The Golf TDI A4, or MkIV Golf, was a record selling car in Europe with significant upgrades in comfort and refinement over the previous generation. Like the previous generation Golf, it shares its platform with the Jetta, in this case the MkIV Jetta (or Bora), as well as the New Beetle
In the model years of 2004-2005 the Golf TDI was powered by a 1.9 liter turbocharged direct injection diesel with a more modern injection system. Designed as a collaboration between Bosch and Volkswagen AG, this system was termed “Pumpe Düse, or “PD”, as each individual injector had its own high pressure fuel pump.
Engine
Engine Code: BEW
Horsepower: 100 @ 4000 RPM
Torque: 177 lb/ft @1800 RPM
Injection Pump Type: PD, “Pumpe Düse”, Unit Injectors (Unit Injector on Wikipedia)
The vehicle uses three fuel pumps in total: a very low pressure in-tank “lift” pump that pushes fuel from the tank to the engine bay; a standard rotary style pump attached to the camshaft which sent higher pressure fuel to the injectors; each individual injector set the final fuel pressure depending on load and engine speed.
These PD injectors also had a fully electronic injection timing using piezo technology.
Transmission
The 2004-2005 MkIV Golf TDI BEW was available with either a 5-speed manual transmission or a 5-speed automatic, referred to as the “Tiptronic” transmission as it had the ability to switch gears manually by shifting the select lever to the right.
The 5-speed manual was equipped with a dual-mass flywheel and clutch design. The clutch was hydraulically operated with a slave cylinder operating a lever to disengage the clutch. The dual-mass flywheel design is prone to failure, so most owners opt to replace their dual-mass design with the more durable single-mass flywheel from the G60/VR6.
The automatic “Tiptronic” transmission proved much stronger and reliable than the 4-speed unit it replaced. However, one gaping flaw was that the transmission filter element was not replaceable without removing the transmission from the car. This discouraged most owners from doing a proper filter and fluid change, opting rather just to replace the fluid. The effects of this seemed negligible as the transmissions operated for hundreds of thousands of miles.
Maintenance
See the Complete BEW TDI Service Schedule
VW Oil Requirement: VW/AUDI 505.01
Timing Belt Interval: The BEW engine originally used a timing belt interval of 100,000 miles. Later on, Volkswagen revised the interval to 80,000 miles, presumably due to the extra strain that the injection system put on the timing belt components. There is some debate as to which cars this revision applies to as there was a seemingly insignificant VIN split in the announcement.
Common Replacement Parts for 2004-2005 Jetta TDI – Sponsored By IDParts.com
Oil Change Kit
Engine Filter Pack
505.01 Approved Oils
Timing Belt Replacement Kit
Clutch Replacement Kit
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