Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 12.2013
Engine code AZV BKD BMN BKP BMA BVE BMR BUZ BWV
Turbo‐ yes yes yes yes yes yes yes yes yes
charging/
supercharg‐
ing
Charge air yes yes yes yes yes yes yes yes yes
cooling
Particulate no no yes no no no yes yes no
filter
2 Rep. gr.00 - Technical data
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 12.2013
10 – Removing and installing engine
1 Removing and installing engine
Removing engine ⇒ page 4 .
Securing engine to assembly stand ⇒ page 11 .
Notes on installing ⇒ page 13 .
Assembly mountings ⇒ page 14 .
Special tools and workshop
equipment required
♦ Torque wrench - V.A.G
1331-
♦ Torque wrench - V.A.G
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Spring-type clip pliers -
VAS 5024 A-
♦ Stepladder - VAS 5085-
♦ Engine bracket - T10012-
1. Removing and installing engine 3
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 12.2013
1.1 Removing engine
Note
♦ Before carrying out further work, disconnect battery earth
strap. First check whether a coded radio is fitted. Obtain anti-
theft coding 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.
WARNING
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
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.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
Procedures for Golf, Golf Plus, Touran ⇒ page 4
Procedures for Passat ⇒ page 7
1.1.1 Procedures for Golf, Golf Plus, Touran
– Read fault memories of all control units before removal ⇒ Di‐
agnosis tester VAS 5051; Guided fault finding; Vehicle system
test or VAS 5052; Vehicle self-diagnosis .
– With ignition switched off, disconnect earth strap from battery.
⇒ Electrical system; Rep. gr. 27 ; Disconnecting and recon‐
necting batteries .
– Remove engine cover.
To do this, pull engine cover upwards abruptly at front and right
-arrows A- and then pull forwards out of rear fastening
-arrow B-.
– Remove plenum chamber bulkhead. ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
4 Rep. gr.10 - Removing and installing engine
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 12.2013
– Remove air filter housing with air mass meter and connecting
pipe.
Remove bolt -arrow A- and pull air filter housing upwards out of
mounting.
– Remove battery and battery tray.
– Remove insulation tray ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body - front; Assembly overview - noise insulation .
– Bring lock carrier into service position ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Lock carrier service position .
– Drain coolant ⇒ page 133
WARNING
♦ 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!
– Disconnect fuel supply and return lines as well as coolant line
on cylinder head.
– Pull fuel filter module upwards out of bracket and lay it with
hoses to side.
Vehicles with air conditioner
Note
To prevent damage to condenser and also to refrigerant lines/
hoses, ensure that the lines 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 relieved.
Continuation for all vehicles
– Remove exhaust pipe and coolant hoses from supplementary
heater.
– Remove connecting pipes between charge air cooler and en‐
gine.
– Pull retainer for wiring harness of oil level and oil temperature
sender - G266- off subframe.
– Remove right drive shaft and unscrew left drive shaft from
gearbox ⇒ Running gear, axles, steering; Rep. gr. 40 ; Re‐
moving and installing drive shaft .
– Remove left wheel housing liner.
1. Removing and installing engine 5
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 12.2013
– Disconnect front exhaust pipe from turbocharger, loosen dou‐
ble clamp and slide exhaust pipe back ⇒ page 270 .
– Pull engine wiring harness connector off control unit:
Golf ⇒ page 257
Golf Plus, Touran ⇒ page 261
– Open cable guide catches on longitudinal member -arrows-.
– Remove wiring harness from cable guide and lay to side on
engine.
For engine code BMN:
– Separate connections at engine bulkhead for:
♦ -1- Exhaust gas temperature sender 2 - G448-
♦ -2- Temperature sender after particulate filter - G527-
♦ -3- Exhaust gas temperature sender 1 - G235-
♦ -4- Lambda probe - G39-
♦ -5- Charge pressure control solenoid valve - N75-
Continuation for all vehicles
– Pull off or disconnect all other electrical connections from en‐
gine and gearbox as necessary and lay to side.
– Separate all connecting, coolant, vacuum and intake hoses
from engine.
For engine code BMN:
– Release connecting clamp for front exhaust pipe/front silenc‐
er.
– Remove subframe and steering ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 .
Note
The engine is lowered downwards with particulate filter fitted.
Engine codes AZV, BKD:
– Disconnect front exhaust pipe from turbocharger, loosen dou‐
ble clamp and slide exhaust pipe back ⇒ page 270 .
Continuation for all vehicles:
– Disconnect selector mechanism from gearbox ⇒ 6-speed
manual gearbox 02Q; Rep. gr. 34 .
– Separate pressure line for hydraulic clutch control.
– Remove pendulum support.
6 Rep. gr.10 - Removing and installing engine