2009 Volkswagen Transporter Box Van T5.2 (T5 facelift) Engine Fastener Tightening Specifications
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| Condition | Value |
|---|
expand_moreAir intake system
expand_moreIntake manifold
| 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–) | 18.44 lbf⋅ft |
| 3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11) | 9.59 lbf⋅ft |
| 3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11) | 9.59 lbf⋅ft |
| 3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11) | 9.59 lbf⋅ft |
| 3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11) | 9.59 lbf⋅ft |
| All other modifications | 14.75 lbf⋅ft |
expand_moreAuxiliary assemblies
expand_moreAuxiliary drive belt deflection pulley
expand_moreAll other modifications
expand_moreWith air-conditioning
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreAuxiliary drive belt tensioner
| 1.9 TDI with diesel straight-4 1.9 L 101 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2006.6–2009.11) | 18.44 lbf⋅ft |
| 1.9 TDI with diesel straight-4 1.9 L 103 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2003.4–2009.11) | 18.44 lbf⋅ft |
| 1.9 TDI with diesel straight-4 1.9 L 83 HP engine (2006.1–2009.11) | 18.44 lbf⋅ft |
| 1.9 TDI with diesel straight-4 1.9 L 84 HP engine (2003.4–2009.11) | 18.44 lbf⋅ft |
expand_more2.0 BiTDI 4motion with diesel straight-4 2.0 L 177 HP at 4000 RPM, 4000 N⋅m at 1500 RPM engine (2009.9–)
| First stage | 14.75 lbf⋅ft |
| Second stage | 90° |
| 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–) | 18.44 lbf⋅ft |
| 3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11) | 16.96 lbf⋅ft |
| 3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11) | 16.96 lbf⋅ft |
| 3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11) | 16.96 lbf⋅ft |
| 3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11) | 16.96 lbf⋅ft |
expand_moreAll other modifications
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreAir-conditioning compressor
| 2.0 BiTDI 4motion with diesel straight-4 2.0 L 177 HP at 4000 RPM, 4000 N⋅m at 1500 RPM engine (2009.9–) | 16.96 lbf⋅ft |
| 2.0 BiTDI with diesel straight-4 2.0 L 177 HP at 4000 RPM, 4000 N⋅m at 1500 RPM engine (2009.9–) | 16.96 lbf⋅ft |
| 2.0 TDI 4motion with diesel straight-4 2.0 L 138 HP at 3500 RPM, 340 N⋅m at 1750 RPM engine (2009.9–) | 16.96 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11) | 18.44 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP engine (2004.7–2009.11) | 18.44 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2004.7–2009.11) | 18.44 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP engine (2004.7–2009.11) | 18.44 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11) | 18.44 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 129 HP engine (2003.4–2009.11) | 18.44 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2003.4–2009.11) | 18.44 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 172 HP engine (2003.4–2009.11) | 18.44 lbf⋅ft |
| All other modifications | 33.19 lbf⋅ft |
expand_moreAir-conditioning compressor bracket
| All Volkswagen gasoline straight-4 2.0 Liters AXA engines | 33.19 lbf⋅ft |
| All Volkswagen diesel straight-4 1.9 Liters AXB engines | 33.19 lbf⋅ft |
| All Volkswagen diesel straight-4 1.9 Liters AXC engines | 33.19 lbf⋅ft |
| All Volkswagen diesel straight-4 1.9 Liters BRR engines | 33.19 lbf⋅ft |
| All Volkswagen diesel straight-4 1.9 Liters BRS engines | 33.19 lbf⋅ft |
expand_moreAll other modifications
expand_moreTop
| First stage | 29.5 lbf⋅ft |
| Second stage | 90° |
expand_moreBottom
| First stage | 29.5 lbf⋅ft |
| Second stage | 180° |
| Air-conditioning compressor pressure line | 14.75 lbf⋅ft |
expand_moreAlternator
| 1.9 TDI with diesel straight-4 1.9 L 101 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2006.6–2009.11) | 18.44 lbf⋅ft |
| 1.9 TDI with diesel straight-4 1.9 L 103 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2003.4–2009.11) | 18.44 lbf⋅ft |
| 1.9 TDI with diesel straight-4 1.9 L 83 HP engine (2006.1–2009.11) | 18.44 lbf⋅ft |
| 1.9 TDI with diesel straight-4 1.9 L 84 HP engine (2003.4–2009.11) | 18.44 lbf⋅ft |
| 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–) | 18.44 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2004.7–2009.11) | 18.44 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP engine (2004.7–2009.11) | 18.44 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2003.4–2009.11) | 18.44 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 172 HP engine (2003.4–2009.11) | 18.44 lbf⋅ft |
| All other modifications | 14.75 lbf⋅ft |
expand_moreGenerator bracket
| 1.9 TDI with diesel straight-4 1.9 L 101 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2006.6–2009.11) | 33.19 lbf⋅ft |
| Cross-wise from inside to outside | |
| 1.9 TDI with diesel straight-4 1.9 L 103 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2003.4–2009.11) | 33.19 lbf⋅ft |
| Cross-wise from inside to outside | |
| 1.9 TDI with diesel straight-4 1.9 L 83 HP engine (2006.1–2009.11) | 33.19 lbf⋅ft |
| Cross-wise from inside to outside | |
| 1.9 TDI with diesel straight-4 1.9 L 84 HP engine (2003.4–2009.11) | 33.19 lbf⋅ft |
| Cross-wise from inside to outside | |
| 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–) | 33.19 lbf⋅ft |
| 3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11) | 14.75 lbf⋅ft |
| 3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11) | 14.75 lbf⋅ft |
| 3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11) | 14.75 lbf⋅ft |
| 3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11) | 14.75 lbf⋅ft |
expand_moreAll other modifications
expand_moreTop
| First stage | 29.5 lbf⋅ft |
| Second stage | 90° |
expand_moreBottom
| First stage | 29.5 lbf⋅ft |
| Second stage | 180° |
expand_morePower steering pump bracket
| All Volkswagen gasoline straight-4 2.0 Liters AXA engines | 33.19 lbf⋅ft |
expand_moreAll other modifications
expand_moreTop
| First stage | 29.5 lbf⋅ft |
| Second stage | 90° |
expand_moreBottom
| First stage | 29.5 lbf⋅ft |
| Second stage | 180° |
| Hydraulic lines at the servo-steering pump | 6.64 lbf⋅ft |
| Servo pump pulley | 18.44 lbf⋅ft |
expand_moreServo steering pump
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11)
| First stage | 29.5 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11)
| First stage | 29.5 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
| All other modifications | 18.44 lbf⋅ft |
expand_moreVacuum pump
expand_more1.9 TDI with diesel straight-4 1.9 L 101 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2006.6–2009.11)
| M6 | 7.38 lbf⋅ft |
| M8 | 14.75 lbf⋅ft |
expand_more1.9 TDI with diesel straight-4 1.9 L 103 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2003.4–2009.11)
| M6 | 7.38 lbf⋅ft |
| M8 | 14.75 lbf⋅ft |
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11)
| M6 | 5.9 lbf⋅ft |
| M8 | 14.75 lbf⋅ft |
expand_more2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11)
| M6 | 5.9 lbf⋅ft |
| M8 | 14.75 lbf⋅ft |
| All other modifications | 7.38 lbf⋅ft |
expand_moreCarburetion
expand_moreExhaust recirculation pipe
| All Volkswagen diesel straight-4 1.9 Liters AXB engines | 18.44 lbf⋅ft |
| Sealing rings must be replaced. | |
| All Volkswagen diesel straight-4 1.9 Liters AXC engines | 18.44 lbf⋅ft |
| Sealing rings must be replaced. | |
expand_moreAll Volkswagen diesel straight-4 1.9 Liters BRS engines
| Nuts | 14.75 lbf⋅ft |
| Sealing rings must be replaced. | |
| Screws | 6.64 lbf⋅ft |
| Sealing rings must be replaced. | |
expand_moreFuel-distributing pipe
| 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–) | 7.38 lbf⋅ft |
| 3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11) | 7.38 lbf⋅ft |
| 3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11) | 7.38 lbf⋅ft |
| 3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11) | 7.38 lbf⋅ft |
| 3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11) | 7.38 lbf⋅ft |
| All other modifications | 16.23 lbf⋅ft |
| High-pressure line | 22.13 lbf⋅ft |
expand_moreHigh-pressure pump
expand_moreAll other modifications
expand_moreM8 × 28 screws
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 45° |
expand_moreM8 × 90 screws
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreHigh-pressure pump pulley
| Central nuts | 70.07 lbf⋅ft |
expand_moreWheel
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
| Injection hoses | 22.13 lbf⋅ft |
expand_moreInjection nozzle (injector)
expand_more1.9 TDI with diesel straight-4 1.9 L 101 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2006.6–2009.11)
| First stage | 8.85 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 270° |
expand_more1.9 TDI with diesel straight-4 1.9 L 103 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2003.4–2009.11)
| First stage | 8.85 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 270° |
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11)
| First stage | 8.85 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 270° |
expand_moreAll other modifications
| First stage | 5.9 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreInjection pump
expand_moreTop
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 45° |
expand_moreBottom
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreCharging
| Charge air pipes | 7.38 lbf⋅ft |
expand_moreTurbo charger
expand_moreAll Volkswagen diesel straight-5 2.5 Liters AXE engines
| On exhaust manifold | 18.44 lbf⋅ft |
| On the engine block | 29.5 lbf⋅ft |
expand_moreAll Volkswagen diesel straight-5 2.5 Liters BPC engines
expand_moreOn exhaust manifold
| First stage | 22.13 lbf⋅ft |
| Use new seal and screws. | |
| Second stage | 180° |
expand_moreOn the engine block
| First stage | 29.5 lbf⋅ft |
| Screws and nuts must be replaced. | |
| Second stage | 90° |
expand_moreAll Volkswagen diesel straight-5 2.5 Liters AXD engines
| On exhaust manifold | 18.44 lbf⋅ft |
| On the engine block | 29.5 lbf⋅ft |
expand_moreAll Volkswagen diesel straight-5 2.5 Liters BNZ engines
expand_moreOn exhaust manifold
| First stage | 22.13 lbf⋅ft |
| Use new seal and screws. | |
| Second stage | 180° |
expand_moreOn the engine block
| First stage | 29.5 lbf⋅ft |
| Screws and nuts must be replaced. | |
| Second stage | 90° |
expand_moreTurbocharger bracket
| All Volkswagen diesel straight-5 2.5 Liters AXD engines | 29.5 lbf⋅ft |
| All Volkswagen diesel straight-5 2.5 Liters AXE engines | 29.5 lbf⋅ft |
expand_moreAll other modifications
| At the turbocharger | 14.75 lbf⋅ft |
| On the engine block | 18.44 lbf⋅ft |
expand_moreTurbocharger oil feed line
| Support nuts on exhaust manifold | 18.44 lbf⋅ft |
| Support screws | 7.38 lbf⋅ft |
| Union nuts | 16.23 lbf⋅ft |
expand_moreTurbocharger oil return line
| At the turbocharger | 12.54 lbf⋅ft |
| Sealing rings must be replaced. | |
| Union nuts on the engine block | 16.23 lbf⋅ft |
expand_moreCooling system
| Coolant drain plug | 14.75 lbf⋅ft |
expand_moreCoolant pump
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11)
| Cap | 18.44 lbf⋅ft |
expand_moreOn the engine block
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11)
| Cap | 18.44 lbf⋅ft |
expand_moreOn the engine block
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
| 3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11) | 5.9 lbf⋅ft |
| 3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11) | 5.9 lbf⋅ft |
| 3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11) | 5.9 lbf⋅ft |
| 3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11) | 5.9 lbf⋅ft |
| All other modifications | 11.06 lbf⋅ft |
expand_moreCoolant pump pulley
| Gear wheel on the coolant pump | 61.96 lbf⋅ft |
| All other modifications | 14.75 lbf⋅ft |
expand_moreCoolant pump drive wheel
| First stage | 7.38 lbf⋅ft |
| Screws must be replaced. Left-hand thread. | |
| Second stage | 90° |
expand_moreRadiator mounting
| 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–) | 2.21 lbf⋅ft |
| 3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11) | 2.21 lbf⋅ft |
| 3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11) | 2.21 lbf⋅ft |
| 3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11) | 2.21 lbf⋅ft |
| 3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11) | 2.21 lbf⋅ft |
| All other modifications | 7.38 lbf⋅ft |
expand_moreCylinder head
expand_moreCamshaft bearing
| 2.0 BiTDI 4motion with diesel straight-4 2.0 L 177 HP at 4000 RPM, 4000 N⋅m at 1500 RPM engine (2009.9–) | 7.38 lbf⋅ft |
| Tighten the screws evenly from inside to outside in several steps. | |
| 2.0 BiTDI with diesel straight-4 2.0 L 177 HP at 4000 RPM, 4000 N⋅m at 1500 RPM engine (2009.9–) | 7.38 lbf⋅ft |
| Tighten the screws evenly from inside to outside in several steps. | |
| 2.0 TDI 4motion with diesel straight-4 2.0 L 138 HP at 3500 RPM, 340 N⋅m at 1750 RPM engine (2009.9–) | 7.38 lbf⋅ft |
| Tighten gradually and alternately from inside to outside. | |
| 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–) | 14.75 lbf⋅ft |
| First tighten bearing covers 2 and 4 alternately and in steps | |
expand_more3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11)
| First stage | 3.69 lbf⋅ft |
| Tighten gradually cross-wise | |
| Second stage | 45° |
expand_more3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11)
| First stage | 3.69 lbf⋅ft |
| Tighten gradually cross-wise | |
| Second stage | 45° |
expand_moreAll other modifications
| First stage | 5.9 lbf⋅ft |
| Tighten new screws crosswise in inside-to-outside order. | |
| Second stage | 90° |
expand_moreCylinder head screws
expand_more2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–)
| First stage | 29.5 lbf⋅ft |
| Screws must be replaced. See figure 1. | |
| Second stage | 90° |
| Third stage | 90° |
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11)
| First stage | 44.25 lbf⋅ft |
| Screws must be replaced. See figure 2. | |
| Second stage | 90° |
| Third stage | 90° |
| Fourth stage | 90° |
| Fifth stage | 90° |
| Sixth stage | loosen by 90° |
| Release using a rigid wrench | |
expand_more2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11)
| First stage | 44.25 lbf⋅ft |
| Screws must be replaced. See figure 2. | |
| Second stage | 90° |
| Third stage | 90° |
| Fourth stage | 90° |
| Fifth stage | 90° |
| Sixth stage | loosen by 90° |
| Release using a rigid wrench | |
expand_more3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11)
| First stage | 22.13 lbf⋅ft |
| Screws must be replaced. See figure 3. | |
| Second stage | 36.88 lbf⋅ft |
| Third stage | 90° |
| Fourth stage | 90° |
expand_more3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11)
| First stage | 22.13 lbf⋅ft |
| Screws must be replaced. See figure 3. | |
| Second stage | 36.88 lbf⋅ft |
| Third stage | 90° |
| Fourth stage | 90° |
expand_moreAll other modifications
| First stage | 25.81 lbf⋅ft |
| Screws must be replaced. See figure 4. | |
| Second stage | 44.25 lbf⋅ft |
| Third stage | 90° |
| Fourth stage | 90° |
expand_moreCylinder head screws shank length (new)
| 1.9 TDI with diesel straight-4 1.9 L 101 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2006.6–2009.11) | 6.54 in |
| 1.9 TDI with diesel straight-4 1.9 L 103 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2003.4–2009.11) | 6.54 in |
| 1.9 TDI with diesel straight-4 1.9 L 83 HP engine (2006.1–2009.11) | 6.54 in |
| 1.9 TDI with diesel straight-4 1.9 L 84 HP engine (2003.4–2009.11) | 6.54 in |
| 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–) | 4.53 in |
expand_more3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11)
| Long screws | 5.55 in |
| Short screws | 4.37 in |
expand_more3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11)
| Long screws | 5.55 in |
| Short screws | 4.37 in |
| All other modifications | 5.91 in |
expand_moreRocker bridge
| First stage | 14.75 lbf⋅ft |
| Tighten new screws in inside-to-outside order. | |
| Second stage | 90° |
expand_moreValve cover
| 2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11) | 11.06 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP engine (2004.7–2009.11) | 11.06 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2004.7–2009.11) | 11.06 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP engine (2004.7–2009.11) | 11.06 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11) | 11.06 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 129 HP engine (2003.4–2009.11) | 11.06 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2003.4–2009.11) | 11.06 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 172 HP engine (2003.4–2009.11) | 11.06 lbf⋅ft |
| All other modifications | 7.38 lbf⋅ft |
| Tighten the screws cross-wise from inside to outside. | |
| Valve cover locking screws | 3.69 lbf⋅ft |
| Valve play adjusting screw lock nuts | 22.13 lbf⋅ft |
expand_moreEngine block
expand_moreBalance shaft gear wheel
expand_moreAll Volkswagen diesel straight-4 2.0 Liters CCHB engines
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreConnecting rod bearing
expand_moreAll other modifications
| First stage | 22.13 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreCrankshaft central screws
expand_more2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–)
| First stage | 66.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11)
| First stage | 73.76 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11)
| First stage | 73.76 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreAll other modifications
| First stage | 88.51 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreCrankshaft pulley
expand_moreAll Volkswagen gasoline straight-4 2.0 Liters AXA engines
| First stage | 7.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreDrive plate
| First stage | 44.25 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreFlywheel
| First stage | 44.25 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreMain bearing
| 2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11) | 22.13 lbf⋅ft |
| Demount cylinder head before loosening the crankshaft bearings. | |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP engine (2004.7–2009.11) | 22.13 lbf⋅ft |
| Demount cylinder head before loosening the crankshaft bearings. | |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2004.7–2009.11) | 22.13 lbf⋅ft |
| Demount cylinder head before loosening the crankshaft bearings. | |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP engine (2004.7–2009.11) | 22.13 lbf⋅ft |
| Demount cylinder head before loosening the crankshaft bearings. | |
| 2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11) | 22.13 lbf⋅ft |
| Demount cylinder head before loosening the crankshaft bearings. | |
| 2.5 TDI with diesel straight-5 2.5 L 129 HP engine (2003.4–2009.11) | 22.13 lbf⋅ft |
| Demount cylinder head before loosening the crankshaft bearings. | |
| 2.5 TDI with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2003.4–2009.11) | 22.13 lbf⋅ft |
| Demount cylinder head before loosening the crankshaft bearings. | |
| 2.5 TDI with diesel straight-5 2.5 L 172 HP engine (2003.4–2009.11) | 22.13 lbf⋅ft |
| Demount cylinder head before loosening the crankshaft bearings. | |
expand_more3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11)
| First stage | 22.13 lbf⋅ft |
| Screws and nuts must be replaced. | |
| Second stage | 180° |
expand_more3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11)
| First stage | 22.13 lbf⋅ft |
| Screws and nuts must be replaced. | |
| Second stage | 180° |
expand_moreAll other modifications
| First stage | 47.94 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreVibration damper
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11)
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11)
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreAll other modifications
| First stage | 7.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreEngine control
| Balance shaft timing chain guide rail | 14.75 lbf⋅ft |
| Balance shaft timing chain tension rail | 14.75 lbf⋅ft |
expand_moreBottom part of the control unit housing
| First stage | 2.95 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 45° |
expand_moreCamshaft adjuster
| Bearing pedestal at the cylinder head | 6.64 lbf⋅ft |
| Central bolt inlet camshaft | 25.81 lbf⋅ft |
| Left-hand thread | |
expand_moreOutlet camshaft
expand_moreCentral screws
expand_moreM6
| First stage | 5.9 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreM8
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreCamshaft drive belt deflection pulley
| All Volkswagen diesel straight-4 1.9 Liters AXB engines | 14.75 lbf⋅ft |
| All Volkswagen diesel straight-4 1.9 Liters AXC engines | 14.75 lbf⋅ft |
| All Volkswagen diesel straight-4 1.9 Liters BRR engines | 14.75 lbf⋅ft |
| All Volkswagen diesel straight-4 1.9 Liters BRS engines | 14.75 lbf⋅ft |
expand_moreAll other modifications
| M8 | 14.75 lbf⋅ft |
expand_moreM10
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreCamshaft timing chain slip rail
expand_moreAll other modifications
| Bottom | 13.28 lbf⋅ft |
| Top | 16.96 lbf⋅ft |
expand_moreCamshaft timing chain tensioner
| All other modifications | 29.5 lbf⋅ft |
| Camshaft timing chain tensioning rail | 14.75 lbf⋅ft |
expand_moreCamshaft timing gear
expand_more1.9 TDI with diesel straight-4 1.9 L 101 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2006.6–2009.11)
| Central screws | 73.76 lbf⋅ft |
| Wheel | 18.44 lbf⋅ft |
expand_more1.9 TDI with diesel straight-4 1.9 L 103 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2003.4–2009.11)
| Central screws | 73.76 lbf⋅ft |
| Wheel | 18.44 lbf⋅ft |
| 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–) | 73.76 lbf⋅ft |
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11)
| First stage | 110.63 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11)
| First stage | 110.63 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreAll other modifications
| Central screws | 73.76 lbf⋅ft |
expand_moreWheel
| First stage | 14.75 lbf⋅ft |
| Second stage | 45° |
| Control drive chain tensioner | 5.9 lbf⋅ft |
| Control drive chain tensioning rail | 5.9 lbf⋅ft |
| Control drive timing chain slip rail | 7.38 lbf⋅ft |
expand_moreDrive belt tensioner device
| All Volkswagen gasoline straight-4 2.0 Liters AXA engines | 18.44 lbf⋅ft |
expand_moreAll other modifications
| First stage | 14.75 lbf⋅ft |
| Second stage | 45° |
| Drive chain balance shaft tensioner | 47.94 lbf⋅ft |
expand_moreInlet camshaft wheel
expand_moreWith camshaft adjuster
| First stage | 44.25 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreIntermediate shaft chain sprocket
expand_moreAll Volkswagen diesel straight-4 2.0 Liters CAAE engines
| First stage | 66.38 lbf⋅ft |
| Replace screw and intermediate wheel when loosening the screw. | |
| Second stage | 90° |
expand_moreAll Volkswagen diesel straight-4 2.0 Liters CCHB engines
| First stage | 66.38 lbf⋅ft |
| Replace screw and intermediate wheel when loosening the screw. | |
| Second stage | 90° |
expand_moreAll other modifications
| M6 | 5.9 lbf⋅ft |
| Use screw-locking compound. | |
expand_moreM12
| First stage | 44.25 lbf⋅ft |
| Second stage | 90° |
| Oil pump drive chain tensioner | 11.06 lbf⋅ft |
expand_moreOutlet camshaft wheel
expand_moreWith camshaft adjuster
| First stage | 44.25 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
| Tension rail bearing screws | 13.28 lbf⋅ft |
expand_moreTiming case cover
| M6 | 5.9 lbf⋅ft |
| M8 | 16.96 lbf⋅ft |
expand_moreToothed belt guard
expand_moreAll Volkswagen gasoline straight-4 2.0 Liters AXA engines
| M7 | 11.06 lbf⋅ft |
| M8 | 14.75 lbf⋅ft |
expand_moreAll other modifications
| M6 | 7.38 lbf⋅ft |
| Screws must be replaced. | |
| M8 | 18.44 lbf⋅ft |
expand_moreToothed belt tensioning roller
| All Volkswagen gasoline straight-4 2.0 Liters AXA engines | 14.75 lbf⋅ft |
expand_moreAll other modifications
| First stage | 14.75 lbf⋅ft |
| Second stage | 45° |
expand_moreTop part of control unit housing
| Camshaft adjuster valve | 6.64 lbf⋅ft |
| Otherwise | 6.64 lbf⋅ft |
expand_moreEngine lubrication
expand_moreOil cooler
| 2.0 BiTDI 4motion with diesel straight-4 2.0 L 177 HP at 4000 RPM, 4000 N⋅m at 1500 RPM engine (2009.9–) | 8.11 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11) | 7.38 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP engine (2004.7–2009.11) | 7.38 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2004.7–2009.11) | 7.38 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11) | 7.38 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 129 HP engine (2003.4–2009.11) | 7.38 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2003.4–2009.11) | 7.38 lbf⋅ft |
| All other modifications | 18.44 lbf⋅ft |
| Oil drain plug | 22.13 lbf⋅ft |
| Screws and nuts must be replaced. | |
expand_moreOil filter housing
expand_more1.9 TDI with diesel straight-4 1.9 L 101 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2006.6–2009.11)
| Oil filter cover | 18.44 lbf⋅ft |
expand_moreOn the engine block
| First stage | 11.06 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more1.9 TDI with diesel straight-4 1.9 L 103 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2003.4–2009.11)
| Oil filter cover | 18.44 lbf⋅ft |
expand_moreOn the engine block
| First stage | 11.06 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–)
expand_moreOn the engine block
| First stage | 11.06 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11)
| Cap | 18.44 lbf⋅ft |
| Otherwise | 14.75 lbf⋅ft |
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2004.7–2009.11)
| Oil filter cover | 18.44 lbf⋅ft |
| On the engine block | 14.75 lbf⋅ft |
expand_more2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11)
| Cap | 18.44 lbf⋅ft |
| Otherwise | 14.75 lbf⋅ft |
expand_more2.5 TDI with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2003.4–2009.11)
| Oil filter cover | 18.44 lbf⋅ft |
| On the engine block | 14.75 lbf⋅ft |
expand_more3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11)
| Oil filter cover | 18.44 lbf⋅ft |
| Oil filter drain plug | 7.38 lbf⋅ft |
| On the engine block | 18.44 lbf⋅ft |
expand_more3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11)
| Oil filter cover | 18.44 lbf⋅ft |
| Oil filter drain plug | 7.38 lbf⋅ft |
| On the engine block | 18.44 lbf⋅ft |
expand_moreAll other modifications
| Oil filter cover | 18.44 lbf⋅ft |
expand_moreOn the engine block
| First stage | 10.33 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreOil lines
| Union nuts | 16.23 lbf⋅ft |
expand_moreOil pump
| 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–) | 11.06 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2004.7–2009.11) | 14.75 lbf⋅ft |
| 2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP engine (2004.7–2009.11) | 14.75 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 172 HP at 3500 RPM, 400 N⋅m at 2000 RPM engine (2003.4–2009.11) | 14.75 lbf⋅ft |
| 2.5 TDI with diesel straight-5 2.5 L 172 HP engine (2003.4–2009.11) | 14.75 lbf⋅ft |
expand_moreAll other modifications
| All Volkswagen diesel straight-4 2.0 Liters CAAE engines | 11.06 lbf⋅ft |
| All Volkswagen diesel straight-4 2.0 Liters CCHB engines | 7.38 lbf⋅ft |
expand_moreOil pump chain wheel
expand_moreAll Volkswagen gasoline straight-4 2.0 Liters AXA engines
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
| All other modifications | 18.44 lbf⋅ft |
expand_moreOil sump
expand_more1.9 TDI with diesel straight-4 1.9 L 101 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2006.6–2009.11)
| At the gearbox | 33.19 lbf⋅ft |
| On the engine block | 11.06 lbf⋅ft |
| Gradually tighten screws crosswise. | |
expand_more1.9 TDI with diesel straight-4 1.9 L 103 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2003.4–2009.11)
| At the gearbox | 33.19 lbf⋅ft |
| On the engine block | 11.06 lbf⋅ft |
| Gradually tighten screws crosswise. | |
expand_more2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–)
| At the gearbox | 33.19 lbf⋅ft |
| On the engine block | 11.06 lbf⋅ft |
| Gradually tighten screws crosswise. | |
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11)
| At the gearbox | 33.19 lbf⋅ft |
| On the engine block | 11.06 lbf⋅ft |
expand_more2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11)
| At the gearbox | 33.19 lbf⋅ft |
| On the engine block | 11.06 lbf⋅ft |
expand_more3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11)
| At the gearbox | 33.19 lbf⋅ft |
| On the engine block | 8.85 lbf⋅ft |
expand_more3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11)
| At the gearbox | 33.19 lbf⋅ft |
| On the engine block | 8.85 lbf⋅ft |
expand_moreAll other modifications
| At the gearbox | 29.5 lbf⋅ft |
| On the engine block | 11.06 lbf⋅ft |
expand_moreEngine management
| Camshaft sensor | 7.38 lbf⋅ft |
| Screws must be replaced. | |
| Charge air pressure sensor | 2.21 lbf⋅ft |
expand_moreCrankshaft sensor
| All Volkswagen gasoline straight-4 2.0 Liters AXA engines | 11.06 lbf⋅ft |
| All other modifications | 3.69 lbf⋅ft |
| Exhaust gas temperature sensor | 33.19 lbf⋅ft |
| Use hot screw paste | |
expand_moreGlow plugs
| All Volkswagen diesel straight-4 2.0 Liters CAAA engines | 12.54 lbf⋅ft |
| All Volkswagen diesel straight-4 2.0 Liters CAAB engines | 12.54 lbf⋅ft |
| All Volkswagen diesel straight-4 2.0 Liters CAAC engines | 12.54 lbf⋅ft |
| All Volkswagen diesel straight-4 2.0 Liters CCHA engines | 12.54 lbf⋅ft |
| All Volkswagen diesel straight-4 2.0 Liters CFCA engines | 12.54 lbf⋅ft |
| All other modifications | 11.06 lbf⋅ft |
| Knock sensor | 14.75 lbf⋅ft |
expand_moreLambda sensor
| All Volkswagen gasoline straight-4 2.0 Liters AXA engines | 40.57 lbf⋅ft |
| All other modifications | 36.88 lbf⋅ft |
expand_moreEngine mounting
expand_moreEngine bracket
expand_more1.9 TDI with diesel straight-4 1.9 L 101 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2006.6–2009.11)
expand_moreOn engine mounting
expand_moreFront side screws (M10 × 135)
| First stage | 66.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreRear (M10 × 65)
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreOn the engine block
expand_moreM8 × 45 screws
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreM10 × 30 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreM10 × 45 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreM10 × 90 screws
| First stage | 29.5 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreM10 × 125 screws
| First stage | 29.5 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_more1.9 TDI with diesel straight-4 1.9 L 103 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2003.4–2009.11)
expand_moreOn engine mounting
expand_moreFront side screws (M10 × 135)
| First stage | 66.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreRear (M10 × 65)
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreOn the engine block
expand_moreM8 × 45 screws
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreM10 × 30 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreM10 × 45 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreM10 × 90 screws
| First stage | 29.5 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreM10 × 125 screws
| First stage | 29.5 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_more2.0 BiTDI 4motion with diesel straight-4 2.0 L 177 HP at 4000 RPM, 4000 N⋅m at 1500 RPM engine (2009.9–)
expand_moreOn the engine block
| First stage | 29.5 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_more2.0 TDI 4motion with diesel straight-4 2.0 L 138 HP at 3500 RPM, 340 N⋅m at 1750 RPM engine (2009.9–)
| First stage | 29.5 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_more2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–)
expand_moreOn engine mounting
expand_moreFront side screws (M10 × 135)
| First stage | 66.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreRear (M10 × 65)
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreOn the engine block
expand_moreM8 × 45 screws
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreM10 × 30 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreM10 × 45 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
| M10 × 90 screws | 33.19 lbf⋅ft |
| Screws must be replaced. | |
| M10 × 112 screws | 33.19 lbf⋅ft |
| Screws must be replaced. | |
expand_more3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11)
expand_moreStrut (M10 × 65)
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreOn engine mounting
expand_moreFront side screws (M12 × 135)
| First stage | 66.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreRight (M12)
| First stage | 66.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreRear (M10 × 65)
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreOn the engine block
| Front (M8) | 18.44 lbf⋅ft |
| Right (M10 × 30) | 33.19 lbf⋅ft |
expand_moreRear (M10 × 45)
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11)
expand_moreStrut (M10 × 65)
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreOn engine mounting
expand_moreFront side screws (M12 × 135)
| First stage | 66.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreRight (M12)
| First stage | 66.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreRear (M10 × 65)
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreOn the engine block
| Front (M8) | 18.44 lbf⋅ft |
| Right (M10 × 30) | 33.19 lbf⋅ft |
expand_moreRear (M10 × 45)
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreAll other modifications
expand_moreM10
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreM12 × 70 screws
| First stage | 66.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreM12 × 135 screws
| First stage | 66.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreEngine mounting
expand_more1.9 TDI with diesel straight-4 1.9 L 101 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2006.6–2009.11)
expand_moreAt the subframe
expand_moreM8 × 20 screws
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 45° |
expand_moreM8 × 75 screws
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreOn chassis
expand_moreM10 × 30 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreOn engine bracket
expand_moreM10 × 65 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more1.9 TDI with diesel straight-4 1.9 L 103 HP at 3500 RPM, 250 N⋅m at 2000 RPM engine (2003.4–2009.11)
expand_moreAt the subframe
expand_moreM8 × 20 screws
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 45° |
expand_moreM8 × 75 screws
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreOn chassis
expand_moreM10 × 30 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreOn engine bracket
expand_moreM10 × 65 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–)
expand_moreAt the subframe
expand_moreM8 × 20 screws
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 45° |
expand_moreM8 × 75 screws
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreOn chassis
expand_moreM10 × 30 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreOn engine bracket
expand_moreM10 × 65 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11)
expand_moreAt the subframe
expand_moreFront side screws (M8 × 20)
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreAt the subframe
expand_moreRear (M8 × 75)
| First stage | 14.75 lbf⋅ft |
| Screws and nuts must be replaced. | |
| Second stage | 180° |
expand_moreOn chassis
expand_moreM10 × 30 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11)
expand_moreAt the subframe
expand_moreFront side screws (M8 × 20)
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreAt the subframe
expand_moreRear (M8 × 75)
| First stage | 14.75 lbf⋅ft |
| Screws and nuts must be replaced. | |
| Second stage | 180° |
expand_moreOn chassis
expand_moreM10 × 30 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11)
expand_moreAt the subframe
expand_moreFront side screws (M8 × 20)
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreAt the subframe
expand_moreRear (M8 × 75)
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreOn chassis
expand_moreM10 × 30 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11)
expand_moreAt the subframe
expand_moreFront side screws (M8 × 20)
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreAt the subframe
expand_moreRear (M8 × 75)
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreOn chassis
expand_moreM10 × 30 screws
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreAll other modifications
expand_moreOn chassis
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreOn engine bracket
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreSubframe
expand_moreOn chassis
| First stage | 110.63 lbf⋅ft |
| Use new screws | |
| Second stage | 180° |
expand_moreTorque arm
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11)
expand_moreOn the engine block
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11)
expand_moreOn the engine block
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreAll other modifications
expand_moreAt the bearing pedestal
expand_moreFront
| First stage | 66.38 lbf⋅ft |
| Screws and nuts must be replaced. | |
| Second stage | 180° |
expand_moreRear
| First stage | 36.88 lbf⋅ft |
| Screws and nuts must be replaced. | |
| Second stage | 90° |
expand_moreOn the engine block
expand_moreFront
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreRear
expand_moreM10
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreM8
| First stage | 14.75 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreTorque support bracket
expand_more2.5 TDI 4motion with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2004.7–2009.11)
expand_moreBearing pedestal
expand_moreFront
| First stage | 66.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreRear
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_more2.5 TDI with diesel straight-5 2.5 L 129 HP at 3500 RPM, 340 N⋅m at 2000 RPM engine (2003.4–2009.11)
expand_moreBearing pedestal
expand_moreFront
| First stage | 66.38 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 180° |
expand_moreRear
| First stage | 36.88 lbf⋅ft |
| Screws must be replaced. | |
| Second stage | 90° |
expand_moreAll other modifications
expand_moreAt the subframe
expand_moreFront
| First stage | 14.75 lbf⋅ft |
| Screws and nuts must be replaced. | |
| Second stage | 90° |
expand_moreRear
| First stage | 14.75 lbf⋅ft |
| Screws and nuts must be replaced. | |
| Second stage | 180° |
expand_moreExhaust system
expand_moreCatalytic converter
| 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–) | 18.44 lbf⋅ft |
| Nuts must be replaced. | |
expand_moreAll other modifications
| Clamps | 5.9 lbf⋅ft |
| Parts must be replaced. | |
expand_moreDiesel particulate filter
expand_moreAll Volkswagen diesel straight-4 1.9 Liters BRS engines
| At the turbocharger | 5.16 lbf⋅ft |
| Sealing rings must be replaced. | |
expand_moreAll other modifications
| Clamps | 5.9 lbf⋅ft |
| Parts must be replaced. | |
| Support | 29.5 lbf⋅ft |
expand_moreExhaust manifold
expand_more3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11)
| M8 | 18.44 lbf⋅ft |
| M10 | 29.5 lbf⋅ft |
expand_more3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11)
| M8 | 18.44 lbf⋅ft |
| M10 | 29.5 lbf⋅ft |
| All other modifications | 18.44 lbf⋅ft |
| Tighten new nuts evenly in several steps. | |
| Exhaust manifold heat shields | 18.44 lbf⋅ft |
expand_moreExhaust pipe
| 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–) | 18.44 lbf⋅ft |
| Nuts must be replaced. | |
expand_more3.2 4motion with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2003.11–2009.11)
| M8 | 18.44 lbf⋅ft |
| M10 | 29.5 lbf⋅ft |
expand_more3.2 V6 with gasoline V6 3.2 L 232 HP at 6200 RPM, 315 N⋅m at 2950 RPM engine (2004.2–2009.11)
| M8 | 18.44 lbf⋅ft |
| M10 | 29.5 lbf⋅ft |
| All other modifications | 5.9 lbf⋅ft |
| Exhaust pipe bracket | 18.44 lbf⋅ft |
expand_moreParticle filter bracket
| M10 × 25 screws | 44.25 lbf⋅ft |
| M10 × 30 screws | 44.25 lbf⋅ft |
expand_moreM10 × 70 screws
| First stage | 36.88 lbf⋅ft |
| Second stage | 90° |
expand_moreFuel supply
expand_moreFuel filter bracket
| All Volkswagen diesel straight-4 1.9 Liters AXB engines | 13.28 lbf⋅ft |
| All Volkswagen diesel straight-4 1.9 Liters AXC engines | 13.28 lbf⋅ft |
| All Volkswagen diesel straight-4 1.9 Liters BRR engines | 13.28 lbf⋅ft |
| All Volkswagen diesel straight-4 1.9 Liters BRS engines | 13.28 lbf⋅ft |
| All other modifications | 18.44 lbf⋅ft |
expand_moreIgnition system
expand_moreSpark plugs
| All Volkswagen gasoline straight-4 2.0 Liters AXA engines | 18.44 lbf⋅ft |
| All other modifications | 14.75 lbf⋅ft |
expand_moreStart system
expand_moreStarter
| All Volkswagen diesel straight-4 2.0 Liters CFCA engines | 55.32 lbf⋅ft |
| All other modifications | 59 lbf⋅ft |
Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2009 Volkswagen Transporter Box Van user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.
Before doing any DIY service please check your insurance policy and Volkswagen warranty policy for your region. In some regions DIY service may invalidate your warranty.
Table of Contents
- Air Conditioning Compressor Oil Capacity
- Air Conditioning Refrigerant Capacity
- All-wheel Drive Clutch Oil Capacity
- Automatic Transmission Fluid Capacity
- Axle Oil Capacity
- Brake Fluid Capacity
- Cooling Fluid Capacity
- Engine Oil Capacity
- Fluid and Lubricant Specifications
- Gearbox Oil Capacity
- Manual Transmission Oil Capacity
- Steering Fluid Capacity
- Brake System Specifications
- Chassis Specifications
- Cooling System Specifications
- Drive Belts Specifications
- Electrical System Specifications
- Emission
- Engine Fastener Tightening Specifications
- Front Suspension Fastener Tightening Specifications
- Rear Suspension Fastener Tightening Specifications
- Transmission Fastener Tightening Specifications
Conquer your fears and never give up!
DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Volkswagen Transporter Box Van service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.
Doing basic service for your 2009 Volkswagen Transporter Box Van you're not only saving money, but also also improving your technical skills and learning something new.
2009 Volkswagen Transporter Box Van generations
In 2009 Volkswagen offered 2 generations of the Transporter Box Van. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.