2009 Volkswagen Transporter Flatbed and Chassis T5 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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11) 9.59 lbf⋅ft
3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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
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°
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 14.75 lbf⋅ft
Screws must be replaced.
Second stage 180°
3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11) 14.75 lbf⋅ft
3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2004.2–2009.11) 14.75 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreAir-conditioning compressor
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
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
1.9 TDI with diesel straight-4 1.9 L 83 HP engine (2006.1–2009.11) 33.19 lbf⋅ft
1.9 TDI with diesel straight-4 1.9 L 84 HP engine (2003.4–2009.11) 33.19 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–) 33.19 lbf⋅ft
3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11) 33.19 lbf⋅ft
3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2004.2–2009.11) 33.19 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreAir-conditioning compressor bracket
expand_moreAll Volkswagen diesel straight-4 2.0 Liters CAAC engines
expand_moreTop
First stage 29.5 lbf⋅ft
Second stage 90°
expand_moreBottom
First stage 29.5 lbf⋅ft
Second stage 180°
expand_moreAll Volkswagen diesel straight-4 2.0 Liters CFCA engines
expand_moreTop
First stage 29.5 lbf⋅ft
Second stage 90°
expand_moreBottom
First stage 29.5 lbf⋅ft
Second stage 180°
All other modifications 33.19 lbf⋅ft
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 (2004.4–2009.11) 18.44 lbf⋅ft
2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP engine (2004.4–2009.11) 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 14.75 lbf⋅ft
expand_moreGenerator bracket
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_moreTop
First stage 29.5 lbf⋅ft
Second stage 90°
expand_moreBottom
First stage 29.5 lbf⋅ft
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–)
expand_moreTop
First stage 29.5 lbf⋅ft
Second stage 90°
expand_moreBottom
First stage 29.5 lbf⋅ft
Second stage 180°
3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11) 14.75 lbf⋅ft
3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2004.2–2009.11) 14.75 lbf⋅ft
All other modifications 33.19 lbf⋅ft
Cross-wise from inside to outside
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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11) 7.38 lbf⋅ft
3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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_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_moreAll Volkswagen diesel straight-4 2.0 Liters CFCA engines
First stage 5.9 lbf⋅ft
Screws must be replaced.
Second stage 180°
expand_moreAll other modifications
First stage 8.85 lbf⋅ft
Screws must be replaced.
Second stage 270°
expand_moreInjection pump
expand_moreTop
First stage 14.75 lbf⋅ft
Second stage 45°
expand_moreBottom
First stage 14.75 lbf⋅ft
Second stage 180°
expand_moreCharging
Charge air pipes 7.38 lbf⋅ft
expand_moreTurbo charger
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 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 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_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_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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11) 5.9 lbf⋅ft
3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2004.2–2009.11) 5.9 lbf⋅ft
All other modifications 11.06 lbf⋅ft
expand_moreCoolant pump pulley
3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11) 14.75 lbf⋅ft
3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2004.2–2009.11) 14.75 lbf⋅ft
expand_moreAll other modifications
Gear wheel on the coolant pump 61.96 lbf⋅ft
expand_moreCoolant pump drive wheel
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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11) 2.21 lbf⋅ft
3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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–)
Figure 1. Cylinder head, Cylinder head screws, 2.0 with gasoline straight-4 2.0 L 114 HP at 5200 RPM, 170 N⋅m at 2600 RPM engine (2003.11–).
Figure 1. Cylinder head, Cylinder head screws, 2.0 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)
Figure 2. Cylinder head, Cylinder head screws, 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).
Figure 2. Cylinder head, Cylinder head screws, 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).
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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11)
Figure 3. Cylinder head, Cylinder head screws, 3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11).
Figure 3. Cylinder head, Cylinder head screws, 3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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
Figure 4. Cylinder head, Cylinder head screws, All other modifications.
Figure 4. Cylinder head, Cylinder head screws, All 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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11)
Long screws 5.55 in
Short screws 4.37 in
expand_more3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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 (2004.4–2009.11) 11.06 lbf⋅ft
2.5 TDI 4motion with diesel straight-5 2.5 L 172 HP engine (2004.4–2009.11) 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.
expand_moreValve cover locking screws
Valve play adjusting screw lock nuts 22.13 lbf⋅ft
expand_moreEngine block
Balance shaft gear wheel 6.64 lbf⋅ft
Screws must be replaced.
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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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 (2004.4–2009.11) 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 (2004.4–2009.11) 22.13 lbf⋅ft
Demount cylinder head before loosening the crankshaft bearings.
2.5 TDI with diesel straight-5 2.5 L 129 HP 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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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
expand_moreBalance shaft timing chain guide rail
expand_moreBalance shaft timing chain tension rail
expand_moreBottom part of the control unit housing
expand_moreCamshaft adjuster
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_more3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11)
Top 16.96 lbf⋅ft
Bottom 13.28 lbf⋅ft
expand_more3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2004.2–2009.11)
Top 16.96 lbf⋅ft
Bottom 13.28 lbf⋅ft
expand_moreCamshaft timing chain tensioner
3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11) 29.5 lbf⋅ft
3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2004.2–2009.11) 29.5 lbf⋅ft
expand_moreCamshaft timing chain tensioning rail
expand_moreCamshaft timing gear
All Volkswagen gasoline straight-4 2.0 Liters AXA engines 73.76 lbf⋅ft
expand_moreAll Volkswagen diesel straight-4 1.9 Liters AXB engines
Central screws 73.76 lbf⋅ft
Wheel 18.44 lbf⋅ft
expand_moreAll Volkswagen diesel straight-4 1.9 Liters BRS engines
Central screws 73.76 lbf⋅ft
Wheel 18.44 lbf⋅ft
expand_moreAll Volkswagen diesel straight-4 2.0 Liters CFCA engines
Central screws 73.76 lbf⋅ft
expand_moreWheel
First stage 14.75 lbf⋅ft
Second stage 45°
expand_moreAll other modifications
First stage 110.63 lbf⋅ft
Screws must be replaced.
Second stage 90°
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°
expand_moreDrive chain balance shaft tensioner
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_more3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11)
M6 5.9 lbf⋅ft
Use screw-locking compound.
expand_moreM12
First stage 44.25 lbf⋅ft
Second stage 90°
expand_more3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2004.2–2009.11)
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
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
2.0 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 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 (2004.4–2009.11) 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_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–)
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_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 (2004.4–2009.11)
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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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 11.06 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreOil lines
Union nuts 16.23 lbf⋅ft
expand_moreOil pump
All Volkswagen gasoline straight-4 2.0 Liters AXA engines 11.06 lbf⋅ft
All other modifications 14.75 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 BiTDI 4motion with diesel straight-4 2.0 L 177 HP at 4000 RPM, 4000 N⋅m at 1500 RPM engine (2009.9–)
At the gearbox 29.5 lbf⋅ft
On the engine block 11.06 lbf⋅ft
expand_moreAll other modifications
At the gearbox 33.19 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 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_moreM10 × 125 screws
First stage 29.5 lbf⋅ft
Screws must be replaced.
Second stage 180°
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_moreM8 × 45 screws
First stage 14.75 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_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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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 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 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_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_more3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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 vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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_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_moreSubframe
expand_moreOn chassis
First stage 110.63 lbf⋅ft
Use new screws
Second stage 180°
expand_moreTorque arm
expand_moreAll Volkswagen diesel straight-4 2.0 Liters CFCA engines
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_moreAll other modifications
expand_moreOn the engine block
First stage 36.88 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreTorque support bracket
expand_moreAll Volkswagen diesel straight-4 2.0 Liters CFCA engines
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_moreAll other modifications
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_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_more3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11)
M10 29.5 lbf⋅ft
M8 18.44 lbf⋅ft
expand_more3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2004.2–2009.11)
M10 29.5 lbf⋅ft
M8 18.44 lbf⋅ft
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_moreExhaust manifold
expand_more3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11)
M8 18.44 lbf⋅ft
M10 29.5 lbf⋅ft
expand_more3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 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
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) 5.16 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) 5.16 lbf⋅ft
1.9 TDI with diesel straight-4 1.9 L 83 HP engine (2006.1–2009.11) 5.16 lbf⋅ft
1.9 TDI with diesel straight-4 1.9 L 84 HP engine (2003.4–2009.11) 5.16 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
Nuts must be replaced.
expand_more3.2 4motion with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2003.11–2009.11)
M8 18.44 lbf⋅ft
M10 29.5 lbf⋅ft
expand_more3.2 V6 with gasoline vr-6 3.2 L 228 HP at 6200 RPM, 315 N⋅m at 2900 RPM engine (2004.2–2009.11)
M8 18.44 lbf⋅ft
M10 29.5 lbf⋅ft
All other modifications 5.9 lbf⋅ft
expand_moreExhaust pipe bracket
All other modifications 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
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) 13.28 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) 13.28 lbf⋅ft
1.9 TDI with diesel straight-4 1.9 L 83 HP engine (2006.1–2009.11) 13.28 lbf⋅ft
1.9 TDI with diesel straight-4 1.9 L 84 HP engine (2003.4–2009.11) 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
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–) 55.32 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–) 55.32 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 (2004.4–2009.11)
M10 29.5 lbf⋅ft
M12 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 Flatbed and Chassis 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

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 Flatbed and Chassis 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 Flatbed and Chassis you're not only saving money, but also also improving your technical skills and learning something new.

2009 Volkswagen Transporter Flatbed and Chassis generations

In 2009 Volkswagen offered 2 generations of the Transporter Flatbed and Chassis. Engine fastener tightening specifications may vary in different generations. Be sure that you are looking at the rigt modification.

T5.2 (T5 facelift)

T5

Type 7JD, Type 7JE, Type 7JL, Type 7JY, Type 7JZ

Volkswagen Transporter Flatbed and Chassis T5 model years

Units:
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