Vehicles with 1.9 l TDI engine and dual clutch gearbox (DSG) — VW

🧭 Before you start

Fits: VW Golf V / Jetta (1K, 2003–2009)

📋 Procedure

1. Disconnect battery .
2. First pull engine cover upwards (arrows A) and then forwards (arrow B).
3. Disconnect connector (1) and release spring-type clip (2) using spring type clip pliersVAS 5024.
4. Pull vacuum hose (arrow) off air filter housing.
5. Remove securing bolt from air filter housing (arrow).

6. Release locking lugs (arrows) and take off cover.
7. Pull hose (arrow) off air filter housing and remove.
8. Pull air filter housing upwards out of brackets and remove.
9. Slide protective cap in direction of (arrow) off solenoid switch.
10. Unscrew positive wire (1) and disconnect connector from terminal 50 (2).
11. Remove upper securing bolt of starter (arrow).
12. Remove lower securing bolt of starter (arrow).
13. Remove starter from vehicle upwards.
14. Tighten threaded connections to specified torques .

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Removing and installing bevel box (vehicles with a 5 or 6-cylinder engine)
• Adjusting output shaft for 1st-4th gears
• 2. and 4th gear brake -B2- adjustment
• Checking modulating piston movement sender and metering adjuster
• Checking Lambda probe heating for Lambda probe before catalytic converter