2 Emptying fuel tank if it is less than 3;4 full

Steps for emptying the fuel tank when less than 3/4 full.

3.4 Removing and installing fuel delivery unit

Procedure for removing and installing the fuel delivery unit.

3.5 Removing and installing fuel gauge sender

Procedure for removing and installing the fuel gauge sender.

3.6 Checking fuel pump

Instructions for checking the fuel pump's function.

3.6.1 Checking delivery pressure of fuel pump

Procedure for checking the fuel pump's delivery pressure.

3.6.2 Checking fuel pump delivery rate

Procedure for checking the fuel pump's delivery rate.

3.6.3 Checking voltage supply of fuel pump

Procedure for checking the fuel pump's voltage supply.

3.6.4 Checking current draw of fuel pump

Procedure for checking the fuel pump's current draw.

3.7 Assembly overview - fuel filter

Overview of fuel filter components and types.

3.7.1 Fuel filter upper part

Details on the upper part of the fuel filter, types A and B.

3.8 Removing and installing fuel cooler

Procedure for removing and installing the fuel cooler.

21 - Turbocharging;supercharging

1 Charge air system with turbocharger

Overview and safety precautions for the charge air system.

1.1 Safety precautions

General safety precautions for working in the engine compartment.

1.2 Rules for cleanliness

Cleanliness rules for working on the turbocharger.

1.3 Hose connections

Instructions for installing hose connections with connector couplings.

1.3.1 Installing hose connections with connector couplings

Steps for installing hose connections with specific connector couplings.

1.3.2 Hose connections with spring band ring

Information on hose connections secured with spring band rings.

1.4 Assembly overview - turbocharger with attachments

Diagram and components of the turbocharger with attachments.

1.4.1 Engine codes AZV, BKD, BKP, BMA, BVE and BWV

Specific notes for engine codes AZV, BKD, BKP, BMA, BVE, BWV.

1.4.2 Engine codes BMN, BMR and BUZ

Specific notes for engine codes BMN, BMR, and BUZ.

1.5 Checking charge air system for leaks

Procedure for checking the charge air system for leaks.

23 - Mixture preparation - injection

1 Diesel direct injection system

Information on the diesel direct injection system, including safety.

1.1 Safety precautions

General safety precautions for working in the engine compartment.

1.2 Rules for cleanliness

Cleanliness rules for working on the fuel supply and injection system.

1.3 Assembly overview - intake manifold with attachments

Diagram and components of the intake manifold assembly.

1.3.1 Engine codes AZV, BKD, BKP, BMA, BVE and BWV

Specific details for intake manifold components based on engine code.

1.3.2 Engine codes BMN, BMR and BUZ

Specific details for intake manifold components based on engine code.

1.4 Assembly overview - pre-wired wiring harness for unit injectors and glow plugs

Diagram and components of the wiring harness for unit injectors and glow plugs.

1.5 Removing and installing pre-wired wiring harness for unit injectors and glow plugs

Procedure for removing and installing the wiring harness.

26 - Exhaust system

1 Front exhaust pipe

Assembly overview of the front exhaust pipe with catalytic converter.

1.1 Assembly overview - front exhaust pipe with catalytic converter

Diagram and components of the front exhaust pipe with catalytic converter.

1.2 Assembly overview - front exhaust pipe with particulate filter

Diagram and components of the front exhaust pipe with particulate filter.

2 Silencer (Golf, Golf Plus)

Assembly overview of silencers for Golf and Golf Plus models.

2.1 Assembly overview - silencer, vehicles with front-wheel drive

Diagram of silencer components for front-wheel drive vehicles.

2.2 Assembly overview - silencer, vehicles with four-wheel drive

Diagram of silencer components for four-wheel drive vehicles.

2.3 Cutting exhaust pipe

Procedure for cutting the exhaust pipe.

2.4 Installation position and specified torque of the clamp

Correct installation position and torque for clamps.

2.5 Aligning exhaust system free of stress

Procedure for aligning the exhaust system without stress.

3 Silencer (Touran)

Assembly overview of silencers for Touran models.

3.1 Assembly overview - silencers

Diagram and components of the silencer assembly.

3.2 Cutting exhaust pipe

Procedure for cutting the exhaust pipe.

3.3 Aligning exhaust system free of stress

Procedure for aligning the exhaust system without stress.

4 Silencer (Passat)

Assembly overview of silencers for Passat models.

4.1 Assembly overview - silencer, vehicles with front-wheel drive

Diagram of silencer components for front-wheel drive vehicles.

4.2 Assembly overview - silencer, vehicles with four-wheel drive

Diagram of silencer components for four-wheel drive vehicles.

4.3 Aligning exhaust system free of stress

Procedure for aligning the exhaust system without stress.

5 Exhaust gas recirculation system

Overview of the exhaust gas recirculation system.

5.1 Assembly overview - exhaust gas recirculation

Diagram and components of the exhaust gas recirculation system.

5.1.1 Engine codes AZV, BKD, BKP, BMA, BVE and BWV

Specific notes for EGR system components based on engine code.

5.1.2 Engine codes BMN, BMR and BUZ

Specific notes for EGR system components based on engine code.

28 - Glow plug system

1 Optical characteristics of metal or ceramic glow plugs

Description of visual differences between metal and ceramic glow plugs.

1.1 Removing and installing metal glow plug

Procedure for removing and installing metal glow plugs.

1.2 Removing and installing ceramic glow plugs

Procedure for removing and installing ceramic glow plugs.

Volkswagen Golf Plus 2005 Specifications

General

Brand	Volkswagen
Model	Golf Plus 2005
Category	Automobile
Language	English